ABB SCK User manual

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ABB MEASUREMENT & ANALYTICS |
OPERATING INSTRUCTION | OI/SCK-EN REV. E
SCK
Sample
conditioning for kiln
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ABB Measurement & Analytics
For your local ABB contact, visit:
www.abb.com/contacts
For more product information, visit:
www.abb.com/analytical
Sampling system for dry gas
sampling at rotary cement kiln gas
exit and calciner gas exit
Measurement made easy
OI/SCK
-EN Rev. E 07.2021 Original instruction
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SCK
Introduction
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.
Additional Information
Additional documentation on SCK is available for
download free of charge at www.abb.com/analytical.
Alternatively simply scan this code:
—
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.
We reserve all rights in this document and in the
subject matter and illustrations contained
therein.
Any reproduction, disclosure to third parties or utilization of its contents – in whole
or in parts
– is forbidden without prior written consent of ABB.
© ABB 2021 3KXG141003R4201

2 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E
Contents
Chapter 1 General....................................................................................................................5
About these operating instructions .......................................................................... 6
Safety instructions in this document........................................................................ 8
System identification ..................................................................................................10
Service............................................................................................................................13
Chapter 2 Description of the sampling system ................................................................. 15
Technical data...............................................................................................................16
Intended conditions of use ........................................................................................17
Structure and function................................................................................................18
Mode of functioning and operating modes ............................................................19
Process monitoring .................................................................................................... 20
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
Chapter 3 Description of control system ........................................................................... 35
Structure and function of the control system ....................................................... 36
User interface: Operation screen ............................................................................. 38
User interface: Trend screen..................................................................................... 40
User interface: Message screen................................................................................ 42
User interface: Parameter screen............................................................................. 44
Error message display................................................................................................ 46
Access permissions .................................................................................................... 47
Default operating parameter settings.................................................................... 48
Optimizing operating parameters............................................................................51
Chapter 4 Safety.................................................................................................................... 53
Basic safety rules ........................................................................................................ 54
Overview of dangers....................................................................................................57
Protective installations .............................................................................................. 59
Warning signs on the system.................................................................................... 63
Requirements to be met by personnel, work places ............................................ 65
Personal safety equipment ........................................................................................67
Safety measures: Transport and unpacking .......................................................... 68
Safety measures: Installation ................................................................................... 69
Safety measures: Start-up..........................................................................................72
Safety measures: Operation ......................................................................................76
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

OI/SCK
-EN Rev. E Operating instruction SCK Gas Sampling System 3
Scope of delivery ......................................................................................................... 92
Chapter 6 Installation ...........................................................................................................93
Overview: installation................................................................................................. 94
Checking site conditions ........................................................................................... 95
Installing the probe retractor ....................................................................................97
Installing the control cabinet.................................................................................. 100
Installing the compressed-air supply .....................................................................101
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
Chapter 7 Start-up ...............................................................................................................111
Overview: Start-up ..................................................................................................... 112
Installation check ....................................................................................................... 113
Preparing the cooling-water circuit........................................................................114
Preparing the compressed-air supply ....................................................................116
Activation.....................................................................................................................118
After switching on: working on the cooling module ........................................... 121
Checking the pneumatic system.............................................................................123
Starting frequency converter and adapting control parameters......................124
Checking/correcting operating parameters ........................................................126
Checks to perform when using probe H ................................................................127
Inserting the probe and switching to automatic mode..................................... 130
Chapter 8 Operation ........................................................................................................... 135
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
Chapter 9 Maintenance.......................................................................................................149
Maintenance plan ...................................................................................................... 150
Equipment layout plan ............................................................................................. 154
Acquiring spare parts and wear parts....................................................................157
Safety regulations for maintenance work.............................................................158
Operating the service switch...................................................................................161
Checking the condition of the system, cleaning the system.............................163
Evaluating trend displays ........................................................................................ 166
Checking the residual current circuit breaker.......................................................167
Checking protective installations .......................................................................... 169
Checking for leaks......................................................................................................173
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

4 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E
Gas sampling probe 60S: Cleaning or replacing the outlet filter..................... 186
Gas sampling probe 60S: Replacing the seal set ................................................ 189
Probe retractor: Checking filter/pressure control combination....................... 191
Probe retractor: Checking and replacing the filter muffler................................193
Probe retractor: Checking and topping up the oiler............................................195
Probe retractor: Checking and tightening the drive chain................................ 198
Probe retractor: Checking and, if necessary, adjusting the position of the
probe ...........................................................................................................................200
Probe retractor: Checking and, if necessary, adjusting the position indicator
(probe end position)................................................................................................. 204
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
Chapter 10 Errors .................................................................................................................. 215
Errors and irregularities............................................................................................216
Touchscreen error displays ......................................................................................218
Handling error messages .........................................................................................223
Chapter 11 Shutting down, storing, putting back into operation, disposal................... 225
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
Chapter 12 Appendix ............................................................................................................ 235
Pneumatic/hydraulic interface plan ...................................................................... 236
Electrical connection plan........................................................................................ 238
Transformer connection plan .................................................................................240
Index .............................................................................................................................241

OI/SCK
-EN Rev. E Operating instruction SCK Gas Sampling System 5
Chapter 1 General
Topic Page
About these operating instructions ...................................................................6
Safety instructions in this document.................................................................8
System identification ..........................................................................................10
Service.................................................................................................................... 13

6 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E
About these operating instructions
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:
Transport at the company (for first-time delivery, relocation, storage,
putting back into operation)
Set-up, unpacking and connection
Start-up
Operation
Diagnostics and troubleshooting
Maintenance
Shutting down, disassembly, putting back into operation, storage and
disposal
These operating instructions are intended for the following groups:
Process engineers and design engineers (for preparation of the installation
site)
Transporter
Assembly personnel
Start-up personnel
Operating personnel
Maintenance personnel
Storage personnel
Disposal personnel
The illustrations in the operating instructions do not always depict the actual
layout of a gas sampling system as delivered. Therefore, the drawings in the
supplied system documentation are always authoritative.
Failing to observe the information in this document can lead to a risk of dam-
age to property, injuries or even death.
In order to ensure safety, all personnel handling the gas sampling system
must have read and understood the following sections of this document
before commencing any work:
the section on Safety on page 53
the sections describing the work to be performed
Scope and purpose
Target group
Illustrations in the
operating
instructions

OI/SCK
-EN Rev. E Operating instruction SCK Gas Sampling System 7
The manufacturer retains copyright to these operating instructions:
ABB Automation GmbH
Geschäftsgebiet Analysentechnik
Stierstädter Straße 5
60488 Frankfurt am Main
GERMANY
These operating instructions contain regulations and drawings of a technical
nature that must not, either in part or in whole, be reproduced, disseminated
or exploited for the purpose of competition or passed on to third parties
without permission.
The manufacturer is not liable for damage and disruptions resulting from a
failure to observe these operating instructions and other applicable docu-
ments.
Identifies safety information to be heeded when handling
the gas sampling system in order to avoid risks to the
operator.
Identifies special information regarding handling of the
gas sampling system as well as use of these operating
instructions.
1, 2, 3, ...
Identifies reference numbers in the figures.
Further information on ABB Analytical products and services is available on
the Internet at "http://www.abb.com/analytical".
Copyright
Liability
Symbols and
typefaces
Further information

8 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E
Safety instructions in this document
Safety instructions are information intended to prevent physical injuries.
Safety instructions contain the following information:
Type of danger
Possible consequences if you fail to observe the instruction
Action to prevent physical injury
This document contains the following types of safety instruction:
Type of safety
instruction
Description Indicated by
Basic safety in-
structions
Generic safety instructions not
pertaining to a particular task:
They provide a general de-
scription of dangers and
safety measures when han-
dling the system.
They are intended to educate
the operator about existing
dangers and to instruct him
in general safety behavior.
They are suitable for safety
instruction of all personnel
handling the gas sampling
system.
Indicated by the
title of the section.
Safety regulations
for specific sec-
tions
Safety instructions pertaining to
all tasks described in this sec-
tion
Indicated by the
title of the section
Safety instructions
at the beginning of
an instruction
Safety instructions with specific
instructions pertaining to the
entire instruction
Safety instructions
on a particular step
Safety instructions with specific
instructions pertaining to one
step only
DANGER
WARNING
CAUTION
What are safety
instructions for?
Types of safety
instruction

OI/SCK
-EN Rev. E Operating instruction SCK Gas Sampling System 9
The safety instructions pertaining to instructions and actions are indicated by
a danger word. The danger word stands for a particular danger level:
Type of safety
instruction
If the instruction is not fol-
lowed ...
And the consequence is
...
DANGER an accident occurs. serious bodily injury or
death.
WARNING the accident may occur. possibly serious bodily
injury or death.
CAUTION the accident will definitely or
may possibly occur.
major or minor bodily
injury.
Warnings of possible damage to property are marked by the word CAUTION
in this document if there is no danger of injury to persons.
Danger levels
Warning of damage
to property

10 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E
System identification
The gas sampling system can be unambiguously identified by means of the
specifications on the nameplate. The nameplate is located on the left side
wall of the control cabinet. The nameplate is laid out as follows:
The individual areas of the nameplate have the following meaning:
No.
Meaning
1
Product name
2
Product number
3
Customer order number
4
Production number
5
Manufacturer's address
6
Serial number of the retractor
7
Serial number of the cooling module
8
Year of manufacture of the system
9
CE mark
10
Environment-Friendly Use Period (EFUP) mark
11
Warning triangle to DIN EN 61010: observe operating instruc-
tions
12
Electric connections
Nameplate