FLK Gas Sampling System Operating Manual
Preliminary Design
Order No. ---------------------------------------
Overview
SQ255
SQ254
SQ251 SQ253
SQ252
SQ256
Legend: SQ250 SQ251 SQ252 SQ253 SQ254 SQ255 SQ256
FLK Gas Sampling System FLK Gas Sampling Probe Electrically Heated Dedusting Filter Valve Combination Heat Exchanger Control Unit Retraction Device
Copyright ® SIEMENS
Page Page Page Page Page Page Page
Page 1
1 - 29 30 - 39 40 - 55 56 - 73 74 - 82 84 - 91 92 - 106
04/04
SQ250 FLK Gas Sampling System Contents
1. 1.1 1.2 1.3 1.4 1.5 1.6 2. 2.1 2.2 2.2.1 2.2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 3. 3.1 3.2 3.2.1
Introduction....................................................................................................................................................... 4 General information .......................................................................................................................................... 4 Personnel qualification requirements ................................................................................................................ 5 Field of application ........................................................................................................................................... 5 Construction ...................................................................................................................................................... 5 Mode of operation............................................................................................................................................. 6 Technical data ................................................................................................................................................... 9 Installation......................................................................................................................................................... 10 General information .......................................................................................................................................... 10 Fitting the probe ................................................................................................................................................ 10 Installation in the kiln inlet chamber................................................................................................................. 10 Installation in the precalciner ............................................................................................................................ 10 Mounting the heat exchanger ............................................................................................................................ 11 Mounting the control cabinet ............................................................................................................................ 11 Mounting the probe with retraction device ....................................................................................................... 11 Laying the coolant line to the probe.................................................................................................................. 12 Compressed air connection ............................................................................................................................... 14 Measuring gas connection................................................................................................................................. 14 Safety measures................................................................................................................................................. 15 Electrical connections ....................................................................................................................................... 16 Operation........................................................................................................................................................... 16 General information .......................................................................................................................................... 16 Start-up.............................................................................................................................................................. 16 Electrical connections ....................................................................................................................................... 17
3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 4. 4.1 4.2 4.2.1 4.2.2 4.2.3 4.3 4.3.1 4.3.2 4.4 4.4.1 4.5
Compressed air.................................................................................................................................................. 18 Purging process ................................................................................................................................................. 18 Heat exchanger unit .......................................................................................................................................... 19 Probe with retraction device.............................................................................................................................. 19 Measures for emergency stop............................................................................................................................ 21 Automatic probe retraction ............................................................................................................................... 21 Maintenance ...................................................................................................................................................... 22 General information .......................................................................................................................................... 22 Optimizing the complete equipment ................................................................................................................. 22 Probe cooling circuit ......................................................................................................................................... 23 Automatic retraction / insertion intervals for the probe .................................................................................... 23 Purging duration, purging interval .................................................................................................................... 23 Leakage test....................................................................................................................................................... 24 Leakage test between four-way ball valve and measuring gas pump. .............................................................. 25 Leakage test of the probe, filter and condensate vessel. ................................................................................... 25 Measures taken during a power failure ............................................................................................................. 27 Work necessary after the power is restored : .................................................................................................... 27 Measures to be taken during faults.................................................................................................................... 28
Note:
Copyright ® SIEMENS
Page 2
04/04
SQ250 FLK Gas Sampling System We would like to point out that the content of this operating manual is not part of an earlier or existing agreement, consent, or a legal relationship nor should it be modified. All obligations on the part of SIEMENS can be taken from the relevant purchasing agreement which also contains the complete and solely valid warranty. These warranty provisions are neither extended nor restricted by this operating manual. We would also like to point out that for reasons of clarity not every conceivable problem situation in conjunction with the application of this product could be described in this operating manual. If you require further information or if particular problems occur which have not been dealt with in enough detail in the operating manual, you can request the required information via the local SIEMENS subsidiary. In the operating manual and in the warning information on the product, signal terms having the following meaning have been used: Danger as used in this operating manual and in warning information on the product itself means that death, severe injury and / or substantial material damage will occur if the appropriate precautions are not taken. Warning as used in this operating manual and in warning information on the product itself means that death, severe injury and / or substantial material damage can occur if the appropriate precautions are not taken. Caution as used in this operating manual and in warning information on the product itself means that slight injury and / or material damage can occur if the appropriate precautions are not taken. Note as used in this operating manual denotes an important item of information about the product or a relevant part of the operating manual requiring particular attention.
Copyright ® SIEMENS
Page 3
04/04
SQ250 FLK Gas Sampling System
1.
Introduction
1.1
General information
Warning! This system is operated by electricity. When operating electrical equipment, it is unavoidable certain parts of this system carry a dangerous voltage.
that
If the warning information is not followed, serious bodily injury and/or material damage may occur. Only appropriately qualified personnel should work on this equipment or in its vicinity. These persons must be thoroughly acquainted with all the warnings and maintenance precautions in accordance with this manual. The proper and safe operation of this device requires correct transport, storage, mounting and erection as well as proper operation and maintenance. In particular the general construction and safety regulations about working on power installations (e.g. DIN, VDE) should be followed as well as the regulations relating to the proper use of lifting equipment and tools and the use of personal protective gear (protective goggles, etc.).
1.2
Personnel qualification requirements
As understood in this operating manual and on warning notices qualified personnel are persons who are acquainted with the mounting, erection, maintenance and operation of this product and who possess appropriate qualifications for their occupation, such as for example covering: -
training or instruction, and authorization for installing, removing, earthing and labeling power circuits, equipment and systems according to the currently valid standards of safety engineering,
-
training or instruction according to the currently valid standards of safety engineering in the care and use of adequate safety equipment;
-
training in first aid.
This product left our factory in a perfectly safe condition. In order to maintain this condition and ensure the safe operation of the device, the information and warning notes given in this manual must be observed.
Copyright ® SIEMENS
Page 4
04/04
SQ250 FLK Gas Sampling System
1.3
Field of application
For reasons of quality assurance, energy saving and environmental protection, continual flue gas analysis is needed in cement plants or rotary kiln facilities. The advantages of gas analysis in the kiln inlet and in precalcining are: •
It enables conclusive assessment of the combustion processes and is therefore necessary for the optimization of burner control, fuel consumption and product quality.
•
Operating faults can be detected at an early stage and prevented with suitable countermeasures. Also, stabilized kiln management reduces noxious emissions and is an aid in environmental protection.
However, up till now technical problems have been set against the advantages of continuous gas sampling. Above all, the high gas temperature of up to 1300° C, high dust concentration up to 2000 g/m3 together with the high alkali, sulphate and chloride content in the gas inlets present problems. In addition any gas sampling system is subject to high mechanical stresses. Many of the numerous problems of continuous gas sampling can be avoided with the FLK gas sampling system matched to the requirements of cement production. During the development of the sampling system, emphasis was placed on the compatibility of the sampling equipment to the standards of process instrumentation. But measures for reducing investment, operational and maintenance costs were also considered. This means that the compact design that has been realized enables any maintenance, servicing and repair work which is needed to be simplified to such an extent that it can be carried out without highly qualified personnel. In order to increase the availability and reliability of the gas sampling system special emphasis was placed on automatic cleaning of the system matched to the kiln conditions. A crucial development objective was an increase in the operational safety, e.g. by protecting the electrostatic filters against explosion during CO formation.
1.4
Construction
The gas sampling system is basically formed from the following components: 1. 2. 3. 4. 5. 6.
Liquid-cooled sampling probe Electrically heated dedusting filter Compressed air/valve combination Retraction device with electrical drive and additional pneumatic motor for redundancy Heat exchanger unit (cooling system) Programmable logic controller and monitoring unit.
Components 1 to 4 are assembled on site to form a compact unit. Items 5 and 6 are set up separately. For the above components there are special, separate operating manuals in which more precise details about construction, erection, operation and servicing are given. This particularly includes the installation location for the probe (retraction device) and the electrical installation. Therefore, this operating manual only deals with the combined operation of the separate components, the laying of lines and the location of the moving parts of the equipment. The complete set of erection material according to the equipment parts list is included as supplied together with the items listed above. When the retraction device is supplied, the local control box for moving the probe and, if applicable, the emergency-stop button with mechanical interlocking are included.
Copyright ® SIEMENS
Page 5
04/04
SQ250 FLK Gas Sampling System
1.5
Mode of operation
It is the rigid multi-pipe construction of the gas sampling probe that mainly guarantees a low level of service and maintenance. The cooling pipe, coolant return pipes and gas sampling probe can be quickly replaced using flange joints that are simple to release. The spatial separation of the gas sampling probe and the dedusting filter also have advantages for service and repair work. The somewhat unfavorable conditions during flue gas analysis in cement production demand special measures in the maintenance, repair and monitoring of all parts of gas analysis equipment. With this gas sampling system it was assumed that higher availability and reliability necessarily imply preventive, automatic maintenance. If dust build-up and baked-on deposits cannot be avoided, they must be detected on time by comprehensive monitoring devices and then effectively remedied. Baked-on deposits on the gas sampling probe are largely prevented by the high operating temperatures of up to 220° C. Special coolant ensures these high temperatures. In order that no temperature differences can arise between the probe and the filter, the filter is electrically heated; baked-on products in the filter space and silting up of the filter pores are therefore prevented. The motor-driven retraction device is another method of increasing the reliability and availability of the gas sampling system. It ensures quick and easy erection and removal of the gas sampling probe in the kiln inlet and protects it from any overheating if the cooling system fails. The numerous automatic functions are provided by a versatile, high performance programmable logic controller. A specially developed program satisfies these requirements. • • •
During insertion and retraction the gas sampling probe can be cleaned internally and externally by compressed air via the built-in pipe. It activates, either manually or automatically when required, the cleaning of the dedusting filter and the gas extraction pipe using compressed air. It monitors the most important processes in the gas sampling, provides corresponding messages and initiates suitable countermeasures in the event of a fault.
The user defines the type and scope of the countermeasures with exact parameters. This means, for example, that he can parameterize when and how often a cleaning program is to be started, how long the cleaning is to last or under which conditions the gas sampling probe is to be withdrawn from the kiln. The programmable logic controller and monitoring unit therefore provides an effective method of damage prevention.
Copyright ® SIEMENS
Page 6
04/04
SQ250 FLK Gas Sampling System The different design versions of the system also contribute to optimized operation. Figure 2 shows the circuits for the analysis gas and for the compressed air for cleaning the gas sampling pipe and the dedusting filter. Figure 3 shows the coolant circuit for cooling the gas sampling probe.
Fig. 2 Gas circuit for sampling device Legends:
Gas sampling probe Gas sampling opening Coolant connection Retraction device Dedusting filter
6 7 8 9 10
Valve combination Control cabinet for controller Installation pipe Valve for blowing dust return Local control box
11 12 13 14
71 Compressed air for purging probe 72 Compressed air for purging filter 73 Compressed air inlet 74 Dust-free measurement gas 75 Four-way motorized valve
76 77 78 79 80 81 82
Condensate preseparator Low-pressure switch Filter and Water separator Compressed air control valve Condensate output Measuring gas line to analyzer cabinet Dust-laden measuring gas
83 Control cable 84 Control cable for pump controller and fault signals to analyzer cabinet 85 Control cable for retraction device 86 Filter supply cable
1 2 3 4 5
Flash light for process warning Horn for process warning Emergency-stop button Control Center
The process gas to be analyzed is extracted by the gas sampling probe, cleaned in the electrically heated dedusting filter and passed to the gas analyzer device. Only a part of the gas flow with a particularly low dust content is extracted due to the specially formed sampling opening at the tip of the probe.
Copyright ® SIEMENS
Page 7
04/04
SQ250 FLK Gas Sampling System
Fig. 3 Coolant circuit for sampling probe Legends:
1 Gas sampling probe 2 Gas sampling opening 60 61 62 63 64 65
Coolant circulation pump Level monitoring Cooler with fan Expansion vessel Thermal switch Three-way control valve
3 Coolant connection 4 Retraction device 66 67 68 69 70 71
Flow monitor Temperature sensor Shut-off valve Coolant filter Coolant line Dust blow-back
7 Heat exchanger 8 Installation pipe 72 82 83 85
Corrugated hose Dust-laden measuring gas Control cable to control cabinet Control cable for retraction device
The concept of the unpressurised, enclosed coolant circuit was selected for the cooling of the special synthetic heat transfer fluid. The liquid-air cooler with an expansion vessel, which handles the cooling of the heat transfer fluid, is the centre-piece of the heat exchanger unit. The axial fan provides the required air flow and the maintenance-free, high-temperature resistant centrifugal pump circulates the heat transfer fluid.
Copyright ® SIEMENS
Page 8
04/04
SQ250 FLK Gas Sampling System
1.6
Technical data
Please refer to the separate operating manuals for technical data on the separate components. Electrical supply data: 3/400V,3/230V,3/500V, + 10%,-15% ; 50...60 Hz Power rating 5.5 kVA 230V, 115V + 10%,-15% ; 50...60 Hz Power rating 1.5 kVA Compressed-air supply data: 6...8 bar Compressed air free of oil, dust and water Approx. 4...6 m3 / h Measuring gas connection: Hose ID 6 mm Needs min. pump power of approx. 0.3 bar negative pressure Approx. 4 ... 7 l/min.Heat output of heat exchanger unit: Approx. 69 kW heat output Temperature range up to 250° C
Copyright ® SIEMENS
Page 9
04/04
SQ250 FLK Gas Sampling System
2.
Installation
2.1
General information
In cement production two main installation areas are relevant: • Kiln inlet • Precalcination It is essential that the installation location and the mounting are defined, with respect to the space requirement, between the machine supplier or user and SIEMENS Note: In relation to the individual components there are separate operating manuals in which the precise details of construction, installation, operation and servicing are dealt with comprehensively. This is especially relevant to the probe installation location (sampling device) and the electrical installation.
2.2
Fitting the probe
2.2.1
Installation in the kiln inlet
The following points should be followed for gas analysis on the kiln inlet: • • • • • • • • •
Preferentially the probe should be fitted at the side on the kiln inlet chamber. It should be positioned slightly oblique to the kiln axis. The probe should be fitted to the side opposite to the side of the raw meal feed. The probe must protrude at least 30 cm behind the kiln seal (vertical distance). The probe must not pass near to the material flow from the preheater tower. It should be ensured that no heavy solids can fall down from the preheater onto the probe. The probe must have a distance of at least 20 cm from the lining of the rotary kiln. When installing the probe in a new kiln, pay attention to the lining and kiln expansion in the hot state. Appropriate space must be available for installing and removing the probe, for the feeder lines such as coolant hoses, compressed air line, measuring gas line and cable. Access to the probe for installation and service work should also be provided.
2.2.2
Installation in the precalciner
The following points should be followed for gas analysis in the precalciner: • • • • • •
The probe must be installed in an area as free of dust as possible. This position is normally after a cyclone and under a diffusion box. This probe must protrude at least 1/3, but at the most up to the middle of the gas line. The installation location should also be so planned such that the effects of heat on components such as the valve combination and the dedusting filter are not too high. With this installation location a closing flap should be fitted if possible to the installation pipe by the customer (possibly automatic or manual). Appropriate space must be available for installing and removing the probe, for the feeder lines such as coolant hoses, compressed air line, measuring gas line and cable. Access to the probe for installation and service work should also be provided.
Copyright ® SIEMENS
Page 10
04/04
SQ250 FLK Gas Sampling System Once the installation position has been defined, an aperture for the connection piece must be provided. Push the connection piece through the aperture and adjust it flush with the probe. The compressed air connection on the connection piece must point upwards and can be aligned with a bar, pipe or thread. During this operation, the 5 degree tilt angle of the probe should be set. Note:
2.3
See the operating manual for the FLK probe. When using a retraction device, see also the separate operating manual, Chapter Installation.
Mounting the heat exchanger
All the equipment fitted to the heat exchanger is mounted compact on a mounting frame and is delivered ready for connection. The heat exchanger unit must be set up in the vicinity of the probe, preferably at the same height so that any coolant losses are minimized when a leak occurs. The coolant lines must be as short as possible in order to prevent errors in the coolant temperature. Caution:
The cooling system in the heat exchanger reaches an operating temperature between 130° C to a maximum of 250° C. Up to 60 kW of heat is radiated by the cooler.
Note: It must be ensured that the exhaust temperature (max. 250°C ) is vented outside. The mounting must be made such that no heat accumulation arises in the immediate vicinity. In order that the cooling performance is not impaired, there must be no obstructions in the feed and exhaust paths of the cooler. The maximum ambient temperature of 45° C should be observed.
2.4
Mounting the control cabinet
The control cabinet can be set up in a control room protected from dust - normally in the same room as the analyzer cabinet. A socket for service purposes should be provided.
2.5
Mounting the probe with retraction device
Please refer to the special operating manual for mounting the retraction device. Once the retraction device and the gas sampling probe have been mounted, the mounting of the valve combination and the electrically heated filter on the fittings is carried out as follows. •
The valve combination is fastened to the opposite side of the drive motor with 4 screws.
•
The filter is aligned during erection such that the measuring gas connections are positioned at the same height. The mounting brackets are designed so that the filter can be correctly aligned both in height and depth.
•
Screw the supplied joining piece for the measuring gas connection with the two union nuts and the tapered ring to the probe and the filter. Tighten the union nuts enough so that, after opening, the tapered rings are seated firmly on the joining piece. The union nuts can then be retightened.
•
Plug the electrical connections from the limit switches, three-phase motor and electrically heated filter on the bottom of the valve combination and latch them mechanically. The plugs are coded so that there is no possibility of confusion.
Copyright ® SIEMENS
Page 11
04/04
SQ250 FLK Gas Sampling System If a retraction device is used, then the filter must be fitted with the fixing bracket at a distance of approx. 10 cm to the measuring gas connection of the probe. It should be ensured that the two measuring gas connections are positioned exactly opposite. The valve combination must be mounted in the immediate vicinity of the probe and the filter. The joining contained in the supplied items must be used to obtain proper functioning.
pieces
•
The two purging connections between the filter and the valve combination are joined with the two stainless steel corrugated hoses (3/4" and 1/2" connections).
•
The connection from the filter to the condensate separator is implemented with TEFLON pipe or with PTFE pressure hose depending on the version.
•
TEFLON pipe: Here the PTFE screw-on gland for the pipe connection is screwed onto the adjustable angular gland on the filter. The PTFE angular screw-in gland is screwed into the condensate separator. These must be joined with the TEFLON pipe such that it does not break off and runs slightly slanting to the condensate separator.
Note: •
All screw glands for the measuring gas must be sealed with TEFLON.
PTFE pressure hose: This PTFE pressure hose is provided with M16x1.5 union nuts at both ends. With this the PTFE pressure hose is connected directly to the screw-glands on the filter and condensate vessel. If an electrically heated measuring gas line is used between the probe and the analyzer cabinet, then it must be connected directly to the filter. When carrying this out, the ERMETO screw glands contained in the supplied items can be used. The measuring gas line must be restrained at the valve combination so that the complete load does not fall on the joining piece.
•
The connection between the valve combination and the pneumatic limit switch consists of the ready-made compressed air lines with conical nipples and union nuts. With the pneumatic limit switch attention must be paid to the connections. The second connection "A" must be sealed with the stop-plug.
•
The connection between the valve combination and pneumatic motor is made with the third ready-made compressed air line.
2.6
Laying the coolant line to the probe
With the movable feed lines to the traversable probe it must be ensured that the complete traversing range remains free without any hindrance due to the lines. The laying of the feed lines must be carried out very carefully. Note: With the relevant mounting plan and the types of installation stated in the mounting instructions, nonmandatory suggestions are given, since normally the local conditions demand adaptation of the line routing. The main points to be considered are as follows: • setting up of the coolant hoses as twist-free as possible; • select the distance between connections not too large, so that hoses are not subject to tensile stresses even in the end positions; • within the complete traversing area do not over-bend hoses - the smallest radius is 200 mm; • do not twist the hoses impermissibly by movement, but instead bend them in the plane of movement as free of twisting as possible; • do not place any obstructions in the traversing area; • the coolant lines must not come into contact with heat-sensitive parts.
Copyright ® SIEMENS
Page 12
04/04
SQ250 FLK Gas Sampling System When laying ( see Figure 4 ) the flexible corrugated hoses of 3 m length ( 12 ), it is practical to temporarily fix these to the pipe bends ( 6 ) on the probe. Then insert the probe. The other end of the coolant lines can then be conveniently fixed to the angular connection on the venting containers ( 11 ). These can then, where constructional circumstances permit it, be fixed above the centre of the traverse area at a sidewards distance of about 50 cm from the probe joining-flanges. A check must now be made of the points listed above by traversing the probe. Correct the fixing point if necessary. The venting containers must then be fixed at the point which is finally determined. Traverse the probe between the front third and the centre. Screw out the corrugated hoses ( 12 ) so that they are suspended on the flanges without twisting. The flange joints can now be finally fastened.
Fig. 4 Connection of the coolant lines to the probe Legends:
1 2 3 4 5
Probe cooling pipe Connection flange, return Connection flange, feed Ball valve Seals
6 7 8 9 10
Pipe-bend 90° Connection flange for coolant line Gas output Cleaning opening Dedusting filter
11 12 13 14 15 16
Venting container Corrugated hoses 3m Pipe ( customer supplied ) Connection flange on cooler Corrugated hoses 1.5m Heat Exchanger
A pipe of NW25 ( 13 ) must be laid by the customer, slightly sloping downwards, from the second connection on the venting containers ( 11 ) up to the vicinity of the heat exchanger unit (14 ). Normal black NW25 pipe can used. Weld-on flanges contained in the supplied items must be welded on to each end of the pipe. Further connection to the heat exchanger with the feed and return connections is implemented with the flexible corrugated hoses of length 1.5 m ( 15 ) with flanges joints at both ends. The length and installation of the coolant lines between the venting containers and the flexible hoses on the heat exchanger are dependent on the local conditions and must therefore be dealt with by the customer. The connection should however be as short as possible. Note: The venting containers must be positioned at the highest point of the coolant circuit. No threaded joints should be present in the coolant lines. Ensure absolute sealing tightness when welding the lines. When the lines have been welded, they must be cleaned to prevent contamination of the coolant. Be sure to use sealing gaskets when making the flange joints. Fully tighten the screws cross-fashion. The connection joints for the connection to the venting containers and the flexible corrugated hoses on the heat exchanger are contained in the supplied items, as is the other material for installing the coolant lines ( except the fastening material for venting containers, etc. ).
Copyright ® SIEMENS
Page 13
04/04
SQ250 FLK Gas Sampling System 2.7
Compressed air connection
The connection point for the compressed air line should be positioned at the same height as the venting containers, but on the opposite side of the probe. The compressed air line NW20 (length 3.5m) with DIN 3483 hose couplings at both ends must be used for the connection from this supply point to the valve combination. At the supply point the compressed air should preferentially be implemented by the customer in 1/2" pipe. A threaded coupling R 1/2" with metal seal as counter piece to the hose coupling is supplied for the transition to this feed line.
2.8
Measuring gas connection
The measuring gas connection from the valve combination to the connection point (the centre of the retraction device) is implemented using a 3.5m long PTFE pressure hose of NW8 with metal braiding ( 2 ) and M16x1.5 union nuts at both ends. The PTFE pressure hose is screwed onto the bulkhead screwed gland ( 1 ) which is fixed to the connection point. A hose connection piece is fastened in the bulkhead gland, so that a PVC hose of ID 6mm ( 3 ) can be led further to the analysis equipment. ( See Figure 5 ).
Legends: 1 2 3 4 5 6 7 8 9 10
Bulkhead gland at connection point PTFE pressure hose PVC hose Analyzer cabinet Measuring gas connection on analysis Inserted probe Central traverse area Condensate vessel Condensate output Gas cooler device
Fig. 5 Installation of the measuring gas line
Copyright ® SIEMENS
Page 14
04/04
SQ250 FLK Gas Sampling System
It should be ensured that the connection between the probe and the connection point with the probe inserted always slopes down ( no collection of condensate in "water pockets"). Also further on, the pipe must be laid as already stated either rising or falling towards the analysis device. With special analyses, such as for example SO2, a heated measuring gas line regulated thermostatically to approx. >150°C must be used. This line is then directly connected to the measuring gas output of the heated filter. It must be fixed with mounting clamps at the connection point and routed further up to the analysis equipment. Secure all hose connections with hose clamps (e.g. Norma or UNEX K010 Hose Connectors). To prevent mechanical damage, the measuring line can be laid in steel conduit or plastic ducting. It should be ensured that edges are rounded off or fitted with plastic edging. At points where there is a risk of frost the measuring line should be laid in an insulated plastic duct running in parallel with a heater pipe. The heater must be designed such that the measuring gas line (e.g. plastic pipe) is not damaged, but freezing is not possible. Keep the length and internal diameter (ID) of the measuring line as small as possible in order to prevent unnecessary dead time in the measurement; the display delay is dependent on the measuring gas flow (Figure 6) and on the length of the pipe (Figure 7).
When laying the measuring gas lines, ensure absolute tightness of sealing, because otherwise extraneous air drawn in by the negative pressure will give erroneous measurements.
Measuring gas flow
For 1m gas line before the gas analysis device 4 mm ID
7 mm ID
10 mm ID
l/min
sec.
sec.
sec.
1,5
1,6
4,8
9,6
c
1,0
0,8
2,4
4,8
b
1,5
0,6
1,6
3,2
a
2,0
0,4
1,2
2,4
Legends:
Fig. 6 Display delay in relation to the measuring gas flow
2.9
a 4mm ID b 7mm ID c 10mm ID
Fig. 7 Display delay in relation to the length of measuring gas line
Safety measures
It is recommended that the area around the probe, including the traverse path, is closed off and provided with warning signs about the high temperature (up to 250° C) of the probe, coolant pipe and cooler as well as the automatic traversing. An emergency-stop button, included in the supplied items, can be fitted within this area, so that when it is operated the automatic probe traversing is stopped. Caution: When there is a power failure and a compressed air motor is used, the probe withdraws despite the EMERGENCY-STOP button being pressed on account of the compressed air.
Copyright ® SIEMENS
Page 15
04/04
SQ250 FLK Gas Sampling System
2.10
Electrical connections
The electrical connections are implemented according to the regulations from the local power supply utility and of the relevant country. The cable for the connection of the devices is not included in the supplied items and should therefore be provided by the user according to our specifications. The required cable and the details about the cable connections can be taken from the wiring diagrams in the supplied wiring manual. However, it should be ensured that high flexibility, temperature resistant cables are used for the connection from the retraction device (valve combination). These must also be suitable for medium, mechanical stresses. In this respect particular care must be paid during laying (coolant operating temperature with hoses up to 250°C). The cables must not come into contact with any hot parts when the probe traverses. Control cables normally found in the relevant cement works can then be used from the connection point ( the centre of the retraction device ). The electrical supply cables on the heat exchanger unit are preferably implemented in steel conduit to the control cabinet. Here it should be ensured that these pipes are laid at a distance > 10cm from the hot pipes, the cooler and the coolant pump. Top laying is the preferred method for the feed cables. All cables must be lead into the cable entries provided in the control boxes.
3.
Operation
3.1
General information
A practical start-up should only be carried out during or after the raw-meal feed. However, the interchange of signals and the electrical functions can be checked beforehand. A temperature at the sampling point of at least approx. 600°C should be present for starting up the cooling circuit. Danger !
3.2
Probe and coolant lines have an operating temperature of up to 220° C! The baked-on deposits on the probe may have temperatures of over 1000° C!
Start-up
Warning!
The probe must only be commissioned by qualified personnel who are familiar with all maintenance measures. Damage may occur if operated by unauthorized personnel and maintenance is improperly
carried out. For safety reasons and guarantee considerations the initial start-up must always be carried out by SIEMENS or by persons that they have instructed.
Copyright ® SIEMENS
Page 16
04/04
SQ250 FLK Gas Sampling System
3.2.1
Electrical connections
Once the electrical connections and connecting cable have been checked for correct laying, the mains voltages must be checked against the voltage figures given in the circuit documentation and against the name-plates. After switching on the voltage in the control cabinet and the PLC controller and after the input of the program the signal test based on the circuit documentation and the functional test can be started. Note:
See also the operating manual for the controller, Chapter Start-up.
Taken individually, the following signals should be checked: •
Signals to the retraction device • Limit switch • The direction of rotation of the driving motor for the retraction device should be checked by a short pressing of contactor relay. • Check the function of the local operating panel with the manual / automatic switch. • Then briefly move the traversing carriage using the local control panel.
Note: •
Signals for the valve combination • • • • •
Note: •
Control of the compressed air valves via counter using OP3 Control of the four-way ball valve (measure, close, blow out, test) Operation of the low-pressure switch and setting to approx. 0,15 bar Operation of the push-button, Purging ON and Purging STOP Here it can be seen whether the purging starts and also stops. See also the operating manual for the valve combination, Chapter Start-up.
Signals and supply for the measuring-gas filter heater •
Note: •
See also the operating manual for the retraction device, Chapter Start-up.
The thermal switch must switch off the heater after the operating temperature has been reached and a signal must be passed to the controller. See also the operating manual for the measuring gas filter, Chapter Start-up
Signals to the analyzer cabinet • •
Note:
Flow bypass (for bypassing the flow monitor when the measuring gas pump is switched off) "Purge" signal for fault-bypassing and limit-bypassing the analysis devices during purging. See also the operating manual for the analyzer cabinet and the circuit documentation.
Copyright ® SIEMENS
Page 17
04/04
SQ250 FLK Gas Sampling System •
Signals to the heat exchanger unit •
Before the motor protective switch in the control cabinet for the heat exchanger unit is switched on, the control signals must be checked by operating the separate contactors. • After switching in the main switch on the left side of the control cabinet and closing the protective switch, the direction of rotation of the blower and the circulation pump can be checked by momentary pressing the corresponding contactor relays. Note:
See also the operating manual for the heat exchanger unit, Chapter Start-up.
After termination of the signal test, the sealing check test and the flow check of the measuring gas line should take place. To do this, a method of changing certain counter values has been provided in the PLC program. See the Chapter Servicing, flow and sealing tests.
3.2.2
Compressed air
After the check of the compressed air hose and the retraction device with the probe installed, the compressed air can be fed with the shut-off valves closed. When using the retraction device with emergency retraction by a compressed air motor, the direction of rotation of the compressed air motor must be checked by slowly opening the main shut-off valve on the valve combination. When no voltage is applied, the traverse carriage must withdraw from the kiln. The compressed air motor is stopped in the withdrawn state by the compressed air limit switch. The compressed air connections should be tight to minimize consumption. Note:
3.2.3
For the limit switch settings and the start-up of the traverse carriage see the operating manual for the retraction device and the valve combination.
Purging process
The purging is started by: 1. 2. 3. 4.
The "Start" push-button on the valve combination or in the controller (when the probe is withdrawn only with the automatic switch in "Manual"); When the probe is inserted; Automatically after expiry of the waiting interval between two purgings ( CTR 1 or 2 ); The negative pressure in the measuring gas line is too high.
The purging process with compressed air can be checked by pressing the "Start" button on the valve combination. Once the purging has started, the four-way ball valve is set to the "CLOSED" position. Then the release of the cleaning cycle (compressed air cleaning) occurs. When finished, the four-way ball valve moves to the position "Blow out condensate". Then the collected condensate is blown out of the condensate vessels. After this period has expired the four-way ball valve moves through the "Test" position (pressure balancing of the measuring gas line) into the "Measure" position. Then a low pressure test occurs after the measuring gas pump has started. When this has terminated, the purging process finishes after a measurement bridging period. The purging can be terminated at any time with the "Stop" buttons on the valve combination and in the controller. With the cleaning cycle, special attention must be paid to the correct sequence for controlling the compressed air valves.
Copyright ® SIEMENS
Page 18
04/04
SQ250 FLK Gas Sampling System
The four-way ball valve is moved to the "Closed" position with the probe withdrawn. The measuring gas pump is only in operation with the probe inserted, when a minimum coolant temperature of 130°C has been reached and when the measuring gas filter has reached its operating temperature.
3.2.4
Heat exchanger unit
See also the operating manual for the heat exchanger unit. After checking the electrical functions, the signal interchange to the controller and the coolant lines, the following settings for the coolant circuit must be checked and adjusted. Settings on the limit monitor: Coolant temperature, min.: Fan starts at : Coolant temperature, max.: Switching hysteresis Set value for three-way valve:
130°C 180° 220°C 2°C
140°C
The precise settings are derived from the operating values over a longer period of time and may vary from system to system. Note:
Do not open the shut-off valves on the venting containers when the pump is stationary unless really necessary, because otherwise air will enter the closed coolant circuit.
3.2.5
Probe with retraction device
In order to be able to begin with the insertion of the probe, the parameters in the PLC controller must be checked according to the "Controller" operating manual. Danger: During automatic or manual traversing of the probe, no unauthorized personnel should be present in the immediate vicinity of the probe, the kiln connection pipe and the retraction device.
Note:
The "EXTERNAL" release must be present ("1" signal on the PLC Input 4.6).
Then a start can be made on the insertion of the probe into the kiln or precalcination chamber. • Set the manual / automatic switch to manual; • Uninterrupted pressing of the button "Insert probe"; It is essential to check the following: • • • • • •
all moving parts such as coolant hoses, measuring gas line and electrical feeders. the open Kiln connection piece the proper functioning of the dust blow-back system (TMR 3,4,11) coolant flow (heat exchanger unit, Lamp H6), flow measurement always on max. indication coolant level min. (heat exchanger unit, Lamp H7) pump fault (heat exchanger unit, Lamp H2)
Copyright ® SIEMENS
Page 19
04/04
SQ250 FLK Gas Sampling System If faults occur during insertion, then the probe must automatically withdraw after the insertion button is released. Insertion of the probe can only be restarted after rectification of these faults. Note:
The probe must first be inserted manually and also after each retraction due to a fault.
Some faults must be simulated to test the safety functions. This should be carried out at the point of their acquisition if possible. The red fault lamp flashes for each fault (exception: probe not on automatic) and after acknowledgement it becomes continuously illuminated. The associated text appears on the display of the OP3 Operator Panel. Since a safety interlock is involved here (danger of overheating the probe and coolant), these functions should be tested in "Automatic" and "Manual" modes. Caution:
•
The automatic retraction of the probe with electrical and pneumatic drives occurs with the following faults: -
•
When simulating the faults on the heat exchanger unit, particular care should be taken that, for example, with a fault on the coolant flow, overheating of the probe and damage to it cannot occur.
Supply to heat exchanger Supply to heated filter Fault on coolant blower Coolant flow < min. (time-delayed) Coolant level < min. Overtemperature > 220 degrees (time-delayed) Coolant pump switched off Limit switch fault, four-way ball valve Position error, four-way ball valve Limit switch fault, probe inserted Time exceeded during insertion / retraction
The automatic retraction of the probe with pneumatic drive occurs with the following faults: -
for power failure for protective tripping of the power supply to the PLC tripping of the motor protective switch for the probe drive-motor
If damp penetrates into the coolant due to the condensate or other effects, sudden gas bubble formation may occur when the coolant is heated, causing interruption of the flow and therefore retraction of the probe. This occurs mainly at temperatures of approx. 125°C. At approx. 200°C...240°C vaporization of the coolant may occur. Therefore, the coolant fluid must be subjected to these ranges during the initial start-up. The following procedure has proven suitable for obtaining these critical points: • Slightly open the cover of the expansion vessel; • Slightly open the venting tap for the pump and cooler; • With the pump running, briefly open the venting container. While doing this, hold the collection container under the outlet; • When the probe withdraws due to interruption in the flow, immediately start the pump again; • After rectification of the fault, immediately insert the probe again; • Close the venting tap on the cooler; • Close the cover on the coolant expansion vessel.
Copyright ® SIEMENS
Page 20
04/04
SQ250 FLK Gas Sampling System If the coolant temperature briefly reaches 230°C, normally no more gas bubble formation occurs. Caution:
The probe temperature and therefore the coolant temperature must only briefly attain 230°C since otherwise the probe may be damaged.
When heating the coolant, all the flange joints and welded seams should be checked for sealing, since the coolant is substantially thinner at high temperature. Any leaks occurring must be immediately remedied. It is essential to retighten the screws on the flange joints after heating the cooling system.
3.2.6
Measures for emergency-stop
It is recommended that the area around the probe (including traversing path) is closed off and access to this area restricted to authorized personnel. Within this area an emergency-stop button, can be fitted which stops the automatic traversing of the probe when operated. Caution:
If the emergency-stop button is pressed, a dangerous condition can arise. For example, if the probe is still in the hot range and a fault occurs causing overheating of the probe (coolant flow >min.). To prevent damage of the probe, the emergency-stop button (with latch) should be released as soon as possible. With power failure the compressed air motor is used to withdraw the probe, even thought the emergency-stop button is pressed.
While ever the emergency-stop button is operated, the red fault lamps in the PLC controller and on the local control panel flash and cannot be cancelled.
3.2.7
Automatic probe retraction
In order to be able to test the automatic insertion and retraction in a short time the hours timer TMR 10 must be set to a minutes timer by entering 60, i.e. the interval for retraction and insertion is now counted in minutes instead of hours. The time up to the start of "Retraction" can be read in the CTR 6 after manual insertion and switching to automatic (enter a minimum of 10min.). When this period expires, the horn and flashing light for the traverse warning turned on. When the horn time expires, the probe starts to retract. When the retraction is finished, the flashing light stops and the waiting period up to the re-insertion starts (TMR 0). Then the retraction warning starts and automatic insertion takes place. In this operating mode the signals, e.g. contactor fault (ESS INSERT, ESS WITHDRAW) and the time delay signals (DELAY INSERTION / RETRACTION) can be simulated. Once these tests are concluded, the TMR 10 must be set to 3600 sec. again. The required time interval for automatic insertion / retraction can be entered in the CTR 6 again in hours. The indicating lamps on the local control panel and on the controller flash if no analysis is not being carried out, i.e.: the measuring gas pump is switched off, also with the purging process running.
Copyright ® SIEMENS
Page 21
04/04
SQ250 FLK Gas Sampling System
4.
Maintenance
4.1
General information
The following maintenance work must be carried out by the user to keep the equipment in an operational state: The sampling device, drive motor, traverse rails, valve combination and heat exchanger unit must be thoroughly cleaned of dust and dirt at least once per week. •
When restarting the Kiln in the first month, the probe should be checked for baked-on deposits and damage each time it is withdrawn. and also when significant changes to the raw meal mixture occur.
•
Regular checking of the coolant circuit.
•
Compressed-air and measuring-gas lines, limit switches and particularly the moving parts must be checked for damage and repaired or renewed if necessary.
- Checks to the cooling circuit •
Here, the flow and level of the coolant fluid should be checked. If required, the coolant should be topped up. As an aid there is a level mark for 180°C on the expansion vessel. If this is undercut at the corresponding temperature, the coolant should be topped up.
•
If the level mark "min." is undercut in the hot condition, then it is essential to closely examine the cooling system for leakage. This may occur on the heat exchanger unit, connection hoses or on and in the probe.
•
Any unsealed points must be rectified as soon as possible.
•
If the flow indicator is no longer in the maximum range, the coolant filter must be removed and cleaned.
The check of the measuring gas line is mainly just a visual check. Here, attention should be given to any water pockets, blockages or damage that has arisen. The flow in the analyzer unit should also be checked. A reducing flow indicates that the measuring gas lines are becoming choked. An interval of one week between checks is recommended. Note:
4.2
Further maintenance measures can be taken from the operating manuals of the separate
components.
Optimizing the complete equipment
It is imperative that optimization of the complete equipment is carried out after start-up. This can however only take place with normal operation of the kiln or precalcination facility and after the addition of the raw meal. Optimization involves the following points: 4.2.1 4.2.2 4.2.3
Probe cooling circuit Automatic insertion / retraction of the probe Purging duration and interval
Copyright ® SIEMENS
Page 22
04/04
SQ250 FLK Gas Sampling System
4.2.1
Probe cooling circuit
When the probe is inserted, its temperature increases very quickly. This temperature increase is firstly damped by the control of the three-way valve and secondly reduced by the cooling blower switching in, so that normally the temperature does not extend beyond 210..220°C. This temperature rise can be influenced by the set value on the three-way valve. Attempts should be made to obtain a working range of 135....215°C. If the coolant is very cold during insertion, then it takes a certain time until the three-way valve releases the coolant circuit via the cooler. Here, it may happen that the temperature increases above the maximum probe operating temperature, causing the probe to withdraw again. In this case the probe should be immediately inserted again after acknowledging the fault. In order to avoid this, the set value of the three-way valve must be reduced. In exceptional cases it is however possible to enter a delay time in the CTR 0 for the fault signal on a 10 sec. time grid. Note:
If the delay time is too large, damage to the probe due to over-temperature may arise in certain situations.
Due to the insulation effect of the baked-on deposits on the probe, the temperature range of the cooling circuit reduces. In order to obtain the longest possible service life of the probe in the kiln, the working temperature range should be as high as possible. To achieve this, the set value of the three-way valve should not be set below 145°C.
4.2.2
Automatic retraction / insertion intervals for the probe
The intensity of the baked-on deposits depends on a number of criteria, such as for example, the composition of the raw meal, installation location and fuel for the kiln heating, etc. If the baked-on deposits are too large, these cause high mechanical stresses in the probe and lead to an operating temperature that is too low. In order to regularly strip off the deposits on the probe, it can be automatically withdrawn after an interval entered in hours in the CTR 6. During this retraction period the deposits are cooled with compressed air and, where possible, blown back through the connection pieces into the hot area. The remaining deposits clinging to the probe cool down due to the waiting period which can be variably parameterized, so that with insertion again they are blown back by compressed air from the probe into the hot region. Depending on the intensity of the deposits on the probe, the interval between automatic retraction / insertion should be lengthened or shortened accordingly. If despite adaptation of this time interval the 130°C coolant temperature is undercut, then a once-only attempt to strip off the deposits from the probe is made by the automatic retraction / insertion. If the coolant temperature further undercuts the limit, the release of the analysis is withdrawn. The probe remains in the hot range until the time CTR6 has expired In this condition the probe must be "manually" withdrawn, cleaned and "manually" inserted again.
4.2.3
Purging duration, purging interval
See the controller operating manual for the purging procedure. Since dust deposits in the probe and filter are unavoidable, the purging process is initiated using an adjustable interval period. This timing interval should be maintained as long as possible, since no analysis is carried out during purging. On the other hand, the purging should be regularly initiated by a low-pressure signal.
Copyright ® SIEMENS
Page 23
04/04
SQ250 FLK Gas Sampling System The purging duration should be kept as short as possible. However, it should be ensured that after purging, the low pressure, if present, returns to its normal value. It is therefore practical to match the purging duration and interval to local conditions. - Setting the purging duration • In order to prevent initiation of purging due to the expired purging interval time, this time must be temporarily set to a high value (CTR 1 to 300 minutes for example). • After approx. -0.08 bar is obtained, the purging process is started. • Then the low pressure is checked on the pressure gauge. • If the low pressure is the same as previously, then the purging duration (CTR 3) can be left as it is. - Setting the purging interval period: • In order to prevent initiation of purging due to the expired purging interval time, this time must be temporarily set to a high value (CTR 1 to 300 minutes for example). • Then it must be found how long it takes on average until the low pressure in the measuring gas line has reached approx. -0.08 bar. The low pressure can be read on the pressure gauge in the valve combination. • The time that has passed since the last purging can be read out from the CTR 1 in minutes using the OP3 Operating Panel. • The value obtained in minutes can now be entered in the CTR 1. • The limit contact in the pressure gauge for the release of the purging by low pressure should be set to -0.15 bar. If during longer operation an increasingly shorter purging interval period is found, then the low pressure must be checked directly after purging. If the low pressure does not correspond to the normal value and no fault can be found, the purging duration in the CTR 3 can be increased to 8 sec.
4.3
Leakage test
This should be carried out every six months or after each manual cleaning of the measuring gas line and after replacement or repair of various parts in the measuring gas line. ( pump, filter, gas cooler, etc.). To simplify the low-pressure ( leakage ) test of the complete system a method has been provided in the programmable logic controller of appropriately controlling the measuring gas four-way ball valve and the measuring gas pump. Here two procedures must be carried out: 4.3.1. Leakage test between the four-way ball valve and the measuring gas pump 4.3.2. Leakage test of the probe, filter and condensate vessel. When doing this, it is essential that the first test is correctly concluded and the sealing of the measuring gas connection is guaranteed.
Copyright ® SIEMENS
Page 24
04/04
SQ250 FLK Gas Sampling System
4.3.1
Leakage test between four-way ball valve and measuring gas pump.
With this test the four-way ball valve is closed and the measuring gas pump switched on. This should always be carried out after a change of filter or any repairs to the measuring gas line, but in any case at least every six months. • Withdraw the probe. • Local control panel: Set the "Manual / Automatic" switch to "Manual". • In the PLC controller: By entering 16 in the CTR 16 the four-way ball valve moves to the "Closed" position and the measuring gas pump starts. • If a Siemens analyzer cabinet is being used, the pump will switch off due to the flow being too low. • This can be bypassed and a still larger negative pressure produced with the push-button "Pump on". • The negative pressure that has built up can be read from the pressure gauge in the valve combination. This should be approx. 0.3 .... 0.4 bar. • After the pump has switched off, the pressure drop should not exceed more than 2mbar after 3 minutes. • If this is not the case, then all connections should be retightened and, if necessary, the leaky points found and rectified. The leaky position can be narrowed down by constricting the measuring gas line from the pump side.
4.3.2
Leakage test of the probe, filter and condensate vessel.
With this test the four-way valve is moved to the "Measure" position and the measuring gas pump is switched on. This can only be carried out after a leakage test has been performed correctly under 4.3.1. Here, leakages between the probe and the four-way ball valve can be found ( including the measuring gas filter, condensate vessel and four-way ball valve ). If a heated measuring gas line is being used, this is also checked. This check should also be carried out at least every six months. • Withdraw the probe. • Local control panel: Set the "Manual / Automatic" switch to "Manual". • Switch off the filter heating and wait until the filter has cooled down (the waiting period can be shortened by starting the purging a number of times). • For a brief check it is sufficient to start the purging after applying a soap solution to all joints between the ball valve and the probe. Leaks can then be found by observing all the joints. • Close the probe at the sampling opening (only for initial start-up or probe replacement). Otherwise the connection between the probe and filter should be opened up. When doing this, loosen the fastening screws on the filter. • Close off the measuring gas input on the filter using stop-plugs. • In the PLC controller: By entering 15 in the CTR 16 the four-way ball valve moves to the "Measure" position and the measuring gas pump starts. • If a Siemens analyzer cabinet is being used, the pump is switched off, because the flow is too low. • This can be bypassed and a greater negative pressure produced with the "Pump on" push-button. • The negative pressure that has built up can be read from the pressure gauge in the valve combination. This should be approx. 0.3 .... 0.4 bar. Copyright ® SIEMENS
Page 25
04/04
• When the pump has switched off, the drop in pressure must not be more than 2mbar in 3 minutes.
Copyright ® SIEMENS
Page 26
04/04
SQ250 FLK Gas Sampling System • If this is not the case, all the joints, including the screws on the condensate container, should be evenly and carefully retightened. If necessary, find the leaky locations and rectify them. • Then restore the connection between the filter and the probe. Special attention should be given to the sealing tightness and correct mounting of the filter.
4.4
Measures taken during a power failure
When the power fails, the probe is withdrawn by a pneumatic motor. To achieve this, it is necessary to provide an adequate supply of compressed air. If no pneumatic drive is present or not enough compressed air is available, then it must be ensured that the probe is moved out of the hot region as quickly as possible - if necessary by rotating the coupling between the drive motor and gearbox. A hand crank can be used if possible. The coolant pump switches off when a power failure occurs and remains switched off until the power is restored. Note: Since the heat exchanger unit switches off during a power failure, a very dangerous state can arise if probe is still in the hot region.
the
The coolant is not circulated and overheating occurs. Due to the overpressure that builds up, very hot, thin coolant can be emitted from the probe, connection hoses or heat exchanger. Also, the complete probe may burn down. Therefore the probe should be supplied with either compressed air or with emergency power.
4.4.1
Work necessary after the power is restored :
• Start the coolant pump with the push-button (press until the flow has established). • Acknowledge the fault (PLC controller or local control panel). • Switch the controller to "Manual" and insert the probe manually. • When the probe has been inserted, a purging process is started automatically. • The measuring gas pump in the analyzer cabinet is started after the purging has terminated. • If the analyzer pump does not start, find the cause and manually start the pump. • Switch the controller to "Automatic".
Copyright ® SIEMENS
Page 27
04/04
SQ250 FLK Gas Sampling System
4.5
Measures to be taken during faults
If a fault occurs and is acquired, the red fault lamp begins to flash quickly. While ever the fault is still present or has not been acknowledged (fault lamp flashes or is continuously illuminated), the relevant message text can be read in the control cabinet with the OP3 Operating Panel. Messag Display text in e operating panel No.
Cause
Effect
Remedy
0
Probe Emergency Stop
Emergency stop button pressed
Probe does not withdraw by electric motor, but instead pneumatically for a fault or power failure
Important!: Dangerous condition during faults, e.g. coolant overtemp. cannot withdraw probe, risk of probe damage. For power failure, probe withdraws despite emergency-off; reset emergency-off, reset, insert probe.
1
Control System Fuse/Voltage fault
Fuse failed
Probe withdraws (el. +pneum.)
Find cause of fuse failure and remedy, replace fuse, reset, insert probe
2
Control System ESB S7 I4.2
Power failure or fuse for PLC failed
Probe withdraws pneumatically
For fuse failure, find the cause and rectify it; after power is restored reset, insert probe
3
Cooling System Flow Coolant flow too low (delayed 10s) < min
Probe withdraws (electr. + pneum.) Coolant pump stops
Check the coolant level, top up if required, check for leakage, manual valves must be open, start pump and vent, blocked oil filter. Reset, insert probe.
4
Cooling System Pump fault
Power failure, flow too low, motor prot. switch tripped
Probe withdraws (electr. + pneum)
Find cause of motor prot. switch trip and rectify.
Cooling System Fan fault
Motor prot. switch tripped
Probe withdraws (electr. + pneum.)
Find cause of motor prot. switch trip and rectify.
Cooling System Level to low
Coolant level too low
Probe withdraws (electr. + pneum.)
Find cause of coolant lost (leakage) and rectify; switch off pump, top up coolant, start pump, vent, reset, insert probe.
5
6
Reset, start pump, insert probe
Reset, start pump, insert probe
Vent again when coolant temperature > 180 °C. 7
Cooling System Temperature to high
Coolant temperature to high (default setting 220°C)
Probe withdraws (electr. + pneum.)
Check coolant level and flow, vent, clean cooler, check GROW controller with 3-way valve, check limit setting on temp. controller. No obstacle in cooling air path? Rectify fault, reset, insert probe, vent again for coolant temp. > 170 °C
8
Probe retraction Plugs not OK
I 9.6 for plug monitoring (Valve combination not "1")
Probe withdraws (electr. + pneum.)
Check plug on valve combination for correct seating; if still not OK, check wiring, reset, insert probe
9
Sampling Gas Probe/Filter clog.
Still low pressure in meas. gas line even after multiple purging (pressure switch)
Probe does not withdraw.
Switch off filter heating fuse F1, start purging 3x to cool down filter, remove filter and clean, clean probe by undoing rear screw, also check line to condensate vessel and measuring gas lines, remover filter, ensuring absolute sealing tightness, switch on fuse F1.
"Purging" lamp flashes at a fast rate
Check for leakage, reset Counter 16, insert probe. 10
Probe withdraws Probe retraction ESS Either output for Contactor Insert or (pneumatically) Motor Contactor Withdraw is on and no feedback or output not on and feedback
Check wiring, especially the limit switches which are directly latched to the corresponding contactor. Check outputs and inputs on the PLC: Output:
Contactor Insert Probe
Input: Feedback Output: Contactor Withdraw Probe Input: Feedback Reset, insert probe
Copyright ® SIEMENS
Page 28
04/04
SQ250 FLK Gas Sampling System Messag Display text in e operating panel No. 11
Cause
Effect
Probe Delaytime Out Monitoring time exceeded for autom. / In insertion / retraction (110 sec.)
Remedy
Check whether traverse device is jammed mech., poss. check motor wiring. Clean probe traverse device, traverse probe manually and ensure smooth running. Reset, insert probe.
12
Probe-Limit Sw. fault
Limit switches ”Probe In” and “Probe Out” simultaneously operated
Probe withdraws (pneumatically)
Clean limit switches and readjust as requ'd, ensure easy switching. Reset, insert probe.
13
4-Way Valve Limit Sw.fault
More than one input for the positions of 4-Way valve = 0
Probe withdraws (electr. + pneum.)
Check in which position the 4-way valve is actually positioned and which additional input is "0". Check wiring and rectify fault. Reset, insert probe; Counter 16
14
4-Way Valve Pos. fault
4-way valve does not change its position within 20 sec. with driven motor.
Probe withdraws
Move valve manually and check, test wiring, measure voltage. If valve jams, remove, clean, reset, mount probe.
Probe system not automatic
Switch set on local control panel, not in “Automatic”
Red "Fault" lamp is on, but does not flash
15
(electr. + pneum.)
Operating signal: Probe does not automatically move into / out of this position. Probe traversing only possible manually. With fault withdraws anyway. Control of 4-way and compressed air valves possible with operating panel. When automatic is selected, red lamp cancels itself if no other fault present.
16
Sampling System Filtertemp. < min
Filter temperature is too low ( < 3 >
< 4 > < 8 >
< 8 > < 9 >
Fig. 3 Suggested fastenings for holding the feed lines.
Legends:
1 2 3 4 5
Valve combination Fastening screw M8 Cable retention bracket Fastening for measuring gas hose Fastening for control cable
Copyright ® SIEMENS
6 7 8 9 10
Flat bar 30 x 4 mm Fastening for compressed air hose Pipe clamp Plastic cable protection M screwed gland for control cable ( Underside )
Page 65
04/04
SQ253 Valve Combination
3.
Operation
3.1
General information
This equipment unit has been supplied functionally tested. Therefore, no complicated checks of the separately installed devices are needed.
3.2
Start-up
Warning! The valve combination in conjunction with the withdrawal device must only be put into operation by qualified personnel, who are familiar with all maintenance measures. Unauthorized operation and improperly carried out start-up procedures can cause damage. The start-up is mainly restricted to a check of the wiring, a functional check and a leakage test of the complete measuring equipment. 3.2.1
Electrical start-up
After checking the wring to the control cabinet, the following functional checks can be carried out. These should be done before the compressed air is switched on. • • • • 3.2.2
The individual settings on the four-way valve should be selected from the PLC controller using the OP3 Operating Panel. Similarly, the function of the compressed air valves -Y2, -Y3, -Y4, and -Y5 should be checked. It must also be checked whether the flushing is initiated and started by the local push buttons. The flushing process must also be started by simulating low pressure (turning back the limit switch contacts to -300 mbar). The flushing sequence must be checked according to the sequence in the operating manual for the controller. Compressed air and leakage test
With the compressed air it must be ensured that the 6...8 bar pressure, the quantity and the quality conform to the specification. Caution:
There should be no one situated in the front area of the probe. The compressed air must be shut off immediately if any leaks occur.
Turn-on should be carried out slowly and special attention must be paid to the joining pieces. The compressed air part with the valves should be checked for sealing tightness (use leak-seeking spray or soap-water solution as an aid). After starting the flushing, the connecting lines to the filter and the probe should be tested for sealing tightness once the leakseeking agent has been applied. If a compressed air motor is being used on the withdrawal device, the function of the withdrawal valves must be checked. • •
In the unenergized state the solenoid valve (Figure 2, Item 5) must be open and the compressed air motor driven. When the pneumatic limit switch on the withdrawal device is operated, the pneumatic valve (Figure 2, Item 4) closes and shuts off the compressed air feed to the motor.
Note: The solenoid valve must close absolutely tight when energized, because otherwise the traverse carriage will move slowly in operation.
Copyright ® SIEMENS
Page 66
04/04
SQ253 Valve Combination
4.
Maintenance
4.1
General information
The user should carry out the following maintenance work so that operational readiness is ensured:
4.2
•
The valve combination must be thoroughly cleaned of dust and dirt every week.
•
The compressed air filter should be cleaned every month.
•
A leakage test of the complete system (compressed air side and measuring gas side) must be carried out every six months.
Compressed air filter
The compressed air filter is used for the effective separation of liquid and solid particles from the compressed air. However, it is not intended for oil separation.
The air flows in the direction of the arrow through the filter and is made turbulent by the guide vane A. The particles of liquid are thrown against the internal walls and run downwards. The separating cap B forms a calm zone which prevents the separated condensate from being taken up again by the air flow. Then the air flows through the filter element C. Here all solid contaminants are retained which are larger than the pore size. When the condensate reaches a certain height, a valve is opened by the float F and the filter is automatically drained. With filters with manual drainage, the filter is drained by operating the drain screw E. Clean the compressed air filter at least once per month, more often if necessary. To do this, shut off the compressed air before the filter. Open the filter by turning the metal container to the right and then clean it.
automatische/manuelle Entleerung automatic / manual drainage Fig. 4 Compressed air filter
Copyright ® SIEMENS
Page 67
04/04
SQ253 Valve Combination 4.3
Compressed-air solenoid valves
This 2/2 solenoid valve is closed in the unenergized state (action Type A). It is suitable for neutral gases and liquids which do not attack the housing material. The sealing material is labeled behind the nominal width on the name-plate (B = NBR, A = EPDM, F = FPM).
Fig. 5 Compressed-air solenoid valve
Copyright ® SIEMENS
Page 68
04/04
SQ253 Valve Combination
4.3.1
Replacing the valves • • • •
Note:
Pull off the cable head after loosening the screw. Loosen screwed joints on the housing. Unscrew the pipes at both ends. Before fitting the new valve Pay attention to voltage and type of current according to the nameplate.
•
Clean the pipe work of contamination (metal swarf, sealing material).
Note: The arrow indicates the direction of flow. Do not use the valve as a lever when screwing it in. Do not block pilot hole on the valve output with pipe ends, sealing material, etc. Use PTFE tape as sealing material. • 4.3.2
Assembly takes place in the reverse sequence. Cleaning the valve
• • • • • • • • •
Note:
Pull off the cable head after loosening the screw. The pilot valve can be removed after loosening the four screws on the solenoid section. Take care with the core and spring. Loosen four screws on the valve cover. Remove the upper part. Take out the diagram and, if necessary, clean it and replace damaged parts. The valve body can now be cleaned. Grease with silicone grease or acid-free Vaseline. Assembly takes place in reverse sequence.
Observe the tightening torque of 1Nm for the cable head.
4.3.3
Faults: • •
Check connections. operating pressure and voltage. Pilot hole on the valve output covered or contaminated ?
Solenoid does not pull in: • • •
Short circuit or coil interruption. Core or core aperture contaminated. With alternating current, jammed core causes coil overheating.
Leaky valve: •
Procedure as under Section 4.3.2
SQ253 Valve Combination Copyright ® SIEMENS
Page 69
04/04
SQ253 Valve Combination
4.4
Condensate separator
The condensate separator consists of a glass bulb, lower and upper cover plates in stainless steel each with a connection opening and O-rings between the glass bulb and covers. Since the condensate vessel is blown out with each flushing process, no maintenance work is required. When replacing the various parts, it should be ensured during assembly that the four threaded bolts with hexagon nuts are tightened evenly and that the O-rings are correctly seated. If any leaks occur: • • •
First, slightly, but evenly tighten the threaded bolts. Check the glass bulb for any damage. Check the O-rings.
Copyright ® SIEMENS
Page 70
04/04
SQ253 Valve Combination 4.5
Four-way ball valve
The 4-way ball valve is constructed in steel with an electrical actuator drive to DIN ISO 5211/3337. The ball valve material is complete in PEEK. The full sealing tightness is achieved by a pressure-aided, maintenance-free sealing system. The actuator drive is also maintenance-free and fitted with an anti-blocking motor with temperature monitoring. 4.5.1
Removing the 4-way ball valve •
Remove inside the housing of the 4 Way-valve. Loosen the 2 screws inside the valve box and remove the valve from the drive.
Note: Attention must be paid to the connecting cable. This is so long that the complete unit can be lifted
out.
4.5.1.1 Checking the limit switches: • • • • •
Remove the complete unit as described above. Check the position of the 4 limit switches The control is provided by the OP3 in the control cabinet. A selected position is approached by entry in the CTR 16 (e.g. Measure). Assembly takes place in the reverse sequence.
Important! When setting the limit switches, pay attention to the 24VDC control voltage.
Copyright ® SIEMENS
Page 71
04/04
SQ253 Valve Combination
4.6
Low-pressure pressure switch
When the filter or probe is contaminated or blocked, a negative pressure is built up by the measuring gas pump. The electrical contact device integrated into the pressure switch function for monitoring and starting the flushing process. The magnetic snap-action contact is suitable for harsh applications which place high demands on switching capacity. The low-pressure pressure switch is largely maintenance-free. With an erroneous indication or for no indication, the connecting hose should be cleaned or, if necessary, the complete pressure switch replaced.
4.7
Electrically operated compressed air valve ( option )
This compressed air valve is included when a compressed air motor is used for the emergency withdrawal on the withdrawal device. When the voltage is switched on, the solenoid is energized and the valve switches. The compressed air supply to the compressed air motor is shut off. The control is implemented directly from the control unit. This Type MCH-3-1/2 can be converted by rotating the seal under the cover to the other valve version Type MOCH-3-1/2. 4.7.1
Replacing the valve • • • • • •
Note:
Pull off the cable head after loosening the screw. Loosen the screwed joints on the housing. Pull off the hose from both sides after opening the hose clamps. Remove the valve. Unscrew the screw-in hose nozzles and the reducing unions. Before fitting the new valve Pay attention to voltage and type of current according to the nameplate.
• • • 4.7.2
Clean the hose nozzles and use PTFE tape to seal the thread. Screw in the hose nozzles into the new valve. Assembly takes place in the reverse sequence. Cleaning a valve:
• • • • • • • • Note:
Pull off the cable head after loosening the screw. Loosen the upper nut on the solenoid coil. Remove solenoid coil. Remove the cover after loosening the two screws. Remove the plunger and diaphragm. Clean and replace damaged parts if necessary. After removing the snap-ring on the bottom, the pilot valve can be removed. Clean the valve body and replace any damaged parts. Assembly takes place in the reverse sequence. Pay attention to the tightening torque of 1Nm for the cable head.
4.7.3
Faults: •
Check connections, operating pressure and voltage.
Solenoid does not pull in: • • •
Short circuit or coil interruption. Core or core aperture contaminated. Jammed core causes coil overheating on alternating current.
Copyright ® SIEMENS
Page 72
04/04
SQ253 Valve Combination Leaky valve: •
Fig. 7
Procedure as in Section 4.7.2 or replace the valve.
Electrically operated compressed air valve
4.8
Pneumatically operated compressed air valve ( optional )
This compressed air valve is only fitted when a compressed air motor is being used for the emergency withdrawal on the withdrawal device. The valve has, depending on the choice of connections, the function "no throughput when unenergized" (11 blocked, 2 to 33 vented) or the function "throughput when energized (11 to 2, 33 blocked). The valve switches only for the duration of the signal on terminal 110 or 12. 4.8.1
Replacing the valve • • • • • • • •
Loosen the screwed joints on the housing. Pull off the hose after opening the hose clamps on both sides. Remove the valve. Unscrew the screw-in hose nozzles and the reducing unions. Check the type of valve before fitting the new one. Clean the hose nozzles, use PTFE tape for sealing the thread. Screw in the new valve. Assembly takes place in the reverse sequence.
Copyright ® SIEMENS
Page 73
04/04
SQ253 Valve Combination
4.8.2
Cleaning the valve: • • • • •
Release the two screws and remove the cover. Take out the plunger and diaphragm and clean, and replace any damaged parts. The pilot valve can be removed after removing the snap-ring on the bottom. Clean the valve body, replacing any damaged parts. Assembly takes place in the reverse sequence.
Fig. 8 Pneumatically operated compressed air valve
Copyright ® SIEMENS
Page 74
04/04
SQ254 Heat Exchanger
Fig. 1 Heat Exchanger
Contents 1. 1.1 1.2 1.3 1.4 1.5 2. 2.1 2.2 2.3 3.
Page
Introduction........................................................................ 76 General information ........................................................... 76 Personnel qualification requirements ................................ 76 Field of application ............................................................ 76 Function description of the heat exchanger....................... 77 Technical data ................................................................... 78 Installation ......................................................................... 79 Installation of the heat exchanger...................................... 79 Electrical connection ......................................................... 79 Filling up the heat exchanger with cooling liquid ............... 79 Setting into operation......................................................... 80
Copyright ® SIEMENS
Page 75
Page 3.1 3.2 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.4 4. 4.1 5.
Safety specifications.......................................................... 80 Preparation before first Start-up ........................................ 80 Adjustment of temp.-controller in switch cabinet .............. 81 Setpoint for temperature adjustment of the 3-WV ............. 81 Setpoint for temp.adjustment of fan .................................. 81 Min. limit value for start gas-sampling ............................... 81 Max. limit value emergency extraction of probe ................ 82 Standard starting ............................................................... 82 Setting out of operation ..................................................... 82 Shutdown the equipment................................................... 82 Maintenance...................................................................... 82
04/04
SQ254 Heat Exchanger Note: We would like to point out that the content of this operating manual is not part of an earlier or existing agreement, consent, or a legal relationship nor should it be modified. All obligations on the part of SIEMENS can be taken from the relevant purchasing agreement, which also contains the complete and solely valid warranty. These warranty provisions are neither extended nor restricted by this operating manual. We would also like to point out that for reasons of clarity not every conceivable problem situation in conjunction with the application of this product could be described in this operating manual. If you require further information or if particular problems occur which have not been dealt with in enough detail in the operating manual, you can request the required information via the local SIEMENS subsidiary. In the operating manual and in the warning information on the product, signal terms having the following meaning have been used: Danger as used in this operating manual and in warning information on the product itself means that death, severe injury and / or substantial material damage will occur if the appropriate precautions are not taken. Warning as used in this operating manual and in warning information on the product itself means that death, severe injury and / or substantial material damage can occur if the appropriate precautions are not taken. Caution as used in this operating manual and in warning information on the product itself means that slight injury and / or material damage can occur if the appropriate precautions are not taken. Note as used in this operating manual denotes an important item of information about the product or a relevant part of the operating manual requiring particular attention.
Copyright ® SIEMENS
Page 76
04/04
SQ254 Heat Exchanger
1.
Introduction
1.1
General information
Warning!
This system is operated by electricity. When operating electrical equipment, it is unavoidable that certain parts of this system carry a dangerous voltage. If the warning information is not followed, serious bodily injury and/or material damage may occur. Only appropriately qualified personnel should work on this equipment or in its vicinity. These persons must be thoroughly acquainted with all the warnings and maintenance precautions in accordance with this manual. The proper and safe operation of this device requires correct transport, storage, mounting and mounting as well as proper operation and maintenance. In particular the general construction and safety regulations about working on power installations (e.g. DIN, VDE) should be followed as well as the regulations relating to the proper use of lifting equipment and tools and the use of personal protective gear (protective goggles, etc.).
1.2
Personnel qualification requirements
As understood in this operating manual and on warning notices qualified personnel are persons who are acquainted with the mounting, mounting, maintenance and operation of this product and who possess appropriate qualifications for their occupation, such as for example covering: -
training or instruction, and authorization for installing, removing, earthing and labeling power circuits, equipment and systems according to the currently valid standards of safety engineering,
-
training or instruction according to the currently valid standards of safety engineering in the care and use of adequate safety equipment;
-
training in first aid.
This product left our factory in a perfectly safe condition. In order to maintain this condition and ensure the safe operation of the device, the information and warning notes given in this manual must be observed.
1.3
Field of application
The heat exchanger is used for cooling the FLK gas sample probe for operation in the inlet of the rotary kiln at process gas temperatures up to 1400°C. The heat exchanger employs a synthetic heat transfer liquid as coolant.
Copyright ® SIEMENS
Page 77
04/04
SQ254 Heat Exchanger
1.4
Function description of the heat exchanger
The device is designed to operate the gas sampling probe and the sample gas at a temperature above the dew point of acids (appr. 130 °C). During the start up the coolant is bypassed by the three-way valve directly to the gas-sampling probe. After exceeding the setpoint of the minimum temperature for the closed position of the three-way-valve, the coolant is directed through the heat exchanger. This method ensures a short heating-up-time of the coolant. Sample gas will not be taken below the minimum temperature. A cooling fan is switched on at coolant temperatures above 180°C to force the cooling of the radiator. If the coolant temperatures drops below 180°C the cooling fan is switched off again. The level switch (6) monitors the “level minimum” in the expansion vessel. In case of low level of the liquid the circulating pump is switched off. For troubleshooting please refer to page 7, “level minimum”. The flow meter (4) monitors the flow of the coolant. If the minimum flow is less than the minimum for more than 5 sec, the circulation pump is switched off and an alarm is generated. For troubleshooting please refer to page 7, “Flow”. For thermal overload protection the probe is being retracted from the kiln at coolant temperatures more than 220°C. For troubleshooting please refer to page 7, “Exceed temperature”. Faults are indicated on the signal lamps on the cabinet. For further utilization it can be wired to a control system by means of potential free contacts.(wiring diagram G 3302-A3254-S004)
Copyright ® SIEMENS
Page 78
04/04
SQ254 Heat Exchanger
1.5
Technical data
Operating Voltage Frequency Control Voltage Frequency Cooling capacity
Volt Hz Volt Hz kW
380-480 50/60 24 V DC from control unit 50/60 65
kW 1/min
2.2 3460
kW 1/min
0,52 1340
°C °C °C °C m2
max. 45 appr. 105 200 170 25
kg
appr. 420 IP 54
Circulation pump Power of motor Motor speed Fan Power of motor Motor speed Heat exchanger Inlet temperature of air Outlet temperature of air Inlet temperature of medium Outlet temperature of medium Cooling surface Cooling unit Weight, incl. filling Protection type
synthetic heat transfer liquid
Cooling medium Total content of the unit
ltr.
appr. 50
The performance data mentioned above are guaranteed provided that Siemens approved heat transfer liquid is used as a cooling medium. Do not use other cooling medium than specified by Siemens. For service, power supply and serial number please refer to the nameplate on the switch cabinet. Factory Settings Temperature of thermostat to be adjusted for 3 way valve Switch temperature for start fan to be adjusted at the Temp.-controller Maximum temperature to be adjusted at the Temp.-controller Minimum temperature to be adjusted at the Temp.-controller Minimum flow to be adjusted at the flow meter Minimum level in compensating tank over bottom
140 °C 180 °C 220 °C 130 °C 1.5m3/h 85 mm
Copyright ® SIEMENS
04/04
Page 79
SQ254 Heat Exchanger
2.
Installation
2.1
Installation of the heat exchanger
The installation platform has to be even and must endure a weight of estimated 400 kg/m2. The device should be protected against direct influence of weather (snow, rain, sun). It is filled up with heat transfer liquid ex works. The connection pieces for the cooling tubes are sealed with blind flanges. The flow direction is marked by means of arrows. After removal of the blind flanges the flexible hoses have to be connected between the sample probe and the heat exchanger. The bleed valves (15) have to be mounted at the highest point of the flexible hose. The 3000mm hoses are for the connection between the sample probe and the bleed valves. The bleed valves are connected to the heat exchanger by means of the 1500mm hoses. The level indicator on the expansion vessel (5) is adjusted to a “cold level” of 87mm. The switch point of the level switch is adjusted to a minimum level of 85 mm, measured from the bottom of the expansion vessel.
2.2
Electrical connection
The electric connection has to be carried out according to the national standards at the installation site.
2.3
Filling up the heat exchanger with cooling liquid
Perform the following steps: 1) close the bleed valves (15) before filling up the cooling liquid 2) remove the screw plug (5) at the expansion vessel 3) fill in the cooling liquid up to estimated ¾ of the expansion vessel 4) close the expansion vessel with the screw plug 5) open the stop valve (14) completely 6) set the main switch into the “ON” position 7) press S1 to start the circulation pump 8) observe the coolant level through the inspection glass 9) press S2 to stop the circulation pump, when the coolant level drops below ¼ of the expansion vessel 10) repeat steps 2 to 9 until the filling level stabilize to “LEVEL COLD” 11) carefully open the bleed valves (15) so that air and bubbles can escape 12) open and close the bleed valves in short terms until air is completely escaped 13) observe the flow meter. Stable flow indicates the bubble free cooling circuit 14) Check the “COLD LEVEL” again and perform steps 2 to 13, if required Excess coolant can be drained by means of the valve at the bottom of the heat exchanger. Check the sieve in the filter neck after some time of operation and clean it, if necessary.
Copyright ® SIEMENS
Page 80
04/04
SQ254 Heat Exchanger
3.
Setting into operation
3.1
Safety specifications
Be aware of the hot coolant. Ensure, that the coolant temperature is low before opening any connections.
3.2
Preparation before first Start-up
Perform the following steps: 1) visual inspection of the device and hose on tightness 2) check the level of the coolant. It must not be less than the “COLD LEVEL” 3) adjust the flow meter to 1,5 m3/h minimum flow 4) open the stop valve (14) entirely 5) set the main switch into the “ON” position 6) press S1 to start the circulation pump 7) adjust the coolant flow by means of the stop valve (14) to 3,6m3/h 8) Open the bleed valve (16) for short time so that air can escape from the expansion vessel 9) observe the coolant through the inspection glass to ensure that no bubbles are in the coolant 10) Insert the probe to the kiln 11) observe the increase of the coolant temperature 12) at a coolant temperature of 180°C the fan should be switched on 13) at 180°C check the coolant level in the expansion vessel 14) in case of too high “COLD LEVEL” the coolant escapes through the check valves
Copyright ® SIEMENS
Page 81
04/04
SQ254 Heat Exchanger
3.3
Adjustment of temperature controller (KS90-1) in the switch cabinet
Changing setpoints see “Quick Reference Guide”
3.3.1 Setpoint for temperature adjustment of the three-way valve The set-point temperature is adjusted to 140 °C factory setting. The adjustment of the set point of the three-way valve can be set at the temperature controller.
3.3.2 Setpoint for temperature adjustment of the fan The set-point temperature is adjusted to 180 °C ex works. When temperature exceeds, the fan is set into operation. As soon as temperature drops below this value, the fan is shut off. The actual value of temperature may be read at the display. Modifications of set point have to be executed according to the instructions for the equipment.
3.3.3 Minimum limit value for start gas-sampling The limit value is adjusted to 130 °C. As soon as temperature exceeds this limit, the sampling pump is set into operation. Attention! The adjusted temperature should always exceed the acid dew point, which is the specific one for the cement plant.
Copyright ® SIEMENS
Page 82
04/04
SQ254 Heat Exchanger
3.3.4 Maximum limit value emergency extraction of probe The set point of excess temperature is adjusted to 220 °C ex works. As soon as this temperature is reached, the probe moves out of the furnace.
3.4
Standard starting
Check level of liquid “Level cold” through the inspection glass, if necessary, refill. Check by visual inspection the tightness of the entire equipment. Turn-on main switc. In case level of cooling liquid has dropped below “Level cold”, the equipment cannot be set into operation. This malfunction is indicated by the signal lamp H7 “Level min”. After having refilled liquid, the equipment can be set into operation.
4.
Setting out of operation
4.1
Shutdown the heat exchanger
The gas sample probe has to be retracted from the kiln. Keep the heat exchanger in operation for a short time in order to avoid an accumulation of heat. In case of repair work, switch off the main switch.
5.
Maintenance
Weekly: Check all flanges and hoses on tightness. If required, tighten screws or replace gaskets. Check axial seal of pump on tightness. If required, replace the seal. Check coolant flow and clean the dirt trap, if necessary. Monthly: Check contamination of cooling fins. In case of severe contaminations, use compressed air for cleaning. Note: Contamination increases the run-time of the cooling fan.
Copyright ® SIEMENS
Page 83
04/04
Siemens
Copyright ® SIEMENS
Page 84
04/04
Siemens SQ255 Control Unit
Fig. 1 FLK Control Unit
Contents
1. 1.1 1.2 1.3 1.4 1.5 1.6 2. 2.1
Page
Introduction.......................................................... 86 General information ............................................ 86 Personnel qualification requirements ................ 86 Field of application .............................................. 86 Construction ......................................................... 87 Mode of operation................................................ 88 Technical data ...................................................... 88 Installation............................................................ 89 General information ............................................ 89
Copyright ® SIEMENS
Page 85
Page
2.2 Mounting the controller cabinet ......................... 89 2.3 Electrical connection............................................ 89 2.4 External cable connection ................................... 89 3. Operation.............................................................. 90 3.1 General information ............................................ 90 3.2 Start-up................................................................. 90 3.2.1 Electrical start-up ................................................ 90 4. Maintenance ......................................................... 90
04/04
Siemens SQ255 Control Unit
Note: We would like to point out that the content of this operating manual is not part of an earlier or existing agreement, consent, or a legal relationship nor should it be modified. All obligations on the part of SIEMENS can be taken from the relevant purchasing agreement, which also contains the complete and solely valid warranty. These warranty provisions are neither extended nor restricted by this operating manual. We would also like to point out that for reasons of clarity not every conceivable problem situation in conjunction with the application of this product could be described in this operating manual. If you require further information or if particular problems occur which have not been dealt with in enough detail in the operating manual, you can request the required information via the local SIEMENS subsidiary. In the operating manual and in the warning information on the product, signal terms having the following meaning have been used: Danger as used in this operating manual and in warning information on the product itself means that death, severe injury and / or substantial material damage will occur if the appropriate precautions are not taken. Warning as used in this operating manual and in warning information on the product itself means that death, severe injury and / or substantial material damage can occur if the appropriate precautions are not taken. Caution as used in this operating manual and in warning information on the product itself means that slight injury and / or material damage can occur if the appropriate precautions are not taken. Note as used in this operating manual denotes an important item of information about the product or a relevant part of the operating manual requiring particular attention.
Copyright ® SIEMENS
Page 86
04/04
Siemens SQ255 Control Unit
1.
Introduction
1.1
General information
Warning! This system is operated by electricity. When operating electrical equipment, it is unavoidable certain parts of this system carry a dangerous voltage.
that
If the warning information is not followed, serious bodily injury and/or material damage may occur. Only appropriately qualified personnel should work on this equipment or in its vicinity. These persons must be thoroughly acquainted with all the warnings and maintenance precautions in accordance with this manual. The proper and safe operation of this device requires correct transport, storage and well as proper operation and maintenance.
mounting as
In particular the general construction and safety regulations about working on power installations (e.g. DIN, VDE) should be followed as well as the regulations relating to the proper use of lifting equipment and tools and the use of personal protective gear (protective goggles, etc.).
1.2
Personnel qualification requirements
As understood in this operating manual and on warning notices qualified personnel are persons who are acquainted with the mounting, maintenance and operation of this product and who possess appropriate qualifications for their occupation, such as for example covering: -
training or instruction, and authorization for installing, removing, earthing and labeling power circuits, equipment and systems according to the currently valid standards of safety engineering,
-
training or instruction according to the currently valid standards of safety engineering in the care and use of adequate safety equipment;
-
training in first aid.
This product left our factory in a perfectly safe condition. In order to maintain this condition and ensure the safe operation of the device, the information and warning notes given in this manual must be observed.
1.3
Field of application
The control unit is used to control the complete FLK Gas Sampling Probe which are mainly used for measuring gas sampling up to approx. 1800 °C with a high dust content. Due to the high dust concentration in the process gas, dust deposits in the sampling probe and in the heated filter are unavoidable. Therefore, automatic, cyclical cleaning has been implemented for the probe and the filter. The mechanical parts required for this are accommodated in the valve combination. If a compressed air motor is being used for the "emergency withdrawal" of the probe, the control valves needed for the motor are also in the valve combination. Note:
See also the general operating manual for the FLK Probe.
Copyright ® SIEMENS
Page 87
04/04
Siemens SQ255 Control Unit
1.4
Construction
The control unit is designed as a compact unit (see Figure 2). All parts like SIMATIC S7 (optional: Allan Bradley PLC), Relays, Fuses, push buttons, OP3 are accommodated so that they are protected from dust, splashing water and from mechanical damage. Buttons for starting and stopping the purging period (Item 2) are located inside the cabinet.
Fig. 2 Control Unit
Legends:
1 2 3 4 5 6
Simatic S7 Reset-Button / Start-Stop Purge-Button Operator Panel (OP3) Main Switch S1 (400V) Main Switch S2 (230V) Indication lamps/Lamp test
Copyright ® SIEMENS
Page 88
04/04
SQ255 Control Unit 1.5
Mode of operation
The PLC programmable logic controller are designed to control the complete FLK probe, to retract the probe in automatic cycle or in case of any fault, to start the purge cycle and to indicate fault messages at OP3. At the OP3 you can adjust timer and counter to control the probe. The PLC are standard SIMATIC S7, optional an Allan Bradely PLC is also available.
1.6
Technical data
Electrical supply data Voltage: Voltage: Control Voltage:
400 VAC / 50Hz 230 VAC / 50Hz / 115 VAC / 60Hz 24 VDC
Permissible ambient temperature:
0 ... 60°Cel.
Dimensions:
760 mm x 760 mm x 210 mm
Type of protection:
IP 54 to DIN 40050
Weight:
30kg
Copyright ® SIEMENS
Page 89
04/04
SQ255 Control Unit
2.
Installation
2.1
General information
The control box is constructed such that it can be easily mounted. Fixing on a mounting frame is possible.
2.2
Mounting the control cabinet
The control cabinet can be set up in a control room protected from dust - normally in the same room as the analyzer cabinet. A socket for service purposes should be provided.
2.3
Electrical connections
The electrical connections are implemented according to the regulations from the local power supply utility and of the relevant country. The cable for the connection of the devices is not included in the supplied items and should therefore be provided by the user according to our specifications. The required cable and the details about the cable connections can be taken from the wiring diagrams in the supplied wiring manual. However, it should be ensured that high flexibility, temperature resistant cables are used for the connection to the retraction device (valve combination). These must also be suitable for medium, mechanical stresses. In this respect particular care must be paid during laying (coolant operating temperature with hoses up to 250°C). The cables must not come into contact with any hot parts when the probe traverses. Control cables normally found in the relevant cement works can then be used from the connection point (the centre of the retraction device). The electrical supply cables on the heat exchanger unit are preferably implemented in steel conduit to the control cabinet. Here it should be ensured that these pipes are laid at a distance > 10cm from the hot pipes, the cooler and the coolant pump. Top laying is the preferred method for the feed cables. All cables must be lead into the cable entries provided in the control boxes.
2.4
External cable connection
The electrical connections are implemented according to the regulations of the local power supply utility and of the relevant country. The cables between the control cabinet (SQ255), heat exchanger (SQ254) local control station (SQ257), analyzer cabinet and valve combination (SQ253) are not included in the supplied items and must therefore be supplied to our specifications by the user. The required cable and the details about the cable connections can be taken from the wiring diagrams in the supplied wiring manual. The cables must be routed through the provided PG screwed glands, sealed and again clamped. The fixtures for the cables, measuring gas lines and compressed air hose should be produced by the user depending on the installation. Note:
See general operating manual Chapter 2.10, Electrical connections.
Copyright ® SIEMENS
Page 90
04/04
SQ255 Control Unit
3.
Operation
3.1
General information
This equipment unit has been supplied functionally tested. Therefore, no complicated checks of the separately installed devices are needed.
3.2
Start-up
Warning!
The control cabinet in conjunction with the rest of the unit must only be put into operation by qualified personnel, who are familiar with all maintenance measures. Unauthorized operation and improperly carried out start-up procedures can cause damage.
The start-up is mainly restricted to a check of the wiring, a functional check and a leakage test of the complete measuring equipment. 3.2.1
Electrical start-up
After checking the wiring to the heat exchanger, valve box, analyzer cabinet and control station, the following functional checks can be carried out.
4.
•
Check that all external units such as heat exchanger and analyzer cabinet switched off.
•
Check that the area around the FLK sampling probe, including the traverse path, is closed off and provided with warning signs about the high temperature (up to 250° C) of the probe, coolant pipe and cooler as well as the automatic traversing.
•
Turn on main switch (S1), Circuit breaker (FA1) for heat exchanger, motor protection switch (Q1).
• •
Turn on main switch (S2), Circuit breaker (F1/F2/F3). Check that all external units powered up, also OP3 and SIMATIC S7 energized.
Maintenance
The control cabinet is maintenance free.
Copyright ® SIEMENS
Page 91
04/04
Copyright ® SIEMENS
Page 92
04/04
SQ256 Retraction Device
Fig. 1 Retraction device with mounted gas sampling probe Contents 1 1.1 1.2 1.3 1.4 1.5 1.6 2 2.1 2.2 2.2.1 2.2.2 2.3
Page
Introduction......................................................................... 95 General information ............................................................ 95 Personnel qualification requirements ................................. 95 Field of application ............................................................. 95 Construction ....................................................................... 96 Mode of operation............................................................... 96 Technical data .................................................................... 97 Installation .......................................................................... 98 General information ............................................................ 98 Point of installation ............................................................. 98 Fitting on the kiln inlet......................................................... 98 Installation in the heat exchanger (precalcination chamber) ............................................................................ 98 Fitting the probe entry pipe and retraction device .............. 99
Copyright ® SIEMENS
Page 93
Page 3 3.1 3.2 4 4.1 4.2 4.3 4.4
Operation........................................................................... 101 General information........................................................... 101 Start-up.............................................................................. 101 Maintenance...................................................................... 102 Transport chain ................................................................. 102 Guide rollers ...................................................................... 103 Chain wheel....................................................................... 104 Three-phase squirrel-cage induction motor with worm drive ......................................................................... 105 4.4.1 Three-phase squirrel-cage induction motor....................... 105 4.4.2 Worm drive with splash lubrication.................................... 105 4.5 Compressed air motor ( optional )..................................... 106
04/04
SQ256 Retraction Device
Note: We would like to point out that the content of this operating manual is not part of an earlier or existing agreement, consent, or a legal relationship nor should it be modified. All obligations on the part of SIEMENS can be taken from the relevant purchasing agreement which also contains the complete and solely valid warranty. These warranty provisions are neither extended nor restricted by this operating manual. We would also like to point out that for reasons of clarity not every conceivable problem situation in conjunction with the application of this product could be described in this operating manual. If you require further information or if particular problems occur which have not been dealt with in enough detail in the operating manual, you can request the required information via the local SIEMENS subsidiary. In the operating manual and in the warning information on the product, signal terms having the following meaning have been used: Danger as used in this operating manual and in warning information on the product itself means that death, severe injury and / or substantial material damage will occur if the appropriate precautions are not taken. Warning as used in this operating manual and in warning information on the product itself means that death, severe injury and / or substantial material damage can occur if the appropriate precautions are not taken. Caution as used in this operating manual and in warning information on the product itself means that slight injury and / or material damage can occur if the appropriate precautions are not taken. Note as used in this operating manual denotes an important item of information about the product or a relevant part of the operating manual requiring particular attention.
Copyright ® SIEMENS
Page 94
04/04
SQ256 Retraction Device
1.
Introduction
1.1
General information
Warning!
This system is operated by electricity. When operating electrical equipment, it is unavoidable that certain parts of this system carry a dangerous voltage. If the warning information is not followed, serious bodily injury and/or material damage may occur. Only appropriately qualified personnel should work on this equipment or in its vicinity. These persons must be thoroughly acquainted with all the warnings and maintenance precautions in accordance with this manual. The proper and safe operation of this device requires correct transport, storage, mounting and mounting as well as proper operation and maintenance. In particular the general construction and safety regulations about working on power installations (e.g. DIN, VDE) should be followed as well as the regulations relating to the proper use of lifting equipment and tools and the use of personal protective gear (protective goggles, etc.).
1.2
Personnel qualification requirements
As understood in this operating manual and on warning notices qualified personnel are persons who are acquainted with the mounting, mounting, maintenance and operation of this product and who possess appropriate qualifications for their occupation, such as for example covering: -
training or instruction, and authorization for installing, removing, earthing and labelling power circuits, equipment and systems according to the currently valid standards of safety engineering,
-
training or instruction according to the currently valid standards of safety engineering in the care and use of adequate safety equipment;
-
training in first aid.
This product left our factory in a perfectly safe condition. In order to maintain this condition and ensure the safe operation of the device, the information and warning notes given in this manual must be observed.
1.3
Field of application
For the application of the motor-driven retraction device for inserting and withdrawing the gas-sampling probe, the following points are decisive with respect to the manual mounting and to the retraction device itself: - Application conditions of the probe in the hot kiln region - Weight of approx. 130 kg - When a fault occurs, the gas-sampling probe can be retracting quickly from the kiln to protect it from damage. - Baked-on materials on the cooling pipe of the probe are stripped off by "Retraction / Insertion" of the probe. - Automation of the insertion and retraction increases the convenience and safety in operation. - The maintenance effort is reduced. - It enables a centralized assembly of the sampling pipe, valve combination and dust removal filter.
Copyright ® SIEMENS
Page 95
04/04
SQ256 Retraction Device 1.4
Construction
The retraction device basically consists of a runner rail and carriage. The gas sampling probe, dust removal filter and compressed air valve combination are mounted on the carriage. - The runner rail is produced from square steel tube. On the bottom of the runner rail there is a mechanically protected, rigidly mounted and self-cleaning roller chain track which engages the chain-wheel on the carriage. The runner is mounted with two mounting supports at the beginning and end of the rail. The supports are anchored to the floor. - The carriage, consisting of strong pressed parts, is pushed along the runner rail. Guidance is provided by closely fitting tapered rollers. The tapered rollers have encapsulated ball bearings and are therefore insensitive to dusty ambient conditions. - An induction motor with self-locking worm drive drives the carriage. The drive motor is completely enclosed in a dust-tight, hose-proof housing. Cooling is provided by cooling ribs on its outer surface. - At the second end of the drive-motor shaft there is a pneumatic auxiliary drive connected via a coupling. When mains failure occurs, this enables the probe to be retracting from the kiln. Where a compressed air motor is not present, this function can be handled by a DC motor under battery operation or by a hand crank. - The end positions of the carriage are defined by adjustable limit switches.
1.5
Mode of operation
The retraction and insertion processes are activated by: • a manual switch on the retraction device • a voltage-free contact on the central control panel • a signal from the programmable logic controller. The running time for the retraction or insertion process is about 1.5 minutes depending on the length of the probe. In order to prevent dangerous overheating of the coolant during a power failure or when the flow ceases, the probe retraction is facilitated by a supplementary auxiliary drive. The auxiliary motor is immediately started, withdrawing the probe, when one or more phases on the three-phase motor fail. When a pneumatic drive is used, it is switched off in the retract state via a pneumatic limit switch.
Copyright ® SIEMENS
Page 96
04/04
SQ256 Retraction Device
1.6
Technical data Type:
Version 1 for probe lengths 2-3m F6534 Version 2 for probe lengths 1-1.5m F6534
Load rating
max 200 kp
Electric motor Voltage:3/400 V~; 3/230V~...3/500V~; + 10%, - 15%; 50...60 Hz Current: 1.7 A Power: 0.55KW Protection: IP 65 to DIN 40050 Compressed air motor Type: Pressure Filter, muffler Limit switches Contact rating Protection:
6AM-FRV-5A 6 ... 8 bar F33-C8-000
380V, 6A, ~ IP 65 to DIN 40050
Compressed air limit switch Pressure 0 ... 8 bar, 0 ... 116psi,
Dimensions:
Depending on probe length 5000mm x 500mm x 500mm
Weight:
100kg
Copyright ® SIEMENS
Page 97
04/04
SQ256 Retraction Device
2
Installation
2.1
General information
Great importance is given to the point of installation of the retraction device, because the run of the probe and therefore its measuring point are then defined. There are mainly two different fields in the cement industry where the probe can be installed: • Kiln inlet • Precalcination It is essential that the installation location and the mounting are defined, with respect to the space requirement, between the machine supplier or user and SIEMENS
2.2 • • • • • •
Point of installation Suitable installation space for the insertion and retraction of the probe and for the movement of the feed lines such as coolant hoses, compressed air, measuring gas and cables must be provided for the complete retraction device. Similarly accessibility in the probe's inserted and retract state should be ensured for installation and maintenance work. The traverse rail should be sloped approx. 1 ... 5° forward to prevent the formation of air pockets in the coolant in the probe. If required, coverage should be provided against rain or falling material (e.g. poker holes). On the platform a base-plate should be provided under the retraction device to prevent risk to persons from falling deposits on the probe. It should be ensured that there are no cables or heat-sensitive parts under the retract probe.
2.2.1
Fitting on the kiln inlet
The following points should be followed for gas analysis on the kiln inlet: Preferentially the probe should be fitted at the side on the kiln inlet chamber. It should be positioned slightly oblique to the kiln axis. The probe should be fitted to the side opposite to the side on which the material is fed. In the inserted state the probe must protrude at least 30 cm behind the rotary seal in the kiln (vertical distance). The probe must not pass through the material flow from the heat exchanger. It should be ensured that no baked-on deposits can fall down from the heat exchanger onto the probe. The probe must have a distance of at least 20 cm from the lining of the rotary kiln. When installing the probe in a new kiln, pay attention to the lining and kiln expansion in the hot state.
2.2.2
Installation in the heat exchanger ( precalcination chamber)
The following points should be followed for gas analysis in the heat exchanger: The probe must be installed in an area as free of dust as possible. This position is normally after a cyclone and under a diffusion box. In the inserted state this probe must protrude at least 1/3, but at the most up to the middle of the gas line. The installation location should also be so planned such that the effects of heat on retraction device are not too high. With this installation location a closing flap should be fitted if possible to the installation pipe by the customer (either automatic or manual). Copyright ® SIEMENS
Page 98
04/04
SQ256 Retraction Device 2.3
Fitting the probe entry pipe and the retraction device
Einlaufstutzen = entry connection piece Abstand ca. 25 - 35 mm = distance approx. 25 - 35 mm Abstand Minimum 500mm = minimum distance 500mm Laufbühne = traverse platform Once the installation position has been defined, an aperture for the connection piece must be provided. Push the connection piece through the aperture and adjust it flush with the probe. The compressed air connection on the connection piece must point upwards and can be aligned with a bar, pipe or thread. During this operation, the 5
Fig. 2 Suggested mounting of the bracket on the kiln
degree tilt angle of the probe should be set. Then a horizontal bracket (see Figure 2) must be welded to the outer casing of the kiln. Place the retraction device with the front support on the bracket and temporarily fasten it. For the rear fastening, the supplied U-section must be screwed to the traverse rail and shortened if necessary, then welded with the steel plates (see Figure 3) and temporarily fastened to the platform. Mount the probe on the retraction device (see probe mounting instructions).
Fig. 3 Suggested mounting of the rear support
Copyright ® SIEMENS
Page 99
04/04
SQ256 Retraction Device The probe can be traversed using a compressed air motor. Insertion and retraction are possible by interchanging the compressed air feed on the motor. The retraction device must be aligned such that the probe is in the correct position in the kiln or cyclone in the inserted state. The centre of the probe must be positioned about 5-10mm above the centre of the probe inlet. The height can be adjusted by washers on the probe or by shims on the support. Then weld the connecting piece with the outer casing of the kiln or cyclone. Seal the pipe inside the kiln or cyclone with special cement. Permanently fix the traverse rail at the front and back.
Fig. 4 Fitting the connection piece Nocke = cam, T-Stück = T-piece
Rohr = pipe
Einzelheit = Detail
Fit the supplied solenoid valve after a compressed air shut-off valve fitted by the customer and connect to the kiln connection pipe with the supplied compressed air hose using the screwed glands from the quick release couplings. Note:
The solenoid valve must not be subjected to severe effects of heat.
Fit the local control panel such that the probe traverse and cooling equipment can be observed. When present, the traverse sounder and warning light should be fitted such that they can be easily seen to bring attention to the traversing. Danger: No unauthorized personnel should be positioned in the immediate vicinity of the probe, kiln connecting pipe and the retraction device during automatic or manual traversing. After the installation of the valve combination on the retraction device (see operating manual), the ready-made cables from the limit switches and the three-phase motor should be connected to it with the plugs. If the terminal box on the three-phase motor is opened, special attention should be given to ensure proper sealing and the mating points should be regreased. The gland plugs should be screwed into the unused cable entry holes. Be sure to fit unused cable entries on the limit switches with plug-caps. The connections from the compressed air limit switch to the compressed air motor must be joined using the supplied compressed air hoses according to the labelling (see also the general operating manual). No sealing tape or similar material is needed due to the self-sealing conical joints on the hoses. Ensure absolute sealing tightness. Copyright ® SIEMENS
Page 100
04/04
Fit the connections and joints on the traverse device according to the relevant operating manuals.
SQ256 Retraction Device
3
Operation
3.1
General information not applicable
3.2
Start-up
Warning!
The probe must only be operated by qualified personnel who are familiar with all maintenance measures. Damage may occur if operated by unauthorized personnel and maintenance is improperly carried out.
Check accessibility to the retraction device. Make a visual check of the installation of the connecting lines. Check the fastenings of the runner rail and the probe. Check the chain tension, chain wheel and rollers and readjust and grease them if necessary. See Maintenance. Important!
Check that the voltage specified on the nameplate agrees with the mains voltage.
Check the direction of rotation of the electrical and pneumatic motors. If the three-phase motor turns in the wrong direction, two mains supply lines must be interchanged. When closing the terminal box, give special attention to proper sealing. Regrease the mating points if necessary. Fit stop-plugs to the unused cable entry holes on the three-phase motor and the limit switches. Adjust the limit switches by inserting and withdrawing the probe. When doing this, loosen the mounting bracket by releasing the screws and then moving it to the required position and retightening. Then move the probe electrically to the limit positions and check the switching of the limit switches. Adjust the limit switches for height if necessary. If the compressed air motor is being used, check the pneumatic limit switch by withdrawing the probe using compressed air and adjust it if necessary. Adjust the probe cover in the inserted state. Note:
The flat point on the cover must be underneath.
Copyright ® SIEMENS
Page 101
04/04
SQ256 Retraction Device
4.
Maintenance
The following maintenance work must be carried out by the user to retain the equipment ready for operation. The retraction device must be cleaned with compressed air regularly each time the probe is retract and the bakedon deposits removed.
4.1
Transport chain
About once per year the transport chain should be checked for tightness and retensioned if necessary. The chain should also be cleaned with a steam jet and regreased.
Legend:
18 Hex. screw M8x30 19 Spring washer 20 Hex. screw M10x80 21 Hex. nut M10 31 Chain guide
32 Anchor plate 33 Tensioning block 34 Bearing block 35 Double chain
Fig. 5 Mounting of transport chain
Ausf. = Vers.
Kettenführung = chain guide
tacked at points
Retensioning the transport chain: • • •
Loosen lock-nut ( 4 ) Tension the chain with screw ( 3 ) Retighten lock-nut ( 4 ).
Copyright ® SIEMENS
Page 102
04/04
SQ256 Retraction Device
4.2
Guide rollers
If the carriage does not run smoothly or a level of play arises on the carriage when, for example, the probe tip is moved up and down, then the guide rollers must be readjusted.
Legends:
1 Hex. fastening screws 2 Hex. adjusting screw 3 Lock-nut
Fig. 6 Cross-sectional drawing of carriage
Guide roller adjustment: • The lower fastening screws on the control box must be removed and the upper screws loosened. Then swivel the control box upwards. • On each side of the housing panel on the carriage, the five fastening screws ( 1 ) for the intermediate rail must be loosened at the bottom. • Then loosen the lock-nut ( 3 ) for the guide roller adjustment. • Slightly tighten the adjustment screw so that the lower guide roller is pressed against the traverse rail. • Traverse the carriage manually over the complete range and make sure that it gives good running characteristics, readjusting if necessary. • Tighten the lock nuts. • Tighten all side fastening screws ( 1 ). • Correctly fasten the control box again.
Copyright ® SIEMENS
Page 103
04/04
SQ256 Retraction Device
4.3
Chain wheel
Schnitt = View
15
The chain wheel should be checked every 2-3 years and when adjusting the guide rollers, the chain wheel entry into the double chain must be checked. Legends:
1 Hardened chain wheel 2 Key 3 Distance piece II 4 Distance piece III 5 Motor drive shaft 6 Keys 7 Torque arm 8 Disc 9 Roller ball-bearing 10 Double chain
11 Running rail 12 Three-phase worm-drive motor 13 Coupling for compressed air motor 14 Threaded bolts 15 Hexagonal nut 16 Hexagonal screw 17 Lock-nut 18 Mounting panel for motor 19 Bolt with retaining washer
Fig. 7 Traversing carriage showing motor
Setting the chain wheel: After unscrewing the front cover with the 4 Allen screws, the chain wheel can be checked for wear. When doing this, the play between the chain wheel and the double chain should be checked and readjusted if necessary. If the wear is too much, the chain wheel must be replaced. • • • •
The nut (15) on the threaded bolt (14) must be loosened at both ends. Loosen the lock-nut (16). Then the play between the chain wheel (1) and the chain (10) is set with the screw (17). Here, the bolt (19) on the bearing rocker arm (7) is used as fulcrum. Secure the screw (16) with the lock (17).
Copyright ® SIEMENS
Page 104
04/04
SQ256 Retraction Device • •
Tighten the threaded bolt and nut (15). Traverse the carriage forwards and backwards. The carriage must not move jerkingly.
Note:
When setting, it must be ensured that the play between the chain wheel and chain is not too small. Otherwise there will be increased wear on the chain wheel.
If the chain wheel has the appearance of high wear, then it must be changed. To replace the chain wheel, the valve combination and the drive motor must be removed.
4.4 4.4.1
Three-phase squirrel-cage induction motor with worm drive Three-phase squirrel-cage induction motor
Three-phase motors in IP65 protection conforming to DIN 40050 are completely enclosed, dust-proof and hoseproof. The three-phase motor is provided with a durable paint coating for protection against corrosion when sited outdoors. The fresh-air intake must not be obstructed by dirt. Therefore, the motor should be frequently cleaned with compressed air. The ring bolt should be retightened if it has become loose during transport. The maintenance periods for the rolling bearings are different depending on the speed, ambient temperature, loading, etc. During regreasing the bearings should be cleaned thoroughly after disassembly (e.g. with cleaning-grade gasoline or clean petroleum) and dried. Then they are lubricated with a quality rolling bearing grease. About half the air space between the rollers should be filled with grease. Note:
4.4.2
With larger quantities of grease there is the danger of increased bearing heating.
Worm drive with splash lubrication
Due to its design, the worm drive is dust-proof and hose-proof. The three-phase motor is provided with a durable paint coating for protection against corrosion when sited outdoors. The gearbox with splash lubrication is supplied with lubricant ready for operation. With normal operating conditions and a lubricant temperature below about 80°C the lubricant should be replaced after about 10,000 operating hours. Irrespective of the operating period, the lubricant should be replaced at the latest after 2 to 3 years. The gearbox has filling and drain screws. These enable the lubricant to be checked and also replaced without disassembly. If required, flushing oil (e.g. spindle oil - no petroleum or trichloroethylene) can be added to the old lubricant. After a few minutes of running on no load, the mixture can be drained. When flushed a number of times with the gearbox on no load, preferably with changes of direction of rotation, the residues of the old lubricant can be collected and drained off. The new lubricant is added with the motor stationary. It is recommended that when changing the lubricant, the consumable parts (bearings and seals) are checked and replaced if necessary. For lubrication of the gearbox, soft and extensible gearbox oils C-LP ISO VG 220 to DIN 51502 and DIN51517 with good EP characteristics are suitable. The lubricant must enable low friction and almost wear-free continuous operation. The damage level during the gear rig test by the FZG-method to DIN 51354 should be above Level 12 and the specific wear below 0.27 mg/kWh. The lubricant should not froth, should protect against corrosion and not attack the rolling bearings, gears and seals. Lubricants of different sorts must not be mixed, because otherwise the lubricating characteristics can be impaired. A long service life is only ensured when the following listed lubricants or their certified equivalents are used. The original lubricant can also be supplied from the factory in small drums (5 and 10 kg). Protective EP gearbox oils as in the following table have been proven for gearbox operation:
Copyright ® SIEMENS
Page 105
04/04
SQ256 Retraction Device Manufacturer
Type of oil
BP CALYPSOL KLÜBER MOBIL SHELL
Energol SG-XP 220 Ecusynth PG 220 Syntheso D 220 EP Glygoyle 30 Tivela Oil WB
The choice of lubricant used by the factory for the initial filling can be seen on a label on the gearbox or will be given on enquiry at the factory.
The quantity of lubricant is about 0.9 l or kg for a horizontal orientation of the output shaft. When filling, it should be ensured that, depending on construction, the gears and rolling bearings situated at the top are also lubricated. In special cases the oil level mark should be taken into account.
4.5
Compressed air motor ( optional )
In order to prevent dangerous overheating of the coolant and burning down of the probe during a power failure, the carriage is traversed back automatically by a compressed air motor. The compressed air motor is coupled to the three-phase motor with a dog clutch and drives the motor shaft using compressed air. The compressed air motor is driven by the three-phase motor when the carriage is moved. Air is then drawn in via the muffler which is screwed into the compressed air outlet.
Compressed Air Motor
protection cover
Air filter Fig. 8 Fitting the compressed air motor
The compressed air motor operates almost maintenance-free. The muffler must be cleaned about every 3 months depending on the dust content of the ambient air. • Unscrew the muffler. • Unscrew off the supply hose. • Clean thoroughly with a brush. • Blow out the felt filter with compressed air. • Apply 3 - 4 drops of oil to the compressed air inlet. Copyright ® SIEMENS
Page 106
04/04
SQ256 Retraction Device • • •
Then fit the muffler. Screw on the supply hose. Power up the motor with compressed air.
If the motor no longer operates properly after a longer period of operation, this is usually due to resinification of oil residues which impair the free sliding of the discs in the rotor slots. In these cases it is best to flush the motor with petroleum. Do not immediately disassemble it! • Loose the four motor mounting screws. • Unscrew the cover on the coupling. • Unscrew both lines or the muffler from the motor. • Insert a few drops of petroleum into the inlet. • Turn the shaft manually for a few minutes in both directions. • Repeat this process. • Connect the air line and start the motor with a low pressure (approx. 0.5 bar) and at a low speed. Caution !
Wear facial protection !
• • • •
When air free of petroleum mist is emitted, lubricate the motor with 3-4 drops of oil. Fasten the motor again. Make sure that the dog clutch is firmly seated.
•
Screw on the coupling cover.
If the motor still does not produce full power, the cleaning procedure with petroleum must be repeated or an overhaul is due. The coupling should be checked every 6 months. • Remove the coupling cover. • Check that that coupling is firmly seated. • Make sure the fastening screws are tight. • Then fix the cover in place again.
Copyright ® SIEMENS
Page 107
04/04
