FLK Gas Sampling System

Retraction Device

Operating Manual Order No. T71A-GAS-BA00-SQ256-V004

Fig. 1 Retraction device with mounted gas sampling probe

Contents Page Page

1 Introduction......................................................................... 3 3 Operation........................................................................... 9
1.1 General information ............................................................ 3 3.1 General information........................................................... 9
1.2 Personnel qualification requirements ................................. 3 3.2 Start-up.............................................................................. 9
1.3 Field of application ............................................................. 3 4 Maintenance...................................................................... 10
1.4 Construction ....................................................................... 4 4.1 Transport chain ................................................................. 10
1.5 Mode of operation............................................................... 4 4.2 Guide rollers ...................................................................... 11
1.6 Technical data .................................................................... 5 4.3 Chain wheel....................................................................... 12
2 Installation .......................................................................... 6 4.4 Three-phase squirrel-cage induction motor with
2.1 General information ............................................................ 6 worm drive ......................................................................... 13
2.2 Point of installation ............................................................. 6 4.4.1 Three-phase squirrel-cage induction motor....................... 13
2.2.1 Fitting on the kiln inlet......................................................... 6 4.4.2 Worm drive with splash lubrication.................................... 13
2.2.2 Installation in the heat exchanger (precalcination 4.5 Compressed air motor ( optional )..................................... 14
chamber) ............................................................................ 6 5. Spare parts and accessories............................................. 16
2.3 Fitting the probe entry pipe and retraction device .............. 7

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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.

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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.

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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.

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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: 6AM-FRV-5A
Pressure 6 ... 8 bar

Filter, muffler F33-C8-000

Limit switches
Contact rating 380V, 6A, ~
Protection: 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

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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).

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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

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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.
Fit the connections and joints on the traverse device according to the relevant operating manuals.

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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.

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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 baked-
on 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 32 Anchor plate

19 Spring washer 33 Tensioning block
20 Hex. screw M10x80 34 Bearing block
21 Hex. nut M10 35 Double chain
31 Chain guide

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 ).

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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.

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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 11 Running rail
2 Key 12 Three-phase worm-drive motor
3 Distance piece II 13 Coupling for compressed air motor
4 Distance piece III 14 Threaded bolts
5 Motor drive shaft 15 Hexagonal nut
6 Keys 16 Hexagonal screw
7 Torque arm 17 Lock-nut
8 Disc 18 Mounting panel for motor
9 Roller ball-bearing 19 Bolt with retaining washer
10 Double chain

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).
• 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.

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4.4 Three-phase squirrel-cage induction motor with worm drive

4.4.1 Three-phase squirrel-cage induction motor

Three-phase motors in IP65 protection conforming to DIN 40050 are completely enclosed, dust-proof and hose-
proof. 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: With larger quantities of grease there is the danger of increased bearing heating.

4.4.2 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:

Manufacturer Type of oil

BP Energol SG-XP 220

CALYPSOL Ecusynth PG 220
KLÜBER Syntheso D 220 EP
MOBIL Glygoyle 30
SHELL 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.

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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.
• 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 gumming 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.

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• 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.

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5. Spare parts and accessories

See system documentation

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