Gas Sampling

Operating instructions

en-16052.055–A

Gas sampling probe type QSB

with

retracting device AURETRAC

Code word

Order number

AAT items

BredemeierH

Draft


Gas sampling probe type QSB with retracting device AURETRAC

Contents

en-16052.055–A

Contents

1 Technical data 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Accident prevention measures 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Components and description of functioning 3–1. . . . . . . . . . . . . . 3.1 Components 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Description of functioning 3–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Control of the gas sampling probe with retracting device 3–21. . . . . . . .

4 Transport und assembly 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Transport and storage requirements 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Assembly 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Lubrication 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Preparation for the test run 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 Checks prior to the test run 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Setting and adjustment 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Maintenance 7–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Inspection 7–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Servicing 7–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Trouble shooting 7–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4 Repair 7–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Spare parts 8–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Appendix 9–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 Technical drawings 9–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Subsuppliers’ documentation 9–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Gas sampling probe type QSB with retracting device AURETRAC 1–1

Technical data

en-16052.055–A

1 Technical data

NOTEInformation concerning the electrical equipment is contained in the separateelectrical documentation or in the subsuppliers’ documentation.

Information on the intended useThe gas sampling system is a part of the kiln system.

Supply systems to be provided by the customer

Cooling water

Quantity approx. 2 m3/h. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure min. 2 bar, max. 10 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature max. 35 °C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quality soft industrial water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Feed/return connections G 1 1/2 internal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressed air

Pressure min. 6 bar, max. 8 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quality free of oil and water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection G 1/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Average total consumption approx. 400 litres per hour. . . . . . . . . . . . . . . . . . . . . . . .

Consumption of gas sampling probe 8 litres per cleaning operation. . . . . . . . . . . . .

Consumption per retracting operation approx. 200 litres. . . . . . . . . . . . . . . . . . . . . . .

Gas sampling probe (1)

Year of construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nominal length mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter 108 mm, external. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nominal width of the clamping flange DN 280. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Length of the entire installation equipment mm. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation site kiln inlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Total weight approx. 150 kg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analysis cabinet

see operating instructions no.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Gas sampling probe type QSB with retracting device AURETRAC1–2

Technical data

en-16052.055–A

Shock blower (1.2)

Type Shock blower B8 in flange design DN 40, PN 40. . . . . . . . . . . . . . . . . . . . . . . .

Tank volume 8 litres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating pressure approx. 6 bar (max. 8 bar). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Actuation electro-pneumatic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressed air connection G 1/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary heating (1.5.1)

Length approx. 5.5 m. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rating approx. 220 W. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature sensor (1.7)

Type Pt100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Large–area filter (1.10)

Number 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter housing

Inlet connection G 3/4 external. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outlet connection G 1/2 internal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight 28 kg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum operating temperature 100 °C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heating

External ∅ / Internal ∅ / Height 210 / 140 / 260 mm. . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rating 450 W. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with thermostat 70 °C ±5 °C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter cartridges

Size 234 mm x 120 mm ∅. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter area 0.4 m2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filtering rate 39 µm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Technical data

en-16052.055–A


Filter housing

Inlet connection G 3/4 external. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outlet connection G 1/2 internal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight 28 kg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Heating

External ∅ / Internal ∅ / Height 210 / 140 / 260 mm. . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rating 450 W. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Filter cartridges

Size 234 mm x 120 mm ∅. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter area 0.4 m2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filtering rate 14 µm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fine filter (1.12)

Filter housing

Type L–10–S–K. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections G 3/4, reduced to G 1/4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Heating

External ∅ / Internal ∅ / Height 130 / 90 / 280 mm. . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rating 100 W. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Filter cartridge

Size 255 mm x 73 mm ∅. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter area 0.6 m2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filtering rate 3 µm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature sensor (1.15)

Type Pt100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Length mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Technical data

en-16052.055–A

Retracting device (2)

Running track length mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Length of traverse mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attachment of the gas sampling probe for flange DN 280. . . . . . . . . . . . . . . . . . . . .

Length without gas sampling probe mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Total weight without gas sampling probe approx. 1200 kg. . . . . . . . . . . . . . . . . . . . .

Cooling water control panel (3)

Dimensions (L x B x H) approx. 1550 x 1000 x 1100 mm. . . . . . . . . . . . . . . . . . . . .

Weight approx. 270 kg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water connections

Primary cooling circulation system G 3/4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Secondary cooling circulation system G 1 1/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heat exchanger (3.1)

Type Funke BLF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling area of the fixed pipe cluster 4.6 m2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting flange DN 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Centrifugal pump (3.3)

Type Grundfos CR4, 4–stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage / Hertz V / Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical power requirement kW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum conveying rate m3/h. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Max. admissible temperature 120 °C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting drive (3.4) of the 4-way mixing valve

Type CENTRA VMM 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage 220 V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stroke 90°. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Actuating time 1.8 min. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Technical data

en-16052.055–A

Expansion chamber (3.5)

Effective capacity 8 litres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Admission pressure 4 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum operating pressure 16 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended maximum operating temperature 70 °C. . . . . . . . . . . . . . . . . . . . . . .

Pressure switch (3.6)

Adjusting range 0.5 to 5 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contact load 250 V/AC, 5A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustment value 1 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning device (4) for filter cartridges

Dimensions (L x B x H) approx. 650 x 330 x 740 mm. . . . . . . . . . . . . . . . . . . . . . . . .

Rating 2000 W. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage / Hertz V / Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tank capacity 60 litres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Required quality of compressed air 75 litres per minute. . . . . . . . . . . . . . . . . . . . . . .

Vacuum –220 mbar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressed–air connection with oil and water separator G 1/2. . . . . . . . . . . . . . . .

Weight approx. 40 kg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Technical data

en-16052.055–A

Pneumatic control system (7)

Air pressure regulator (7.13)

Adjustment value 6 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil mist lubricator (7.14)

Adjustment value 1 drop per travel operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Data on the switch contact of the level monitor (7.27) in the oil mist lubricator

Switched power 10 VA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage 250 V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

max. temperature 60 °C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type of protection IP 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The switch contact is connected to the control system by an appliance socket.

Pneumatic motor (7.19)

Type LZL 05. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rated power 1.4 kW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


necessary pressure max. 6–7 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vibrator (7.20)

Type K 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sealing flap (8)

Control cylinder (8.2)

Actuating force 989 N. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Actuating stroke 160 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .




Technical data

en-16052.055–A

Electrical control box (9)

Connected voltage V, AC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type of protection IP 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control times – starting position

see parameter list of control program in the section 9.1 Technical drawings

Temperature regulator (9.1) for cooling water

Type KS 4290. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Basic parameter adjustments

Supply temperature of the primary circulating system (w) 70 °C. . . . . . . . . . . . . . . .

Max. cooling water temperature of the primary circulating system (L+) 95 °C. . . .

Temperature regulator (9.2) for auxiliary heating

Type TR 3400 W. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature setpoint (w) 75 °C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Safety

en-16052.055–A

2 Safety

NOTEBe sure to comply with the general safety instructions in the supplement Importantnotes on the documentation.

Use of the machinery

+ The measuring device is intended exclusively for the extraction of process gas.Be sure to comply with the information concerning the intended use of themachinery in the section Technical data.

+ Any use of the machinery other than for the intended use is forbidden.KRUPP POLYSIUS AG is not responsible for any damage resulting from anyother than the intended use of the machine. All other use is at the user’s own risk.

+ Observance of the operating instructions and compliance with the conditions formaintenance are part of the intended use.

Transport and assembly

+ All transport information in these operating instructions refer exclusively to thetransport of the measuring device in the plant area.

+ Use only suitable hoisting and lifting equipment which is in serviceable order andhas a sufficient load bearing capacity.

+ Never work under a suspended load.

Preparation for commissioning

+ Do not make any unauthorised changes to the control system.

Operation

The following safety sign is fitted to the machine:

The carriage starts automatically and without prior warning.The carriage may hit you on the head and cause severe injuries.Never step between the carriage and the rotary kiln.

+ Secure the space below the carriage with protection devices to preventunauthorized access.

+ Any safety checks before or during operation are governed by the applicablenational provisions. The plant management is responsible for the performanceand recording of such checks.

+ If changes in the machine or its operating behaviour relevant to safety occur, shutit down immediately.



Safety

en-16052.055–A

2.1 Accident prevention measures

Despite the safety precautions integrated into the circuitry, any work on theequipment, in particular repair work on the shock blower may, in accordance with thegeneral accident prevention regulations, only be performed if

+ the compressed–air supply has been stopped via the ball valve (7.10),

+ the shock blower (1.2) has been depressurized via 3/2-directional control valve(7.28) [open when de–energized] and the pressureless condition has beenchecked,

+ the drain valve (1.2.1) of the shock blower (1.2) is open.

Maintenance

+ Ensure that for the entire duration of the maintenance work, all machines andmotors whose operation might endanger persons or equipment are switched offand safeguarded against restarting.

+ Before performing any work on the machine, make sure there is no risk of burnswhen touching the machine.

+ Keep the machine free of oily and combustible substances and materials. Neveruse gasoline or other flammable substances for cleaning the machine.

+ Disconnect the power supply to the electrical components before starting anymaintenance work.

+ Make sure that pneumatic pipes are depressurised before disconnecting them.

+ After all maintenance work, check that all connections and connecting points arefree of leaks.

+ Strictly observe the welding instructions when performing any welding work.

+ If you carry out electrical welding on any part of the machine, never conduct thewelding current through sliding or antifriction bearings, other movableconnections or measuring equipment. Always directly connect the welding currentreturn lead to the part being welded.

+ Remount all protection devices and properly close all inspection and maintenanceflaps when maintenance work has been finished.



Components and description of functioning

en-16052.055–A

3 Components and description of functioning

Gas analysis systemGas analysis systems play an important part in cement works as process measuringequipment and safety measuring equipment. In these measuring tasks, a highdegree of reliability and sufficient accuracy are important.

An extractive gas analysis system consists of two main components:

Gas extraction with preliminary filtering

Gas transport and preparation

Gas analysis

Gas sampling probe

Analysis cabinet

Gas sampling probe

The design of the gas sampling probe is heavily dependant on the ambientconditions such as the dust content, the dust composition, the temperature and thedew point of the process gas. Because a gas sampling probe is therefore onlyconceived for a specific operating site, transfer to another operating site isinadmissible.

Analysis cabinet

The analysis cabinet contains the gas pump required for transport, the gaspreparation equipment and the analyzer unit. See also the associated operatinginstructions.

NOTEBecause the components of the gas sampling probe and the analysis cabinetmust be exactly matched to each other to produce an operational gas analysissystem, we warn against the use of gas sampling probes and analysis cabinets fromdifferent manufacturers!




en-16052.055–A

3.1 Components

NOTESome details of the drawings in this manual may not be identical with the drawingssupplied under the contract as listed in the section 9.1 Technical drawings.

Assemblies of the gas analysis system

1 Gas sampling probe

2 Retracting device AURETRAC

3 Cooling water control panel

4 Cleaning device for filter cartridges

5 Analysis cabinet

6 Heated PTFE gas line

7 Pneumatic control system

8 Sealing flap

9 Electrical control box




en-16052.055–A

Figure 1




en-16052.055–A

Parts of the gas sampling probe (1) with shock blower and filter

1.1 Probe tube

1.2 Shock blower

1.2.1 Drain valve

1.2.2 Control unit

1.3 Probe flange

1.3.1 Spring

1.3.2 Sealing plate

1.5 Hose for analysis gas

1.5.1 Auxiliary heating

1.5.2 Insulation

1.6 Gas connection

1.7 Temperature sensor

1.10 Large–area filter


1.12 Fine filter

1.15 Temperature sensor

1.16 Turnbuckle

3.9 Hose (feed flow, primary circulating system for cooling water)

3.10 Hose (return flow, primary circulating system for cooling water)

7.9 Compressed air hose


7.25 Pinch valve

7.26 3/2-directional control solenoid valve Y10.05

7.28 3/2-directional control solenoid valve Y10.04




en-16052.055–A

Figure 2




en-16052.055–A

Parts of the probe tube (1.1)

1.1.1 Feed flow chamber

1.1.2 Return flow chamber

1.1.3 Pipe for temperature sensor

1.1.4 Gas inlet

1.1.5 Gas outlet

1.1.6 Pipe for gas extraction

1.1.7 Pipe for cooling water feed

1.1.8 Pipe for cooling water return

1.1.9 Expansion joints

Parts of the measuring gas connection (1.6)

1.6.1 Hose clip

1.6.2 Hose nipple

1.6.3 Socket

1.6.4 PTFE screw connection

1.6.5 Adhesive tape, heat–resistant

1.5 Hose for analysis gas

1.5.2 Insulation

6 Heated PTFE gas line

6.1 Heating strip




en-16052.055–A

Probe tube (1.1)

Figure 3

Gas connection (1.6)

Figure 4




en-16052.055–A

Parts of the retracting device (2)

2.1 Running rail

2.2 Carriage with holder for the gas sampling probe

2.3 Castors

2.4 Round–linked chain

2.5 Drive wheel

2.6 Return wheel

2.7 Proximity switch (gas sampling probe extended)

2.8 Proximity switch (gas sampling probe retracted)

2.9 Terminal box

2.10 Flexible lines (hoses for compressed air and water, cables, gas line)

2.11 C–rail

2.12 Connection trolley

2.13 Chain tensioner

2.14 Switching rule [for 3/2-directional control valve (7.23)]

2.15 Switching rule [for 3/2-directional control valve (7.24)]



7 Pneumatic control system

8 Sealing flap

9 Electrical control box

NOTEFigure 5 shows a gas sampling probe in an extended position.




en-16052.055–A

Figure 5




en-16052.055–A

Parts of the cooling water control panel (3)

3.1 Heat exchanger

3.2 Mixing valve

3.3 Centrifugal pump

3.4 Actuator

3.5 Expansion chamber

3.6 Pressure switch

3.7 Pressure gauge, return flow

3.8 Thermometer, return flow

3.9 Hose (feed flow, primary circulating system)

3.9.1 Piping (feed flow, primary circulating system)

3.10 Hose (return flow, primary circulating system)

3.10.1 Piping (return flow, primary circulating system)

3.11 Filling connection of the primary circulating system

3.12 Feed flow connection of the secondary circulating system

3.13 Return flow connection of the secondary circulating system

3.14 Pressure gauge, feed flow

3.15 Thermometer, feed flow

3.16 Thermometer, cooling circulation system

3.17 Safety valve

3.18 Shut–off slide valve, primary circulating system

3.19 Shut–off slide valve, secondary circulating system

3.20 Shut–off slide valve, filling connection

A Primary circulating system

B Secondary circulating system

C Feed flow connection of the primary circulating system

D Return flow connection of the primary circulating systems


9.1 Temperature regulator for cooling water; in the electrical control box (9)




en-16052.055–A

Figure 6




en-16052.055–A

Parts of the cleaning devices (4) for filter cartridges

4.1 Dust extractor

4.2 Housing

4.3 Turntable to turn the filter cartridge

4.4 Air nozzle adjusting device

4.5 Compressed air filter

A Compressed air connection




en-16052.055–A

Figure 7




en-16052.055–A

Parts of the pneumatic control system (7)

7.1 3/2-directional control valve (safety valve)

7.2 3/2-directional control valve (retraction of the gas sampling probe)

7.3 3/2-directional control valve (extension of the gas sampling probe)

7.4 3/2-directional control valve, pneumatically controlled („extension”)

7.5 3/2-directional control valve, pneumatically controlled („retraction”)

7.6 Throttle valve („extension”)

7.7 Throttle valve („retraction”)

7.8 5/2-directional control valve


7.10 Ball valve with breather


7.12 Oil and water separator

7.13 Pressure regulator with pressure gauge

7.14 Oil mist lubricator

7.15 Condensation drain


7.18 Filter with silencer

7.19 Compressed air motor

7.20 Vibrator


7.22 Throttle valve

7.23 3/2-directional control valve (end position gas sampling probe retracted)

7.24 3/2-directional control valve (end position Gas sampling probe extended)

7.25 Pinch valve

7.26 3/2-directional control valve (control valve for pinch valve)

7.27 Filling level monitoring


7.29 Compressed air control line

A Compressed air supply

1.2 Shock blower

8.2 Positioning cylinder of the sealing flap





en-16052.055–A

Figure 8




en-16052.055–A

Parts of the pneumatic control system (7)






7.6 Throttle valve

7.7 Throttle valve


7.9 Compressed air hose to the shock blower



7.12 Oil and water separator

7.13 Pressure regulator with pressure gauge

7.14 Oil mist lubricator

7.15 Condensation drain

7.16 Compressed air hose to pinch valve

7.18 Filter with silencer

7.19 Pneumatic motor

7.20 Vibrator


7.22 Throttle valve

7.23 3/2-directional control valve (end position gas sampling probe retracted)

7.24 3/2-directional control valve (end position gas sampling probe extended)

7.25 Pinch valve

7.26 3/2-directional control valve (control valve for pinch valve)

7.27 Filling level monitoring


7.29 Compressed air control line

A Compressed air supply




en-16052.055–A

Figure 9




en-16052.055–A

Parts of the sealing flap (8)

8.1 Sealing cover

8.2 Positioning cylinder


8.4 Socket

8.5 Bellows

D Compressed air connection for opening sealing flap

E Compressed air connection for closing sealing flap

Figure 10




en-16052.055–A

Parts of the electrical control box (9)

9.1 Temperature regulator for cooling water (N40.01)

9.2 Temperature regulator for auxiliary heating (N40.02)

9.3 Key switch for shock blower (S40.02)

9.4 Selector switch manual or automatic operation (S40.01)

9.5 Button „Extend” (S02.01)

9.6 Button „Retract” (S02.02)

9.7 Dust protection frame

Figure 11




en-16052.055–A

3.2 Description of functioning


The dust–bearing, hot gas is cooled at the gas inlet (1.1.4) to the cooling water supplytemperature, adjusted at the temperature regulator (9.1), and held constant abovethe dew point. The portion of dust borne by the gas is heavily reduced in thesucceeding filters (1.10, 1.11 and 1.12).

The filter heaters and the heated and insulated gas lines prevent the developmentof condensation. The cyclically–activated shock blower (1.2) is installed to eliminatecaking in the pipe to the gas extractor (1.1.6). Before each air blast, the gas line isclosed by a pinch valve (7.25) to protect the succeeding gas preparation andanalysis equipment.


The retracting device AURETRAC helps to protect and to better maintain the gassampling probe (1). This is attached to a carriage (2.2) and can be retracted fromthe process chamber by a pneumatic motor (7.19) on a rail (2.1). Activation occursautomatically under abnormal operating conditions or manually.

NOTEThe pressure of the compressed air supply must remain greater than 4 bar forat least 10 seconds after a power failure.


The cooling water control panel protects the gas sampling probe (1) againstoverheating and holds the gas at a constant temperature above the dew point.


The filter cartridges are to be cleaned with 39 µm and 14 µm retention rate of thelarge–area filters (1.10 and 1.11) with this device. The cleaning device consists ofa dust extractor with an attached housing. The filter cartridges are cleaned in thishousing on a turntable with compressed air and the dust is simultaneously extracted.Effective cleaning is achieved by adjustment of the compressed air nozzles.




en-16052.055–A

3.3 Control of the gas sampling probe with retracting device

Prerequisites

+ The control voltage is connected.

+ The pressure in the pneumatic system is higher than 4 bar.

+ The ball valves (7.10 and 7.11) are open.

+ The oil mist lubricator (7.14) is filled with oil.

+ Parameters of the temperature regulator (9.1) have been entered.

+ The primary circulating system in the cooling water control panel (3) has theminimum pressure set at the pressure switch (3.6).

Automatic operation

� Set selector switch S40.01 (9.4) to Automatic .

In this mode of operation,

+ the carriage moves to the end position Extended;

+ the shock blower is activated cyclically;

+ the carriage is moved cyclically;

+ on faults, the carriage moves to the end position Retracted and the sealingflap (8) is closed automatically;

+ when the fault has been eliminated, the carriage moves back to the endposition Extended.

Manual operation

� Set selector switch S40.01 (9.4) to Manual .


+ the carriage can be extended as desired with the button S02.01 (9.5);

+ the carriage can be retracted as desired with the button S02.02 (9.6);

+ the shock blower (1.2) can be activated with the key switch S40.02 (9.3);

+ the carriage moves automatically to the end position Retracted on faults andthe sealing flap (8) is closed automatically.

Switching off the equipment

� Set selector switch S40.01 (9.4) to OFF.


+ the carriage moves to the end position Retracted and the sealing flap (8) isclosed automatically.




en-16052.055–A

Extending procedure

� Set selector switch S40.01 (9.4) to Automaticor

� Set selector switch S40.01 (9.4) to Manual and press button S02.01 (9.5).

+ The magnet Y10.06 of the 5/2-directional control valve (7.8) is activated andthe sealing flap (8) opens.

+ The magnet Y10.01 of the 3/2-directional control valve (7.3) is activated.

+ The control compressed air passes through the 3/2-directional control valve(7.24) to the 3/2-directional control valve (7.4).

+ The compressed air passes through the 3/2-directional control valve (7.4) tothe pneumatic motor (7.19), through the 3/2-directional control valve (7.5), thethrottle valve (7.6) and the filter with silencer (7.18) to the exterior.The carriage moves forwards.

+ When the end position Extended has been reached, the 3/2-directional controlvalve (7.24) switches off the control air to the 3/2-directional control valve(7.4).The carriage comes to a halt.

+ The proximity switch (2.7) signals the control system „Gas sampling probeextended”.

+ The magnet Y10.05 of the 3/2-directional control valve (7.26) activates thepinch valve (7.25).The gas route to the analysis cabinet is blocked.

+ The magnet Y10.04 of the 3/2-directional control valve (7.28) is activatedbriefly. The shock blower (1.2) is activated and the pipe to the gas extractor(1.1.6) is cleaned.

+ The magnet Y10.05 of the 3/2-directional control valve (7.26) is deactivatedand ventilates the pinch valve (7.25).The gas route to the analysis cabinet is reopened.




en-16052.055–A

Extension procedure

� Set selector switch S40.01 (9.4) to OFFor

� Set selector switch S40.01 (9.4) to Manual and press button S02.02 (9.6).

+ The magnet Y10.02 of the 3/2-directional control valve (7.2) is activated.

+ The control compressed air passes through the 3/2-directional control valve(7.23) to the 3/2-directional control valve (7.5).

+ The compressed air passes through the 3/2-directional control valve (7.5) tothe pneumatic motor (7.19), through 3/2-directional control valve (7.4), thethrottle valve (7.7) and the filter with silencer (7.18) to the exterior.The carriage moves backwards.

+ The magnet Y10.07 of 2/2-directional control valve (7.21) is activated for adefined period. The vibrator (7.20) is activated through the throttle valve (7.22)and the 2/2-directional control valve (7.21). Caking in the probe tube (1.1) isdislodged.

+ When the end position Retracted has been reached, the 3/2-directionalcontrol valve (7.23) switches off the control air to the 3/2-directional controlvalve (7.5).The carriage comes to a halt.

+ The proximity switch (2.8) signals the control system „Gas sampling proberetracted”.

+ The magnet Y10.06 of the 5/2-directional control valve (7.8) is deactivatedand the sealing flap (8) is closed.




en-16052.055–A

Manual cleaning of the pipe to the gas extractor (1.1.6)

DANGER Ensure that no persons are in the vicinity of the gas inlet (1.1.4) during thecleaning procedure.

� Set selector switch S40.01 (9.4) to Manual .

� Activate shock blower (1.2) with key switch S40.02 (9.3).

+ The magnet Y10.05 of the 3/2-directional control valve (7.26) activates thepinch valve (7.25).The gas route to the analysis cabinet is blocked.

+ The magnet Y10.04 of the 3/2-directional control valve (7.28) is activatedbriefly. The shock blower (1.2) is activated and the pipe to the gas extractor(1.1.6) is cleaned.

+ The magnet Y10.05 of the 3/2-directional control valve (7.26) is deactivatedand ventilates the pinch valve (7.25).The gas route to the analysis cabinet is reopened.

NOTEDuring maintenance work on the shock blower (1.2), the ball valve (7.10) must firstlybe closed and the shock blower depressurized by hand or with the key switch S40.02(9.3).As soon as the ball valves (7.10 and 7.11) are opened, the shock blower (1.2) is filled.The shock blower is reloaded immediately after each shot.


� Set the temperature regulator (9.1) to Automatic .

� Switch on centrifugal pump (3.3).

+ The actual temperature value (x) at the probe is measured by the temperaturesensor (1.10) in the feed flow chamber (1.1.1), is displayed on thetemperature regulator (9.1) and is compared with the adjusted setpoint (w).

+ The cooling water passes through the feed flow chamber (1.1.1), the returnflow chamber (1.1.2) and reaches the mixing valve (3.2).

+ If a control deviation (xw) occurs, the temperature regulator (9.1) adjusts themixing valve (3.2). This diverts a partial flow of the cooling water through aheat exchanger (3.1) and mixes it with a second partial flow, which passesdirectly.

+ The regulated cooling water now reaches the feed flow chamber (1.1.1) of theprobe through the centrifugal pump (3.3).



Transport und assembly

en-16052.055–A

4 Transport und assembly

4.1 Transport and storage requirements

The machine is transported in single parts or in sub–assemblies. Make absolutelysure that suitable lifting equipment is employed in removing the parts from thetransport vehicles and transferring to the storage area.

When they arrive at the site, all parts must be inspected for transport damage andplaced on wooden beams with the provision of suitable protection against moisture,contamination and damage. Never place the parts directly on the ground.

All parts must be stored in well–ventilated buildings and must be protected againstmoisture.

4.2 Assembly

General requirements

The following assembly instructions do not detail the individual steps for assemblingthe unit, but rather give an overview of the work to be performed.

Changes in the planning of the plant during the processing of the contract may leadto deviations from these assembly instructions.

NOTEFinal assembly and assembly inspection by an assembly specialist fromKRUPP POLYSIUS AG are preconditions for our warranty.

We recommend that the assembly work is supervised from start to finish byspecialists from KRUPP POLYSIUS AG.

Careful selection of the used tools and appliances and the personnel is important forthe correct execution of the assembly work.

CAUTIONIf you carry out electrical welding on any part of the machine, never conductthe welding current through sliding or antifriction bearings, other movableconnections or measuring equipment, to prevent damage to such parts.Always directly connect the welding current return lead to the part beingwelded.




en-16052.055–A

Assembly sequence

Retracting device (2) with gas sampling probe

� The running rail (2.1) is to be attached at the installation site according to theequipment installation plan in a level position with 3 suspension points (A), asevenly separated as possible or on supports. The running rail must also beconnected horizontally towards the kiln to absorb axial forces.

� The socket (8.4) with the sealing cover (8.1) must also be installed on siteaccording to the equipment installation plan in a level position.

� After installation of the retracting device, the two end positions of the carriagemust be adjusted with the 3/2-directional control valves (7.23 and 7.24).

� The carriage (2.2) must move far enough that the gas sampling probe (1) closesagainst the sealing plate (1.3.2) of the socket (8.4). This is achieved by adjustingthe switching rule (2.15) on the carriage for the 3/2-directional control valve(7.24).

� Connect the compressed air connection (8.3) of the adjusting cylinder (8.2) withden compressed air control lines (7.29). The sealing flap must close when the5/2-directional control valve (7.8) is not under power and when compressed airis available. If the sealing flap opens, the compressed air hoses (8.3) must beexchanged.

Figure 12




en-16052.055–A

Cooling water supply

� The piping (3.9.1 and 3.10.1) between the retracting device and the coolingwater control panel (primary circulating system) must be constructed withgalvanized water pipe G 3/4 or copper pipe 22 mm ∅ .

� The connections(3.12 and 3.13) of the secondary circulating system must beconnected to the works cooling water supply by piping (G 1 1/2).

� The filling connection (3.11) for the primary circulating system must beconnected to the utility water supply by a detachable connection (hose) G 1/2.

NOTEIn general, it must be observed that the supply and return flow are notexchanged. The direction of flow of the cooling water is marked with arrows.

Electrical supply

� Install the electrical connections (A) to the electrical control box (9).The energy supply of the electrical control box (9) must be connected with acable 3 x 2.5 mm2.

Compressed air supply

� Connect the pneumatic control system (7) to the compressed air supply withpiping G 1/2.

Figure 13




en-16052.055–A

Connections to the gas sampling probe with the following flexible lines (2.10)

+ hose (3.9) (feed flow, primary circulating system)

+ hose (3.10) (return flow, primary circulating system)

+ compressed air hose (7.9) to the shock blower

+ compressed air hose (7.16) to the pinch valve

+ hose (1.5) for analysis gas

+ cable for monitoring of the gas sampling probe and the retracting device

� Install hoses (3.9 and 3.10) for the cooling water between the pipes (3.9.1 and3.10.1) and the gas sampling probe.

� The compressed air hose (7.9) from the pneumatic control system (7) to the gassampling probe, the compressed air hose to the vibrator (7.20) and thecompressed air hose (7.16) to the pinch valve must be checked.

� Connect hose (1.5) for analysis gas with the heated gas line (6) at the gasconnection (1.6).

Figure 14

� The cables for the monitoring of the gas sampling probe and the retracting deviceAURETRAC from the control panel are to be found in the electricaldocumentation.



Lubrication

en-16052.055–A

5 Lubrication

NOTEThe POLYSIUS table of lubricants with the lubricant reference numbers iscontained in the supplement Important notes on the documentation at the beginningof the overall documentation. Each lubricant has a clear reference number to whichthe lubrication instructions in this section relate. The table gives a complete list ofthe suppliers and products permitted by KRUPP POLYSIUS AG.It is the responsibility of the lubricant supplier to select appropriate lubricantscorresponding to the reference numbers . KRUPP POLYSIUS AG is notresponsible for the correctness of this data.The use of a lubricant not explicitly stated in the table of lubricants has to bepreviously approved by KRUPP POLYSIUS AG.The supplement Important notes on the documentation also contains the generallyvalid Notes on lubrication .

Ensure that the lubricants are stored, used and disposed of in anenvironmentally–friendly manner and observe your national environmentallegislation when handling lubricants.



Lubrication

en-16052.055–A

Lubrication chart

Figure 15

Lubrication points Quantity (ltr/kg) per lubrication

point

Lubrication intervals (weeks)

No. Qty. Designation Lubricant ref. no.

Initial filling

Toppingup

Toppingup

Firstchange

Furtherchanges

1 1 Gearing of the pneumatic motor �

24 1.6 Permanent lubrication

2 1 Service unit 2 0.4 as required as required

3 1 Centrifugal pump according to manufacturer’s instructions

The different makes of lubricant corresponding to the lubricant reference numbers are shown in the table of lubricants in thesupplement Important Notes on the Documentation at the beginning of the overall documentation.

Explanation of the numbers

� Also observe the manufacturer’s instructions.



Preparation for the test run

en-16052.055–A

6 Preparation for the test run

NOTEIt is a prerequisite of our warranty that the test run is carried out in the presence ofand according to the instructions of specialists from KRUPP POLYSIUS AG.

6.1 Checks prior to the test run

After completion of the assembly work and prior to the first test run, check all partsof the plant according to the list below. Take particular care that all material remnants,tools and assembly aids are removed.

� Is the retracting device (2) completely mounted and have the fixing screws beentightened?

� Are the proximity switches (2.7 and 2.8) correctly adjusted?

� Are the drive wheel (2.5) and the return wheel (2.6) correctly aligned?

� Has the function of the carriage (2.2) been checked?

� Are the connection trolley (2.12) and the flexible lines (2.10) freely movable overthe entire traverse of the carriage?

� Is the gas sampling probe (1) completely mounted and correctly attached to thecarriage (2.2)?

� Has the gas connection (1.6) been made correctly and been checked for leaks?

� Are the large–area filters (1.10 and 1.11) and the fine filter (1.12) correctlymounted and have their functions been checked?

� Has the auxiliary heating (1.5.1) been correctly installed and connected?

� Has the function of the temperature sensor (1.15) been checked?

� Has the shock blower (1.2) been checked according to the manufacturer’sinstructions?

� Is the cooling water control panel (3) completely mounted?

� Is all piping correctly mounted and has it been checked for leaks?

� Has the centrifugal pump (3.3) been checked according to the manufacturer’sinstructions and is the direction of rotation correct?

� Has the function of the adjusting drive (3.4) been checked?

� Is cooling water available in the specified quality and quantity?

� Has the entire cooling water circulation system been bled?




en-16052.055–A

� Is the sealing flap (8) mounted and has its correct function been checked?

� Have the components of the pneumatic control system (7) been checked forleaks?

� Is the pressure regulator (7.13) correctly adjusted?

� Has the pneumatic motor (7.19) been checked according to the manufacturer’sinstructions?

� Has the function of the vibrator (7.20) been checked?

� Has the oil mist lubricator (7.14) been filled with the specified type and quantityof oil?

� Are the switching rules (2.14 and 2.15) and the 3/2-directional control valves(7.23 and 7.24) for the end positions of the carriage correctly adjusted?

� Is compressed air available in the specified quality and quantity?

� Has the correct function of the pneumatic control system been checked?

� Do the electrical connection values of the mains supply conform with those ofthe electrical control box (9)?




en-16052.055–A

6.2 Setting and adjustment

Cooling water control panel

Fill the primary circulating system with soft and clean water (utility water or drinkingwater) from the mains supply and bleed. A pressure of at least 1.0 bar should bepresent at the pressure gauge (3.7) in this cooling circulation system.

The secondary circulating system must be connected to the works water supply. Thepiping must be laid so that the drain lies slightly higher than the inlet. This ensuredthat the heat exchangers are completely filled and do not contain air bubbles.

+ Adjust pressure switch (3.6).

NOTEIn regions where there is a danger of frost, both cooling circulation systems must bedrained when the plant is shut down to prevent damage.

Retracting device AURETRAC (2)

+ The chain tension is preset and can be readjusted at the chain tensioners (2.13)if necessary.

+ The proximity switch (2.7) must be adjusted when the gas sampling probe isextended and the proximity switch (2.8) when it is retracted.

+ The switching rules (2.14 and 2.15) for the 3/2-directional control valves (7.23 and7.24) must be adjusted.

+ The intensity of the vibrator (7.20) must be adjusted at the throttle valve (7.22).


+ The parameters of the temperature regulator (9.1) for cooling water must beentered.

+ The temperature regulator (9.2) of the auxiliary heating must be adjusted.


+ The pressure regulator (7.13) must be adjusted.

+ The oil mist lubricator (7.14) must be adjusted.




en-16052.055–A

First commissioning

Extending the gas sampling probe

� The control of the retracting device and the temperature regulator (9.1) must beset to Manual at the selector switch (9.4).

� The setpoint and the limiting value of the temperature regulator (9.1) must bechecked.

� Switch on the centrifugal pump (3.3) and open the shut–off slide valves (3.18 and3.19) of the secondary circulating system so that cooling water flows initiallythrough both heat exchangers (3.1).

� In manual operation, extend the gas sampling probe with the retracting deviceinto the plant with the button (9.5). Observe the temperature display on thetemperature regulator (9.1) and adjust the mixing valve (3.2) by hand until thetemperature of the gas sampling probe slowly approaches the setpoint of theregulator.

� When the gas sampling probe has reached its normal temperature, the coolingwater supply must be closed for one heat exchanger. One heat exchangershould be adequate for continued operation.

� The temperature regulator (9.1) and the control system can now be set toAutomatic at the selector switch (9.4).

� The parameters of the temperature regulator (9.1) can now be adjusted tooptimize the regulating behavior (see manufacturer’s documentation).



Maintenance

en-16052.055–A

7 Maintenance

7.1 Inspection

DANGERThe carriage starts automatically and without previous warning and the gassampling probe is hot.You can suffer the most severe injuries!Never enter between the carriage and the rotary kiln and wear the necessaryprotective clothing.

No. Work to be performed Frequency Remarks

1 Checking the cooling water control panel (3)

+ Supply temperature at the thermometer(3.15)

daily

+ Return flow temperature of the coolingwater at the thermometer (3.8)

daily

+ Cooling water pressure at the pressure gauge (3.7)

daily

+ Leaks in the hoses (3.9 and 3.10) daily

+ Inspection work on the centrifugal pump(3.3)

according tomanufacturer’sinstructions

2 Checking the electrical control box (9)

+ Probe temperature at the temperature regulator (9.1)

+ Temperature of the auxiliary heating at thetemperature regulator (9.2)

daily

3 Checking the pneumatic control system (7) weekly

+ Oil level in the oil mist lubricator (7.14)

+ All components for leaks

+ Pressure at the pressure gauge (7.13)

+ Condition of the compressed air hoses (7.9 and 7.16)

+ Function of the pinch valve (7.25)

+ Function of the vibrator (7.20)

+ Inspection work on the pneumatic motor(7.19)




Maintenance

en-16052.055–A

RemarksFrequencyWork to be performedNo.

4 Checking the retracting device (2) monthly

+ Function of the rollers (2.3)

+ Wear of the drive wheel (2.5)

+ Wear of the return wheel (2.6)

+ Function of the connection trolley (2.12)

+ Function of the proximity switches (2.7, 2.8)

5 Gas sampling probe (1)

+ Retract the gas sampling probe and checkfor caking of the gas inlet

daily

+ Visual check of the pressure gauge of theanalysis cabinet whether the vacuum in thegas extraction system has increased

1x per shift if the limit value isreached, replace or clean the filter cartridges

+ Check the gas hoses and screw couplingsfor leaks

monthly

+ Inspection work on the shock blower (1.2) according tomanufacturer’sinstructions

6 Check the sealing flap (8) for function monthly



Maintenance

en-16052.055–A

7.2 Servicing

DANGERWhen automatic shock blowers are used, after electrical shutdown.Danger from unintended firing by residual pressure.During maintenance work on the shock blower (1.2), the ball valve (7.10) mustfirst be closed and the shock blower depressurised by hand or by the keyswitch. Set the selector switch S40.01 (9.4) to OFF.The condensation in the fine filter can contain acids.You can suffer skin injury!Wear appropriate safety clothing.

No. Work to be performed Frequency Remarks

1 Large–area filter (1.10) Clean or replace filter cartridges

1x per shift

2 Large–area filter (1.11) Clean or replace filter cartridges

weekly when the limit valueof the pressuregauge in theanalysis cabinet isreached

3 Drain condensation from the fine filter (1.12) weekly see note

4 Clean the gas inlet (1.1.4) of the probe pipe weekly

5 Clean oil and water separator (7.12) weekly

6 Clean filter (7.18) with silencer weekly

7 Fine filter (1.12) Replace filter cartridges

as required when the limit valueof the pressuregauge in theanalysis cabinet isreached



Maintenance

en-16052.055–A

RemarksFrequencyWork to be performedNo.

8 Check the rubber insert of the pinch valve(7.25) and replace if necessary

as required

9 Descale probe tube (1.1) annually

10 Maintenance of the shock blower (1.2) according tomanufacturer’sinstructions

11 Maintenance work on the centrifugal pump(3.3)


NOTEHold a container under the fine filter and loosen the drain screw (1.12.15).Dispose of the condensation appropriately.If the O–ring (1.12.16) is defective, it must be replaced before the drain screw isretightened.



Maintenance

en-16052.055–A

7.3 Trouble shooting

Fault Cause Elimination

Carriage moves automatically to the end position Retracted

Power failure Return mains supply

IndicatorT i h

Heat exchanger (3.1) is dirty Clean heat exchangerTemperature in the gas sampling probe too high Shut–off slide valve

(3.18 or 3.19) are notcorrectly open

Completely open shut–off slide valves

Mixing valve (3.2) is damaged � Repair mixing valve

� Repair adjusting drive (3.4)

Temperature regulator (9.1) is misadjusted or defective

Readjust or replace temperature regulator

Centrifugal pump (3.3) is defective

Repair or replace centrifugal pump

IndicatorPressure in the

i i l ti t

Centrifugal pump (3.3) is defective

Repair or replace centrifugal pump

primary circulating system is < min. Pressure switch (3.6)

is misadjusted or defectiveReadjust or replace pressure switch

Insufficient cooling water inthe primary circulating systemdue to leaks

� Top up cooling water

� Eliminate leakages

IndicatorFault in the pneumatic control system (7)

Oil deficiency in oil mist lubricator (7.14)

Fill the oil mist lubricator with oil

pneumatic control system (7)SignalFilling level monitor transmitsalarm

Switch contact of the filling level monitor (7.27) is defective

Replace switch contact

Sealing flap (8) does notclose correctly

Compressed air hoses (8.3)leak

Correctly connect or replacecompressed air hoses

5/2-directional control valve is damaged

Replace 5/2-directional control valve



Maintenance

en-16052.055–A

EliminationCauseFault

Vibrator (7.20) does not work properly

Throttle valve (7.22) is not correctly adjusted

Readjust throttle valve

2/2-directional control valve(7.21) is defective


Ball valve (7.10) is closed Open ball valve

Vibrator (7.20) is defective Replace vibrator

Pinch valve (7.25) does not close correctly

3/2-directional control valve(7.26) is damaged


Rubber inset of the pinch valve is defective

Replace rubber insert

Shock blower (1.2) does not work properly

3/2-directional control valve(7.28) is damaged


Ball valve (7.10) is closed Open ball valve

Shock blower is defective Repair shock blower; see manufacturer’sdocumentation

If faults occur that are not described above, additional information regarding causesand remedial measures can be taken from the subsuppliers’ documentation.



Maintenance

en-16052.055–A

7.4 Repair

NOTEThe gas sampling probe must be withdrawn from the extraction point with theretracting device (2) for repair work.

Before performing any repair work, switch off the power supply to all electricalcomponents.

Ensure absolute cleanliness at all times during repair work in order to prevent dirtfrom entering the bearings, the drive units or other sensitive parts of the machine orplant.

Do not remove or open flaps and protection devices until all rotating parts havestopped.

DANGERWhen automatic shock blowers are used, after electrical shutdown.Danger from unintended firing by residual pressure.During repair work on the shock blower (1.2), the ball valve (7.10) must firstbe closed and the shock blower depressurised by hand or by the key switch.

Repair work on the following components is described in the manufacturer’sdocumentation.

+ Shock blower (1.2)

+ Centrifugal pump (3.3)

+ Actuator (3.4)

+ Compressed air motor (7.19)

+ Oil and water separator (7.12)

+ Pressure regulator (7.13)

+ Oil mist lubricator (7.14)


� Shut off the water supply if the rotary kiln is shut down for a long period.

� On danger of frost, drain water–bearing systems.

NOTEPerform preferred servicing after recommissioning of the kiln plant, as heavycontamination occurs in this case.



Maintenance

en-16052.055–A


Replacing the filter cartridges

� Loosen locking screw (1.10.11), unclip locking clip (1.10.10) and remove thedust container (1.10.9).

� Open the bayonet coupling (1.10.6) by turning it through 90° and pull the filtercartridge (1.10.5) with the sleeve (1.10.4) out of the housing.

� Clean the interior of the housing (1.10.3), the dust container and the sealingsurfaces.

NOTEDamaged parts and seals must be replaced.

� Place sleeve (1.10.4) on the new or cleaned filter cartridge and insert in thehousing.

� Insert and close bayonet coupling (1.10.6).

� Attach the dust container (1.10.9) with O–ring (1.10.8), fold the locking clip(1.10.10) downwards and secure with the locking screw (1.10.11).

Cleaning the filter cartridges

� Clean the filter cartridge as described in this section under Cleaning device forfilter cartridges or blow out the dust residue with dry compressed air from theworks supply.

If the filter cartridges are heavily contaminated, they can be subjected to wetcleaning.

Wet cleaning of filter cartridges

� Blow out the coarsest dirt from the filter cartridge with oil–free compressed air.

� Place the filter cartridge in vinegar for approx. 24 hours.The filter cartridge must be completely immersed in vinegar.

� Rinse the filter cartridge with clear water and dry.


Replacement of the filter cartridges in the large–area filter (1.11) is performed in thesame way as for the large–area filter (1.10).

NOTEThe filter cartridges (1.11.5) of the large–area filter (1.11) cannot be wet cleaned.



Maintenance

en-16052.055–A

Figure 16



Maintenance

en-16052.055–A

Fine filter (1.12)

Replacing filter cartridges

� Loosen nut (1.12.8) and remove the entire lower unit.

� Pull the housing (1.12.2) out of the heater (1.12.6).

� Unscrew the tie rod and remove all parts from the housing.

� Clean all parts with a mild, normal laboratory cleaning agent for metal and withsoft brushes and then rinse all parts with clean water.

� Dry the parts in the air.

� Check the housing and filter cartidge seals.Damaged parts must be replaced.

Assembly of the fine filter

� Push the spring (1.12.13) on the the treaded pin in the housing.

� Screw the tie rod (1.12.7) with installed seal (1.12.12) into the thresed pin of thehousing.

� Slide the holder (1.12.11) and the centering spring (1.12.14) onto the tie rod.

� Insert the flat seals (1.12.5) at both ends of the filter cartridge (1.12.4) and insertin the housing.

� Place O–ring (1.12.3) in the groove of the housing, press the entire unit againstthe housing head (1.12.1) and screw on the nut (1.12.8) with the seal (1.12.9)and tighten.

NOTEBecause the replacement of the filter cartridge is repeated more or less frequentlydepending on the quality of the gas, we recommend that a corresponding stock offilter cartridges are held in storage for immediate use.



Maintenance

en-16052.055–A

Figure 17



Maintenance

en-16052.055–A


� Close the ball valve (7.11) before beginning maintenance work on thecomponents of the pneumatic control system (7).

Mounting and maintenance of the 3/2-directional control valves

The 3/2-directional control valves have to be mounted free of stresses. Furthermore,dirt must not be alowed to enter the 3/2-directional control valves. Special attentionmust be paid to the sealing materials at the connecting points.

Mechanically–operated 3/2-directional control valves must be carefully aligned. Theoptimum contact inclination of the switching rule is 15°. The switching traverse madein this directional control should lie slightly above the minimum value and as far belowthe maximum value of the tappet stroke of the mechanically–operated3/2-directional control valve. The switching point of the 3/2-directional control valveis vertically adjustable.

Cleaning device for filter cartridges

The filter cartridges 39 Lm + 14 Lm are to be cleaned with the cleaning device.

NOTEWhen using the cleaning device, observe the operating instructions of the dustextractor.

� Connect the cleaning device with the electrical plug to the works mains supply;

� make the compressed air connection;

� switch on the dust extractor (4.1);

� insert the filter cartridge in the gousing (4.2) on the turntable (4.3);

� open the compressed air line slowly at the installed ball valve;

� Turn the turntable (4.3) with the inserted filter cartridge slowly and blow cleanwith the adjustable air nozzles (4.4).

� Depending on the amount of dust, empty the dust extractor container (4.1).

CAUTIONAfter you have completed the repair work, you must check the machine/plantagain according to the section Preparation for the test run .

Tools and auxiliary equipment

No special tools are required for repair work on the machine. However, torquewrenches of a bigger size than normal may be necessary.

Whether you will need auxiliary equipment, such as scaffolding or hoists, dependson the conditions in your plant.



Spare parts

en-16052.055–A

8 Spare parts

Notes for enquiring about and ordering spare partsDear Customer,

KRUPP POLYSIUS AG strive to render your enquiring about and ordering of spareparts as easy, and as a consequence, as efficient as possible. For this purpose wehave prepared a table summarising all data required by our spare parts departmentto ensure optimum processing in the most speedy and trouble-free manner.

Please copy the page with the respective table and mark those parts which yourequire with a cross in the column Order or Enquiry .

If the table relates to more than one machine, please also inform us of the AAT itemof the machine for which you require the spare parts.



Spare parts

en-16052.055–A

Figure 18



Spare parts

en-16052.055–A


Code word: Order no.: AAT item:

Item Designation Qty. Unit Order Enquiry

1 Gas sampling probe, complete 1 piece

1.1 Probe tube, complete 1 piece

1.2 Shock blower see manufacturer’s documentation

1.3 Clamping flange 1 piece

1.3.1 Spring 1 piece

1.3.2 Sealing plate 1 piece

1.5 Hose for analysis gas with auxiliary heating and insulation

1 set

1.6 Gas connection, complete 1 piece

1.6.1 Hose clip 1 piece

1.6.2 Hose nipple 1 piece

1.6.3 Socket 1 piece

1.6.4 PTFE screw coupling 1 piece

1.6.5 Adhesive tape, heat–resistant 1 roller

1.7 Temperature sensor 1 piece

1.15 Temperature sensor 1 piece

1.16 Turnbuckle 1 piece



Spare parts

en-16052.055–A

Figure 19



Spare parts

en-16052.055–A




1.10 Large–area filter, complete,however without filter cartridge 2 piece

1.10.1 Cover 1 piece

1.10.2 O–ring, 65 x 4 1 piece

1.10.3 Housing 1 piece

1.10.4 Sleeve 1 piece

1.10.5 Filter cartridge 39 µm piece

1.10.6 Bayonet coupling 1 piece

1.10.7 Heater, complete 1 piece

1.10.8 O–ring, 142 x 6 1 piece

1.10.9 Dust container 1 piece

1.10.10 Locking clip 1 piece

1.10.11 Locking screw 1 piece

The type, batch number, pore size/filter rate are embossed in the end caps of theSartorius filter cartridges.

These specifications are identical with the specifications on the labels of thepackaging.



Spare parts

en-16052.055–A

Figure 20



Spare parts

en-16052.055–A




1.11 Large–area filter, complete,but without filter cartridge 1 piece

1.11.1 Cover 1 piece

1.11.2 O–ring, 65 x 4 1 piece


1.11.4 Sleeve 1 piece


1.11.6 Fastener 1 piece

1.11.7 Heater, complete 1 piece

1.11.8 O–ring, 142 x 6 1 piece

1.11.9 Dust container 1 piece

1.11.10 Locking clip 1 piece

1.11.11 Locking screw 1 piece





Spare parts

en-16052.055–A

Figure 21



Spare parts

en-16052.055–A

Fine filter (1.12)



1.12 Fine filter, complete 1 piece

1.12.1 Housing cap 1 piece


1.12.3 O–ring, housing seal 1 piece


1.12.5 Flat seal for filter cartridge 2 piece

1.12.6 Heating 1 piece

1.12.7 Tie rod 1 piece

1.12.8 Nut 1 piece

1.12.9 Seal 1 piece

1.12.10 Fixing screw with seal 2 piece

1.12.11 Holder for filter cartridge 1 piece

1.12.12 Seal 1 piece

1.12.13 Spring 1 piece

1.12.14 Centering spring 1 piece

1.12.15 Drain screw 1 piece

1.12.16 O–ring 1 piece





Spare parts

en-16052.055–A

Figure 22



Spare parts

en-16052.055–A




2.3 Castor 4 piece

2.4 Round–linked chain meter

2.5 Drive wheel 1 piece

2.6 Return wheel 1 piece

2.7 Proximity switch 1 piece

2.8 Proximity switch 1 piece

2.11 C–rail 1 piece

2.12 Connection trolley 3 piece

2.13 Chain tensioner 1 piece



Spare parts

en-16052.055–A

Figure 23



Spare parts

en-16052.055–A




3.1 Heat exchanger 2 piece

3.2 Mixing valve 1 piece

3.3 Centrifugal pump 1 piece

3.4 Actuator 1 piece

3.5 Expansion chamber 1 piece

3.6 Pressure switch 1 piece

3.7 Pressure gauge 1 piece

3.8 Thermometer 1 piece

3.14 Pressure gauge 1 piece



3.17 Safety valve 1 piece

3.18 Shut–off slide valve 4 piece





Spare parts

en-16052.055–A

Figure 24



Spare parts

en-16052.055–A




4.1 Dust extractor 1 piece

4.2 Housing 1 piece

4.3 Turntable to turn the filter cartridge 1 piece

4.4 Air nozzle adjusting device 1 piece

4.5 Compressed air filter 1 piece



Spare parts

en-16052.055–A

Figure 25



Spare parts

en-16052.055–A

Pneumatic control box (7)



7.1 3/2-directional control valve 1 piece





7.6 Throttle valve 1 piece



7.9 Compressed air hose 1 piece

7.10 Ball valve 1 piece

7.11 Ball valve 1 piece

7.12 Oil and water separator 1 piece

7.13 Pressure regulator with pressure gauge 1 piece

7.14 Oil mist lubricator 1 piece

7.15 Condensation drain 1 piece


7.18 Filter with silencer 1 piece

7.19 Pneumatic motor see manufacturer’s documentation

7.20 Vibrator 1 piece





7.25 Pinch valve 1 piece


7.27 Filling level monitoring 1 piece




Spare parts

en-16052.055–A

Sealing flap (8)



8 Sealing flap, complete 1 piece

8.2 Adjusting cylinder, complete 1 piece


8.5 Bellows 1 piece

Figure 26



Appendix

en-16052.055–A

9 Appendix

9.1 Technical drawings

Designation Drawing no.

Cleaning device for filter cartridges 160.55.21 – 473 212

Planning drawing AURETRAC 160.52.21 – 643 929

Planning drawing cooling water control panel 160.52.21 – 1 045 614

Equipment installation plan TMI 2


Assembly plan 160.52.21 –

Circuit and terminal diagram 160.52.23 –

Circuit diagram of control program 160.52.23 –

Parameter list of control program 160.52.00 –



Appendix

en-16052.055–A

9.2 Subsuppliers’ documentation

Shock blower (1.2)

Heat exchanger (3.1)

Mixing valve (3.2)

Centrifugal pump (3.3)

Actuator (3.4)

Dust extractor (4)

Pneumatic motor (7.19)

Vibrator (7.20)

Pinch valve (7.25)

Temperature regulator (9.1)

Temperature regulator (9.2)

Documents

Gas Sampling