ABB SCK Operating Instructions Manual
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ABB SCK Operating Instructions Manual

ABB SCK Operating Instructions Manual

Sampling system for dry gas sampling at rotary cement kiln gas exit and calciner gas exit
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A B B M EA S U R E M E N T & A N A L Y T I C S | O P E R A T I N G I N S T R U C T I O N | O I / S C K - E N R E V . E
SCK
Sample conditioning for kiln
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Introduction
SCK
The SCK is a sampling system for dry gas
sampling at rotary kiln exit and calciner gas exit.
The SCK sampling system is suitable for
applications in rough environmental conditions
and for outdoor installations thanks to a
complete protection cover.
Sampling system for dry gas
sampling at rotary cement kiln gas
exit and calciner gas exit
Measurement made easy
Additional Information
Additional documentation on SCK is available for
download free of charge at www.abb.com/analytical.
Alternatively simply scan this code:

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Summary of Contents for ABB SCK

  • Page 1 Measurement made easy — Introduction Additional Information The SCK is a sampling system for dry gas Additional documentation on SCK is available for sampling at rotary kiln exit and calciner gas exit. download free of charge at www.abb.com/analytical. Alternatively simply scan this code:...

  • Page 2: Table Of Contents

    Safety measures: Maintenance and troubleshooting .......... 80 Chapter 5 Transport and unpacking ................... 85 General transport information ................. 86 Transport the system in the company ..............89 Unpacking the system ....................91 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 3 Gas sampling probe H: Removing incrustations ..........176 Gas sampling probe H: Replacing the intake filter ..........178 Gas sampling probe H: Replacing membrane pump membranes ....181 Gas sampling probe 60S: Removing incrustations ..........184 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 4 Putting the system back into operation ..............233 Disposing of the system ..................234 Chapter 12 Appendix ......................235 Pneumatic/hydraulic interface plan ..............236 Electrical connection plan..................238 Transformer connection plan ................. 240 Index ..........................241 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 5: Chapter 1 General

    Chapter 1 General Topic Page About these operating instructions ..............6 Safety instructions in this document ..............8 System identification ..................10 Service ........................13 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 6: About These Operating Instructions

    About these operating instructions Scope and purpose These operating instructions apply to the SCK gas sampling system, product number: 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 7 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". OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 8: Safety Instructions In This Document

    DANGER Safety instructions Safety instructions with specific WARNING on a particular step instructions pertaining to one CAUTION step only Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 9 Warning of damage Warnings of possible damage to property are marked by the word CAUTION to property in this document if there is no danger of injury to persons. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 10: 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 instruc- tions Electric connections Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 11 Status signals as relay contacts Profibus Signals as relay contacts + Profibus Connection to ACX via Modbus Connection to ACX + signals as relay con- tact 12th digit Certificates CE design CSA design OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 12 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 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 13: Service

     for ordering spare parts  for ordering maintenance work Service address Contact your local ABB Service representative. For emergencies, please con- tact: ABB Service, Telephone: +49-(0)180-5-222580, Telefax: +49-(0)621- 38193129031, E-Mail: automation.service@de.abb.com OI/SCK-EN Rev.

  • Page 15: Chapter 2 Description Of The Sampling System

    Controls and displays ..................22 Probe retractor ..................... 24 Gas sampling probe H ..................26 Gas sampling probe 60S ..................28 Cooling module ....................30 Transformer ......................32 Compressed-air tank and pneumatic system ..........33 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 16: 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 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 17: 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. Restrictions The gas sampling system may not be used on use ...

  • Page 18: 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 func- tions: Designation Function Retractor mechanical movement of the probe   automatic removal of the probe when...

  • Page 19: Mode Of Functioning And Operating Modes

    Probe cleaning steps take place after set intervals (these can be defined using the controller). Manual mode Allows operation of the system in manual mode, required for maintenance, for example. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 20: Process Monitoring

     Cooling water pump function check Com- Pressure switch  Ensures adequate  Triggers the retrac- pressed air central compressed- tion program if min- air supply imum input pressure is not reached Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 21 Reed contact  Protects the plunger  Triggers the retrac- retracted against overheating tion program if end position is not reached OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 22: Controls And Displays

    Warning buzzer  See on page 59 Service switch  Puts the system into service mode  Cancels service mode Other controls There are additional controls and displays on the retractor: Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 23 Designation and illus- Function tration Protective installations EMERGENCY STOP  see on page 59 switch on pneumatic Protective installations Warning lamps (2) on  see on page 59 the terminal box OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 24: Probe Retractor

    Warn about insertion and retrac- tion movements of the gas sam- pling probe. Energy chain Guides pneumatic lines and electrical cables and the heated sample gas line and cooling water tubes. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 25 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. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 26: Gas Sampling Probe H

    Initial filtering of the sample gas for dust removal. Plunger Removes incrustations on the in- take opening. Sample gas intake open- Sucks in the sample gas in the rota- ry kiln. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 27 Incrustations on the intake hole are removed hole by means of plunger by periodical pneumatically controlled move- movements ments of the plunger. Probe filter cleaning Filter in probe pipe is cleaned periodically with compressed air. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 28: Gas Sampling Probe 60S

    Gas outlet Passes the sample gas to the downline sample gas analysis system. Heating sleeve Heats the filter unit to prevent condensation build-up. Pipe sealing device Spring-mounted sealing of the tube Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 29 Material deposits and incrustations on the the probe 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. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 30: Cooling Module

    The completely closed system monitors the following pa- rameters:  Cooling water temperature  Cooling water flow rate  Cooling water pressure Structure The following illustrations show the cooling module: Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 31 The water flows through the heat exchanger and pressure-compensating vessel. Additional instruments for measuring pressure, flow rate and temper- ature and fitted in the water pipe. Monitoring is performed on the touchscreen on the control cabinet. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 32: Transformer

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

  • Page 33: Compressed-Air Tank And Pneumatic System

    This tank is not required if the on-site compressed-air supply is of stable performance. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 35: Chapter 3 Description Of Control System

    User interface: Trend screen ................40 User interface: Message screen................. 42 User interface: Parameter screen..............44 Error message display ..................45 Access permissions ..................... 47 Default operating parameter settings ............48 Optimizing operating parameters ..............51 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 36: Structure And Function Of The Control System

    Without user authorization, the operator can only access the dialogs in the Diagnosis menu. For an overview of access permissions in the various areas Access permission of the control system, please refer to the section on page 47. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 37 User interface: operating screen on page 38  User interface: trend screen on page 40  User interface: message screen on page 42  User interface: parameter screen on page 44  OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 38: 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 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 39 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 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 40: 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 dia- navigation gram and move the window currently dis- played Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 41 Save contents: Save diagram data in xls format Move contents of window left/right Zoom in/out Colors The following colors are used in the trend screen line diagram: Color Meaning blue Measured value yellow Pre-alarm Main alarm OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 42: 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 message, etc. (see next page) Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 43 Click on crossed-out clock to display pending messages only Colors The following colors are used in the message screen display area: Color Meaning green Status message in normal operation yellow Maintenance required Error message OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 44: User Interface: Parameter Screen

    Allows navigation in the parameter list navigation Navigation Allows the following functions: area  jump to Message menu  jump to main menu  jump to previous menu Save Saves parameter settings Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 45: Error Message Display

    You can edit alarm limits in a set range to suit specific system conditions. Touch a parameter entry to select it. The program displays an input box for you to input the appropriate value. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 46: Error Message Display

    (message screen). Touch the Message button on the Errors interface to display this logbook. Refer to the section on on page 215 for details on error messages and handling. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 47: Access Permissions

    3 ment of the system. Changes in these access areas may only be performed by experienced skilled personnel with ABB certification as level-2 service techni- cian. Always be extremely careful to whom you disclose the password for this level.

  • Page 48: Default Operating Parameter Settings

    Parameter Default 3 min Back-Purging Interval 90 s Probe Retraction Check Time 100 s Time for Measured Value Release 30 s Automatic Retraction Interval Time 60 s Suction Unit Duration Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 49 1–100 °C Probe Heating Temp. MIN 190 °C 30–200°C Probe Heating Temp. MAX 600 mbar 250–900 mbar Sample Gas Probe Pressure (indicated only when SCK is connected to the ACX analysis system) OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 50 Parameter Default Tolerance range Action / Cleaning Cycle Ratio 80 °C 15–140 °C C. Water Return Temp. Set Point 100 °C 1–190 °C Probe Heating Temp. Set Point Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 51: 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. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 53: 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 ................76 Safety measures: Maintenance and troubleshooting ........80 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 54: Basic Safety Rules

     Use only original spare parts when replacing defective components.  The gas sampling system may only be operated if maintenance work is performed regularly and expertly. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 55 The probe is only retracted out of the rotary kiln after pressing the service switch. Disconnect the system from Turn off the main switch the mains Evacuate the compressed-air Close the stop valve in the pneumatic box system OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 56 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 76 Safety measures: maintenance and troubleshooting on page 80 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 57: Overview Of Dangers

    Hot surfaces During operation of the gas sampling system surfaces and parts get hot. This means:  Danger of burning due to hot surfaces during and after operation of the system. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 58 The pneumatic system contains compressed air. This means the pneumatic  Danger of eye injuries if compressed air escapes, e.g. if compressed-air system pipes burst, when opening screw connections or inadvertently opening compressed-air pipes with no additional connector. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 59: 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 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 60  Automatic mode: ap- prox. 20 seconds be- fore probe movement  Manual mode: immedi- ately after pressing the "Retract probe" button  Error: immediately before probe retrac- tion Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 61 When the protective in- stallation is opened dur- ing operation:  the warning lamps flash  the warning buzzer buzzes  the probe moves out of the rotary kiln to parked position. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 62 An EMERGENCY-STOP switch additionally installed by the operator has the EMERGENCY-STOP same function as the enclosed EMERGENCY-STOP switch described above. switch The additional EMERGENCY-STOP switch must be installed if the above- described EMERGENCY-STOP switch is difficult to access. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • 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 ex- changer. OI/SCK-EN Rev. E Operating instruction 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 retract- ed and the warning lamps go out. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

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

     Shutting down  correct storage  Trained unskilled worker Storage personnel  packing of the system for transport  Trained disposal personnel Disposal Disposal of the gas sam- personnel pling system OI/SCK-EN Rev. E Operating instruction 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 danger area around the retractor that is protected by the protective installation. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 67: Personal Safety Equipment

    The following additional protective equipment is required when performing equipment maintenance work:  Dust mask  Face mask against heat  Heat-proof gloves and protective welder's clothing  Respiratory protection against toxic gases from the rotary kiln OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 68: Safety Measures: Transport And Unpacking

     Do not stand under sus- pended loads.  Follow the transport instructions in these op- erating instructions care- fully. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 69: Safety Measures: Installation

     Do not stand under sus- pended loads.  Follow the transport instructions in these op- erating instructions care- fully. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 70  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. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 71  If any lubricating oil gets in the eyes despite pro- tective glasses, rinse them thoroughly under running water, holding the eyelids open.  Observe instructions in the lubricating oil manu- facturer's safety data sheet. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 72: Safety Measures: Start-Up

     when actuating the retractor after the warn- service switch ing lamps light up or the  when opening the warning buzzer buzzes. protective installa- tion securing the danger area around the retractor Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 73  the heated sam- clothing. pling filter  the entire gas sam- pling probe  the metal structure of the retractor  the shutter of the duct opening OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 74  If cooling water or anti- freeze gets in the eyes despite protective glass- es, rinse them thoroughly under running water, holding the eyelids open.  Observe instructions in the anti-freeze manufac- turer's safety data sheet. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 75 Around the gas sam-  Always keep the floor pling system due to around the gas sampling cooling water or lubri- system clean and dry. cating oil that escapes or is spilled. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 76: Safety Measures: Operation

     failure of the control system  when manually starting probe trav-  when actuating the service switch  when opening the protective installa- tion securing the danger area around the retractor Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 77  the heated sam- pling filter  the entire gas sam- pling probe  the metal structure of the retractor  the shutter of the duct opening OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 78  If any lubricating oil gets in the eyes despite pro- tective glasses, rinse them thoroughly under running water, holding the eyelids open.  Observe instructions in the lubricating oil manu- facturer's safety data sheet. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 79 Around the gas sam-  Always keep the floor pling system due to around the gas sampling cooling water or lubri- system clean and dry. cating oil that escapes or is spilled. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 80: Safety Measures: Maintenance And Troubleshooting

     Do not stand under sus- pended loads.  Follow the transport instructions in these op- erating instructions care- fully. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 81 STOP switch immediately the retractor if anyone is still in the danger area around the retractor after the warn- ing lamps light up or the warning buzzer buzzes. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 82  the heated sam- pling filter  the entire gas sam- pling probe  the metal structure of the retractor  the shutter of the duct opening Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 83  Do not perform work on due to hot cooling cooling water system, the cooling water circuit water particularly: until the gas sampling  ventilation open- system has cooled down. ings  screw connections OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 84 Around the gas sam-  Always keep the floor pling system due to around the gas sampling cooling water or lubri- system clean and dry. cating oil that escapes or is spilled. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 85: Chapter 5 Transport And Unpacking

    Chapter 5 Transport and unpacking Topic Page General transport information ................86 Transport the system in the company .............89 Unpacking the system ..................91 Scope of delivery ....................92 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 86: 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. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 87  May only be transported on its side. air tank  Ensure adequate protection of the attachments. (optional)  Only store after draining all water.  Transport recommendation: For-lift truck or hand lift OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 88 (optional) ing water or condensation: -20 °C to +55 °C Air humidity: Year-round average max. 75 %, short-term max. 95 %, occasional slight condensation is permitted Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 89: Transport The System In The Company

     Protect cooling fins with a board to avoid damage.  Only store after draining all water.  Lifting gear may only be attached at the designated attachment points (transport lugs).  Transport recommendation: For-lift truck or crane OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 90  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 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 91: Unpacking The System

    Note: The retractor must not be transported with a fork- lift truck. Dispose of packaging material in accordance with the national regulations. Transport system parts to the place of installation (see Transporting the system in the company on page 89). OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 92: Scope Of Delivery

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

  • Page 93: Chapter 6 Installation

    Installing the cooling module................103 Installing the cooling water circuit ..............104 Connecting the sample gas line to the retractor ......... 105 Connecting internal electric cables ..............106 Connecting external electric cables ..............108 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 94: Overview: Installation

    Connecting internal electric Connect electric lines. cables on page 106 Connecting external electric Connect external electric cables cables. on page 108 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 95: Checking Site Conditions

    Position to set up the cooling of the cooling module module defined. Choosing the place of installation If a compressed-air tank is of the compressed-air tank required: Position to set up the compressed-air tank defined. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 96 Creating the base area for the The danger area around the probe retractor is protected by retractor Creating the protective installa- a protective installation. tion around the retractor Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 97: 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. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 98 During assembly it may be necessary to move the probe retractor without during assembly with compressed-air supply or control cabinet. However, this should be lim- ited to absolutely necessary cases. Proceed as follows: Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 99 200. 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. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 100: Installing The Control Cabinet

    How to install the control cabinet: Step Procedure Choos- Fasten control cabinet in suitable position (see ing the place of installation of the control cabinet ) with 4 assembly screws or bolts. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 101: Installing The Compressed-Air Supply

    ) with 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. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 102 Observe the following rules:  Pneumatic connections must be installed so as to rule out any damage caused by working in the proximity of the sampling system. ABB recom- mends 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 adapters.

  • Page 103: Installing The Cooling Module

    ) with 4 assembly screws or bolts on the ground. -J62 Attach suitable drain pipe to safety valve outlet order to prevent danger of cooling water escaping. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 104: Installing The Cooling Water Circuit

    Observe the following rules:  Install cooling-water hoses so as to rule out any damage caused by work- ing in the proximity of the gas sampling system. ABB recommends in- stalling 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 adapters.

  • Page 105: 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. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 106: Connecting Internal Electric Cables

    All required lines are pre- installed in the probe retractor area. All downline connections are installed via the central connection point to the electrical terminal box. Required documents  Electrical connection plan Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 107 Connecting the system bus cable to the frequency converter:  Loosen the short system bus cable with T-piece from its transport fixing and connect it to the CAN adapter at the frequency converter. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 108: Connecting External Electric Cables

     Check that the voltage setting of the analyzer system matches the mains voltage.  Make sure the power supply leads have an adequately dimensioned protec- tive device (circuit breaker). Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 109  Signal cable for movable protective installation  Signal cable for external warning horn  System status signal cable  Profibus cable to analyzer cabinet (option "Profibus DP")  Modbus cable to analyzer cabinet (option "ACX") OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 110 (see Detail "A" in pneumatic/hydraulic EMERGENCY-STOP interface plan). To connect an additional EMERGENCY-STOP switch, remove switch the jumper and connect the connection wires to the EMERGENCY-STOP switch. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 111: Chapter 7 Start-Up

    Starting frequency converter and adapting control parameters....124 Checking/correcting operating parameters ..........126 Checks to perform when using probe H ............127 Inserting the probe and switching to automatic mode ......130 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 112: Overview: Start-Up

    130 adjust oil delivery rate on the compressed-air oiler, and check direction of rotation of the heat exchanger. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • 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. OI/SCK-EN Rev. E Operating instruction 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 requirements (do 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 cir-...
  • Page 115 (target cooling water pressure in cooled state: 1-1.5 bar (1000-1500 hPa)). Instructions: check Proceed as follows: for leaks Step Procedure Check cooling water circuit for leaks. Remedy any leaks before continuing with start-up. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 116: Preparing The Compressed-Air Supply

    One probe travel (2 x 20 s) requires approx. 1 m 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. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 117 Remove any oil residue with a cloth. Open the compressed-air gate valve again. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 118: Activation

     The system must not have any visible damage (see also condition on page 141).  The customer-side central compressed-air supply is switched on. Tools required  Control cabinet key to open the control cabinet Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 119 "Cable Drag Chain Sample Gas Line Temp. Error" Path: Diagnosis ► Message Turn service switch to position. Note: This step resets various safety functions. Turn service switch to position. Result: The gas sampling system is in manual mode. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 120  Checking frequency converter settings  on page 124 Checking/correcting operating parameters on page 126  Checks to perform when using probe H  on page 127 Close the control cabinet. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • 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 position, the gas sampling probe is retracted Operating the service switch from the kiln (see on page 161). OI/SCK-EN Rev. E Operating instruction 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. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • 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. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 124: Starting Frequency Converter And Adapting Control Parameters

    Requirements The following conditions must be met: The service switch is in the position; the gas sampling probe is retracted Operating the service switch from the kiln (see on page 161). Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 125 Adjust control parameter KI to further optimize the tempera- ture run (TN, default: 10). If necessary, also adjust control parameter KD (TV, default: 0). Save control parameter settings using the button. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 126: Checking/Correcting Operating Parameters

    48. You can display the operating parameters on the control cabinet touchscreen (Setup ► Time Parameters, Setup ► Limit Parameters, Setup ► Basic Parameters). Optimizing operating parameters Refer to on page 51 for details on editing operating parameters. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 127: Checks To Perform When Using Probe H

    Requirements The following conditions must be met: The service switch is in the position, the gas sampling probe is retracted Operating the service switch from the kiln (see on page 161). OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 128 Start-up delay There is a DIP switch under the white flap. Check the following settings here: 1 Undercurrent monitor- 2 NC contact operation 3 Storage off 4 (Default) Close the control cabinet. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 129 Check the following possibilities for adequate supply:  Lay larger cross-sections  Reduce lengths of supply lines OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 130: Inserting The Probe And Switching To Automatic Mode

    Note: Inserting the gas sampling probe when the duct opening is clogged can lead to damage to the probe and is therefore not permitted. Leave danger area around the retractor, close protective instal- lation and turn service switch to position. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 131 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. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 132 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 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 133 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 damage or total loss of the gas sampling probe. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 135: Chapter 8 Operation

    Safety regulations for operation ..............136 Monitoring automatic mode ................139 Checking general condition ................141 Cleaning gas sampling probe H ..............143 Cleaning gas sampling probe 60S ..............145 Using the EMERGENCY-STOP switch ............. 147 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 136: Safety Regulations For Operation

     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 elec- tric components. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 137 Risk of scalding when hot cooling water escapes from the cooling system in the event of a malfunction  Wait until the entire cooling water has been evacuated before approach- ing. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 138 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. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 139: Monitoring Automatic Mode

    To resume normal measuring operation you must manually insert the gas sampling probe into the kiln and then switch to automatic mode (see section Start-up on page 111). OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 140 It can be assumed that safe operation is no longer possible:  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. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 141: Checking General Condition

    If there are any defects that impact safety, inform the responsible mainte- nance personnel. If cleaning is necessary, follow the instructions in Checking the condition of the system, cleaning the system on page 163. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 142 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 damage or total loss of the gas sampling probe. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 143: Cleaning Gas Sampling Probe H

    Gas sampling probe moves out and in to scrape off any adher- ing material. Plunger moves forward and backward to clean the sample gas inlet. Air blast to clean the probe filter. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 144 Cleaning in the event Note: The following function is available only when SCK is connected to the of error message ACX analysis system. When used with other analysis systems, a default sam- ple gas probe pressure of "9999 hPa" is indicated in the "Diagnosis" menu.

  • Page 145: Cleaning Gas Sampling Probe 60S

    Two air blasts lasting 1 second each to clean the probe filter. Three air blasts lasting 1 second each to clean the filter casing. Air blast lasting 3 seconds to clean the probe pipe. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 146 Cleaning in the event Note: The following function is available only when SCK is connected to the of error message ACX analysis system. When used with other analysis systems, a default sam- ple gas probe pressure of "9999 hPa" is indicated in the "Diagnosis" menu.

  • Page 147: Using The Emergency-Stop Switch

    Result: The gas sampling probe is automatically retracted out Maintenance of the kiln, the controller displays the message. Turn service switch back to the initial position ( OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 149: Chapter 9 Maintenance

    Probe retractor: Checking the bellows ............207 Cooling module: Vent the cooling-water circuit .......... 208 Cooling module: Checking and topping up cooling water ......210 Pneumatic system: Replacing the compressed-air filter ......213 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 150: 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 representative responsible for you. Service switch...
  • Page 151 176  Replace intake filter Gas sampling probe H: Replacing the intake filter on page 178  Replace membrane pump Gas sampling probe H: Replacing membranes membrane pump membranes on page OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 152 200  Check position indicator on Probe retractor: Checking and, if nec- the retractor and, if neces- essary, adjusting the position indica- sary, re-align tor (probe end position) on page 204 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 153 Pneumatic system  Replace compressed-air Pneumatic system: Replacing the filter in pneumatic box compressed-air filter on page 213  Check compressed-air Checking for leaks on page 173 system for leaks OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 154: Equipment Layout Plan

    -J78 Pneumatic valve "shutter" -J79 Pneumatic motor -J81 Gate valve -J82 Air filter -J83 Probe movement warning lamp -P71 -P72 Probe movement warning lamp not illustrated Position indicators -B71, -B72, -S72 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 155 Heat exchanger circuit breaker -F35 Cooling-water pump circuit breaker -F36 Cooling-water pump motor breaker -F37 -S31 Service switch Main switch for normal voltage -Q30 Main switch for UPS (optional) -Q40 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 156 Diagram of location of maintenance-relevant equipment on cooling module: Equipment The following table lists the above-mentioned equipment: Designation Shut-off valve cooling water -J63 Cooling water inlet Cooling water feed Safety relief valve outlet Heat exchanger -J60 Cooling water return Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 157: 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 OI/SCK-EN Rev. E...

  • Page 158: Safety Regulations For Maintenance Work

     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. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 159  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 respiratory protection. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 160 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. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 161: Operating The Service Switch

    Safety regulations for maintenance work on Explanation of safety measures: page 158. Requirement The service switch is in the position. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 162 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. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 163: Checking The Condition Of The System, Cleaning The System

     If any lubricating oil gets in the eyes despite protective glasses, rinse them thoroughly under running water, holding the eyelids open.  Observe instructions in the lubricating oil manufacturer's safety data sheet. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 164 Clean touchscreen, particularly edge areas, with compressed- air and/or moist cloth (if you use cleaning agents, you can request a resistance table from ABB Service). Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 165 If you observe signs of wear, you must reposition the gas sam- pling probe in the process gas flow; if you have any questions regarding repositioning the probe, contact ABB Service. Checking the Check the wall tube for clogging and deposits at regular intervals and clean if duct opening necessary.

  • Page 166: 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 Description of control system further details refer to section on page 35. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 167: Checking The Residual Current Circuit Breaker

     Control cabinet key to open the control cabinet Requirements The service switch is in the position; the gas sampling probe is completely Operating the service switch retracted from the kiln (see on page 161). OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 168 Perform steps 1 through 3 with residual current circuit breaker -F40 for UPS (if present). -F30/-F40 Switch residual current circuit breaker back on. Lock the control cabinet. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 169: Checking Protective Installations

    Safety regulations for maintenance work on page 158. Requirements The following conditions must be met:  System is in operation.  Gas sampling probe is inserted into the kiln.  Service switch is in the position. OI/SCK-EN Rev. E Operating instruction 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 carriage until the probe is completely inserted into the kiln and the warning lamps go out. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 171 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. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 172 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. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 173: Checking For Leaks

    Safety regulations for maintenance work on Explanation of safety measures: page 158. Required tools The following tools are required:  For checking the compressed-air system and cooling-water circuit for leaks: leak detection spray OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 174 Do not stand in the area Probe moves into the kiln. of travel of the probe or probe carriage until the probe is com- pletely inserted into the kiln and the warning lamps go out. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 175 Do not stand in the Probe moves into the kiln. area of travel of the probe or probe carriage until the probe is completely inserted into the kiln and the warning lamps go out. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 176: Gas Sampling Probe H: Removing Incrustations

     Always keep the floor around the gas sampling system clean and dry. Safety regulations for maintenance work on Explanation of safety measures: page 158. Tools required  Chisel  Hammer Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 177 In controller: wait for heat-up time until the following error messages disappear: "C. Water Return Temp. MIN" Path: Diagnosis ► Message In controller: switch gas sampling probe to AUTOMATIC mode: Operation ► Automatic on / off OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 178: Gas Sampling Probe H: Replacing The Intake Filter

    For extensive work on the probe tip (e.g. when replacing the filter) it is advis- able 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. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 179 Do not touch the probe until it has cooled down to below 50 °C. Unscrew the adjustment screws on the probe carriage until you can swing the probe out. Swing the probe out to the right. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 180 In controller: wait for heat-up time until the following error messages disappear: "C. Water Return Temp. MIN" Path: Diagnosis ► Message In controller: switch gas sampling probe to AUTOMATIC mode: Path: Operation ► Automatic on / off Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 181: Gas Sampling Probe H: Replacing Membrane Pump Membranes

    Power off pump at the circuit breaker Clean outside of pump housing. Unscrew the four screws to open the pump housing. -M71 Detach the pump tubes, remove the pump and clean it externally. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 182 Reconnect pump hoses. Screw pump housing back on. -F34 Switch circuit breaker back on. Close control cabinet again. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 183 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. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 184: Gas Sampling Probe 60S: Removing Incrustations

     Always keep the floor around the gas sampling system clean and dry. Safety regulations for maintenance work on Explanation of safety measures: page 158. Tools required  Chisel  Hammer Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 185 In controller: wait for heat-up time until the following error messages disappear: "C. Water Return Temp. MIN" Path: Diagnosis ► Message In controller: switch gas sampling probe to AUTOMATIC mode: Path: Operation ► Automatic on / off OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 186: 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 below 50 °C. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 187 Wear appropriate protective clothing when cleaning. Replace filter stone. Gas sampling probe 60S: Re- If necessary, replace seals (see placing the seal set on page 189). OI/SCK-EN Rev. E Operating instruction 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 completely inserted into the kiln and the warning lamps go out. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 189: 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 below 50 °C. OI/SCK-EN Rev. E Operating instruction 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 completely inserted into the kiln and the warning lamps go out. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 191: Probe Retractor: Checking Filter/Pressure Control Combination

    The following conditions must be met:  The service switch is in the position; the gas sampling probe is retract- Operating the service switch ed from the kiln (see on page 161). OI/SCK-EN Rev. E Operating instruction 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 completely inserted into the kiln and the warning lamps go out. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 193: Probe Retractor: Checking And Replacing The Filter Muffler

    The following conditions must be met:  The service switch is in the position; the gas sampling probe is com- Operating the service switch pletely retracted from the kiln (see on page 161). OI/SCK-EN Rev. E Operating instruction 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 completely inserted into the kiln and the warning lamps go out. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 195: Probe Retractor: Checking And Topping Up The Oiler

    The following conditions must be met:  The service switch is in the position, the gas sampling probe is retract- Operating the service switch ed from the kiln (see on page 161). OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 196 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. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 197 If this is not ensured, the compressed-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 neces- sary. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 198: Probe Retractor: Checking And Tightening The Drive Chain

     The service switch is in the position; the gas sampling probe is retract- Operating the service switch ed from the kiln (see on page 161).  The EMERGENCY STOP switch is pressed. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 199 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. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 200: Probe Retractor: Checking And, If Necessary, Adjusting The Position Of The Probe

    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 and the warn- ing lamps go out. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 201 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. Unscrew counter nuts on probe carriage. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 202 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. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 203 Follow the instruc- tions in Probe retractor: Checking and, if necessary, adjusting the position indicator (probe end position) on page 204. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 204: 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. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 205 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. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 206 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. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 207: 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 carriage until the probe is completely inserted into the kiln and the warning lamps go out. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 208: 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 Tempera- ture Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 209 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. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 210: Cooling Module: Checking And Topping Up Cooling Water

    Anti-freeze If ambient temperatures below 0 °C can be expected, you must admix anti- requirements freeze. ABB recommends Glykol as anti-freeze. Anti-freeze with anti-corrosive additive is not permitted. Maintenance interval Check cooling water pressure and cooling water flow rate on a daily basis.
  • Page 211 Unscrew cap and slowly open vent cock (red) so that air can escape. -J63 Open shut-off valve and allow cooling water to flow in slowly until bubble-free cooling water appears at the heat exchanger drain valve. -J63 Close shut-off valve OI/SCK-EN Rev. E Operating instruction 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 completely inserted into the kiln and the warning lamps go out. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 213: Pneumatic System: Replacing The Compressed-Air Filter

    Explanation of safety measures: page 158. Requirements The service switch is in the position; the gas sampling probe is retracted Operating the service switch from the kiln (see on page 161). OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 214 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. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 215: Chapter 10 Errors

    Chapter 10 Errors Topic Page Errors and irregularities ..................216 Touchscreen error displays ................218 Handling error messages ................. 223 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 216: Errors And Irregularities

    Venting the cooling- cooling-water water circuit circuit on page  Top up cooling water, Cooling module: Checking and topping up cooling water on page Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 217  Do not begin repair work until it has cooled down Probe movement  Mechanical damage  Press EMERGENCY STOP blocked  Incrustation switch before working on the probe  Remove blockage OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 218: Touchscreen Error Displays

     Check central compressed- pressed Air air supply input pres- supply disrupted air supply Not OK sure too low  Pressure switch 577 error  Check functioning and set- ting of pressure switch 577 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 219 Error Posi- Plunger movement  Both plunger movement  Check function and position tion Switch limit switch error limit switches triggered of limit switches Plunger simultaneously Action OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 220 Retraction  Rear limit switch error proper functioning  Check and, if necessary, clean gas sampling probe entry zone  Check gas sampling probe travel time, modify speed setting if necessary Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 221 CAN Error Can bus error to  Can bus connection error  Check CAN bus cable for Slave 1 slave 1 damage slave 1 -D31  Contact ABB Service if nec- essary OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 222 CAN Error Can bus error to  Can bus connection error  Check CAN bus cable for Slave 9 slave 9 damage slave 9 -D74  Contact ABB Service if nec- essary Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 223: 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 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 225: Chapter 11 Shutting Down, Storing, Putting Back Into Operation, Disposal

    Topic Page Shutting down the system ................226 Disassembling the system ................229 Storing the system..................... 232 Putting the system back into operation ............233 Disposing of the system ................... 234 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 226: Shutting Down The System

     If cooling water or anti-freeze gets in the eyes despite protective glass- es, rinse them thoroughly under running water, holding the eyelids open.  Observe instructions in the anti-freeze manufacturer's safety data sheet. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 227 15 minutes. Clean any residue and incrustations off the filter unit and probe pipe. Note: Only clean mechanically. Do not use chemicals (particu- larly acids and lyes) for cleaning. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 228 If anti-freeze (Glykol) was admixed, observe disposal regulations in accord- ance with national legislation. Disassembling the system Further procedure Refer to on page 229 for details on further proce- dure. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 229: Disassembling The System

    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. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 230 Unscrew and remove fastening screws on mounting flange and attachment points. Using lifting gear, lower probe retractor until you can screw on the enclosed transport supports. Place probe retractor on ground and secure from falling over. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 231 Note: The retractor must not be transported by fork-lift truck without suitable additional transport packaging. Start-up is to be put back into on page 111. operation OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 232: Storing The System

    (optional) ing water or condensation: -20 °C to +55 °C Air humidity: Year-round average max. 75 %, short-term max. 95 %, occasional slight condensation is permitted Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 233: 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. OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 234: Disposing Of The System

     All other components of the gas sampling system must be disposed of expertly and in accordance with national legislation. Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 235: Chapter 12 Appendix

    Chapter 12 Appendix Topic Page Pneumatic/hydraulic interface plan ............... 236 Electrical connection plan................. 238 Transformer connection plan ................. 240 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 236: Pneumatic/Hydraulic Interface Plan

    Pneumatic/hydraulic interface plan Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 237 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 238: Electrical Connection Plan

    Electrical connection plan Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 239 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...

  • Page 240: Transformer Connection Plan

    Transformer connection plan Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...

  • Page 241: Index

    Installing the cooling module • 103 Installing the cooling water circuit • 104 Installing the probe retractor • 97 Default operating parameter settings • 48 Intended conditions of use • 17 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 242 Checking and topping up the oiler • 195 Transformer • 32 Checking and, if necessary, adjusting the position indicator (probe end position) • Transformer connection plan • 240 Transport and unpacking • 85 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E...
  • Page 243 Message screen • 42 Operation screen • 38 Parameter screen • 44 Trend screen • 40 Using the EMERGENCY-STOP switch • 147 Warning signs on the system • 63 Work places • 65 OI/SCK-EN Rev. E Operating instruction SCK Gas Sampling System...
  • Page 244 We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.

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