FLK Gas Sampling System - MPIP - Free

FLK Gas Sampling System 

Operating Manual 

Preliminary Design Order No. --------------------------------------- 

Overview 

SQ254 

SQ255 

SQ251 

SQ252 

SQ253 

SQ256 

Legend: 

SQ250 FLK Gas Sampling System Page 1 - 29 

SQ251 FLK Gas Sampling Probe Page 30 - 39 

SQ252 Electrically Heated Dedusting Filter Page 40 - 55 

SQ253 Valve Combination Page 56 - 73 

SQ254 Heat Exchanger Page 74 - 82 

SQ255 Control Unit Page 84 - 91 

SQ256 Retraction Device Page 92 - 106 

Copyright ® SIEMENS Page 1 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. 



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 

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. 



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/m 3 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. Liquid-cooled sampling probe 

2. Electrically heated dedusting filter 

3. Compressed air/valve combination 

4. Retraction device with electrical drive and additional pneumatic motor for redundancy 

5. Heat exchanger unit (cooling system) 

6. 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. 



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. 



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: 

1 Gas sampling probe 

2 Gas sampling opening 

3 Coolant connection 

4 Retraction device 

5 Dedusting filter 

6 Valve combination 

7 Control cabinet for controller 

8 Installation pipe 

9 Valve for blowing dust return 

10 Local control box 

11 Flash light for process warning 

12 Horn for process warning 

13 Emergency-stop button 

14 Control Center 

71 Compressed air for purging 76 Condensate preseparator 

probe 

77 Low-pressure switch 

72 Compressed air for purging 78 Filter and Water separator 

filter 

79 Compressed air control valve 

73 Compressed air inlet 

80 Condensate output 

74 Dust-free measurement gas 81 Measuring gas line to analyzer cabinet 

75 Four-way motorized valve 82 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 

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. 



Fig. 3 Coolant circuit for sampling probe 

Legends: 

1 Gas sampling probe 

2 Gas sampling opening 

3 Coolant connection 


7 Heat exchanger 

8 Installation pipe 

60 Coolant circulation pump 

61 Level monitoring 

62 Cooler with fan 

63 Expansion vessel 

64 Thermal switch 

65 Three-way control valve 

66 Flow monitor 

67 Temperature sensor 

68 Shut-off valve 

69 Coolant filter 

70 Coolant line 

71 Dust blow-back 

72 Corrugated hose 

82 Dust-laden measuring gas 

83 Control cable to control cabinet 

85 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. 



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 m 3 / 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 



2. Installation 


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. 



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: 

See the operating manual for the FLK probe. 

When using a retraction device, see also the separate operating manual, Chapter Installation. 

2.3 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. 



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. 

• 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. 

pieces 

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. 



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 Probe cooling pipe 

2 Connection flange, return 

3 Connection flange, feed 

4 Ball valve 

5 Seals 

6 Pipe-bend 90° 

7 Connection flange for coolant line 

8 Gas output 

9 Cleaning opening 


11 Venting container 

12 Corrugated hoses 3m 

13 Pipe ( customer supplied ) 

14 Connection flange on cooler 

15 Corrugated hoses 1.5m 

16 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. ). 



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 Bulkhead gland at connection point 

2 PTFE pressure hose 

3 PVC hose 

4 Analyzer cabinet 

5 Measuring gas connection on analysis 

6 Inserted probe 

7 Central traverse area 

8 Condensate vessel 

9 Condensate output 

10 Gas cooler device 

Fig. 5 Installation of the measuring gas line 



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 SO 2 , 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: 

a 4mm ID 

b 7mm ID 

c 10mm ID 

Fig. 6 Display delay in relation to the measuring gas flow 

Fig. 7 Display delay in relation to the length of measuring gas line 

2.9 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. 



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 


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 ! 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! 

3.2 Start-up 

Warning! 

carried out. 

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 

For safety reasons and guarantee considerations the initial start-up must always be carried out by 

SIEMENS or by persons that they have instructed. 



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: 

See also the operating manual for the retraction device, Chapter Start-up. 

• Signals for the valve combination 

• 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. 

Note: 

See also the operating manual for the valve combination, Chapter Start-up. 

• Signals and supply for the measuring-gas filter heater 

• The thermal switch must switch off the heater after the operating temperature has been reached and 

a signal must be passed to the controller. 

Note: 

See also the operating manual for the measuring gas filter, Chapter Start-up 

• Signals to the analyzer cabinet 

• 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. 

Note: 

See also the operating manual for the analyzer cabinet and the circuit documentation. 



• 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: 

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. 

3.2.3 Purging process 

The purging is started by: 

1. The "Start" push-button on the valve combination or in the controller (when the probe is withdrawn only with the 

automatic switch in "Manual"); 

2. When the probe is inserted; 

3. Automatically after expiry of the waiting interval between two purgings ( CTR 1 or 2 ); 

4. 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. 



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.: 130°C 

Fan starts at : 180° 

Coolant temperature, max.: 220°C 

Switching hysteresis 2°C 

Set value for three-way valve: 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) 



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: 

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. 

• The automatic retraction of the probe with electrical and pneumatic drives occurs with the following faults: 

- 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. 



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. 



4. Maintenance 


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: Further maintenance measures can be taken from the operating manuals of the separate components. 

4.2 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 Probe cooling circuit 

4.2.2 Automatic insertion / retraction of the probe 

4.2.3 Purging duration and interval 



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. 



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. 



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. 


• When the pump has switched off, the drop in pressure must not be more than 2mbar in 3 minutes. 



• 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 the 

probe is still in the hot region. 

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". 



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 

e 

No. 

Display text in 

operating panel 

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 


pneumatically 

For fuse failure, find the cause and rectify it; after 

power is restored reset, insert probe 

3 Cooling System Flow 

< min 

Coolant flow too low 

(delayed 10s) 


(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 


(electr. + pneum) 

Find cause of motor prot. switch trip and rectify. 

Reset, start pump, insert probe 

5 Cooling System Fan 

fault 

Motor prot. switch 

tripped 



Find cause of motor prot. switch trip and rectify. 

Reset, start pump, insert probe 


Level to low 

Coolant level too low 



Find cause of coolant lost (leakage) and rectify; switch 

off pump, top up coolant, start pump, vent, reset, insert 

probe. 

Vent again when coolant temperature > 180 °C. 


Temperature to high 

Coolant temperature 

to high (default setting 

220°C) 



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") 



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. 

"Purging" lamp flashes at a 

fast rate 

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. 

Check for leakage, reset Counter 16, insert probe. 

10 Probe retraction ESS 

Motor 

Either output for 

Contactor Insert or 

Contactor Withdraw is on 

and no feedback or 

output not on and 

feedback 


(pneumatically) 

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 



Messag 

e 

No. 

Display text in 

operating panel 

Cause Effect Remedy 

11 Probe Delaytime Out 

/ In 

Monitoring time 

exceeded for autom. 

insertion / retraction (110 

sec.) 

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 


(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 



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. 



Move valve manually and check, test wiring, measure 

voltage. If valve jams, remove, clean, reset, mount 

probe. 

15 Probe system not 

automatic 

Switch set on local 

control panel, 

not in “Automatic” 

Red "Fault" lamp is on, but 

does not flash 

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 (


SQ251 FLK Gas Sampling Probe 

Fig. 1 FLK Gas Sampling Probe 

Contents Page Page 

1 Introduction ....................................................................... 33 

1.1 General information........................................................... 33 

1.2 Personnel qualification requirements................................ 33 

1.3 Field of application ............................................................ 33 

1.4 Construction and mode of operation ................................. 34 

1.5 Technical data................................................................... 35 

2 Installation ......................................................................... 36 

2.1 Gas sampling probe .......................................................... 36 

2.3 Coolant lines ......................................................................38 

2.4 Measuring gas connection.................................................39 

2.5 Covering flange..................................................................39 

3 Operation ...........................................................................40 

3.1 General information ...........................................................40 

3.2 Start-up ..............................................................................40 

4 Maintenance ......................................................................40 



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. 





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. 




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.). 


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, 




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. 


The sampling probe is used for the continuous sampling of hot, aggressive and dust-laden flue gases such as 

NO, CO, CO 2 

, O 2 

and SO 2 

, from rotary kiln or precalcination chambers. It is an unpressurized, liquid-cooled, dry 

probe. The length of the probe can be adapted to different installation locations. 



1.4 Construction and mode of operation 

The gas-sampling probe is basically constructed from four units: 

• sampling chamber, 

• cooling pipe with coolant return pipes, 

• gas sampling pipe, 

• mounting flange. 

Legends: 1. Connecting flange for coolant feed 5. Covering flange 

2. Connecting flange for coolant return 6. Cooling pipe 

3. Measuring gas output 7. Sampling chamber 

4. Mounting rail 8. Sampling opening 

Fig. 2 FLK Gas Sampling Probe 

The sampling chamber is located at the tip of the probe and has a sampling opening at the side. This arrangement 

of the opening prevents the direct entry of the gas / dust mixture. The opening is positioned in a partial gas flow 

and allows only relatively dust-free gas into the probe. 

The cooling pipe in high temperature-resistant special steel is hermetically enclosed and contains the coolant 

return pipe. The oval shape of the cooling pipe ensures a high vertical bending strength. The cooling liquid is 

carried to the probe tip via two feed pipes and flows back in the intervening space on the outer pipe. The two feed 

pipes are fastened at the probe head with a flange and can therefore be disassembled separately and without 

problem. A specially developed, synthetic heat transfer fluid is used as the coolant. This liquid has a very high 

boiling point and a high heat absorption capacity. The operating temperatures of over 200 °C obtained with the 

fluid are higher than the flue gas condensation point and acid dew point of the process gases. The coolant feed / 

return hoses are connected to the probe via ball valves, enabling the probe to be removed without loss of coolant. 

The gas-sampling pipe is a pipe arranged centrally in the cooling pipe at a distinct separation. The gas enters 

through an opening situated in the sampling chamber. This produces a slightly lower dust content in the gas. 

When high levels of contamination occur, this pipe can be easily cleaned. As with the two coolants return pipes, 

the gas-sampling pipe is joined to the cooling pipe via flange joints and can therefore be easily disassembled. 

The mounting flange provides the mechanical joint between the gas-sampling probe and the furnace inlet 

chamber or the precalcination chamber. When an automatic device is used for inserting and withdrawing the 

probe, the joint cannot be made using a screw-connected flange. 




Type: F6534 -B12 

Lengths of different versions depending on penetration depth: 

3000 mm 

2500 mm 

2000 mm 

1500 mm 

1000 mm 

Type of sampling opening depending on installation orientation: 

E1 Sampling opening left 

E2 Sampling opening right 

( Viewed from coolant connection.) 

Operating temperature: max. 250°C 

Coolant: 

Coolant flow rate: 

Weight (filled with coolant): 

synthetic heat transfer liquid 

max. 3200 l/h 

approx. 150 kg depending on version 



2 Installation 

2.1 Gas sampling probe 

The gas-sampling probe can basically be installed according to requirements, but the following possible methods 

should be considered. 

• On a manual retraction device. 

• On an automatic retraction device. 

It should be ensured however that the probe is mounted at an angle of about 5° sloping down to the probe tip. 

This prevents the formation of air bubbles in the probe. 

A fixed installation of the probe is not recommended. 

• Because if the cooling fails (also with power failure) and with cessation of the flow, dangerous coolant 

overheating may occur. 

• The weight of the probe is about 130 kg. 

• Excessive material deposits on the cooling pipe lead to increased mechanical loading and to excessive 

cooling of the cooling medium. When the cooling medium cools below the acid dew point, this leads to 

blockage of the sampling pipe. The probe would then have to be removed for cleaning. 

With an installation with a manual retraction device, appropriate mounting holes for the probe must be provided on 

the carriage together with mounting for the valve combination and the dust removal filter. 

Note: 

Installation plans must be requested from the relevant SIEMENS subsidiary. 

Mountings are provided for the probe, valve combination and dust removal filter for installation with an automatic 

retraction device. 

After mounting the retraction device, the probe is placed on the carriage and fastened to it (see Figure 3). 

See the separate operating manual for the installation of the retraction device. 



Ansicht = View Sonde = Probe Detail = Detail 

Legends: 1 Cheese-head screw M12x60 5 Shim 

2 Cup spring 6 Hex. nut 

3 Spherical disc 7 Cheese-head screw M12x50 

4 Ball socket D14.2 8 Washer ø24xø13x10 

Fig. 3 Carriage and probe mounting (detail drawing) 

The probe must be aligned such that the cooling pipe is positioned with its tip about 1 cm over the centre of the 

inlet connection piece. To do this, traverse the probe until the tip penetrates a little into the inlet connection piece. 

The fine vertical adjustment of the probe is made with the cheese-head screw ( 7 ) and lock nut ( 6 ). Here, it 

should be ensured that the rear screws ( 1....5 Detail B ) are loosened. Once the probe has been aligned, tighten 

all screws, particularly the lock nut ( 6 ). 



2.3 Coolant lines 

As supplied, the probe is already filled with coolant and the connecting flanges closed off with blank flanges. All 

screw fasteners and sealing gaskets for the flange joints are contained in the supplied items. 

Legends: 

1 Probe cooling pipe 

2 Return flange connection 

3 Feed flange connection 

4 Ball valve 

5 Seals 

6 Pipe bend 90° 

7 Connection flange for cooling 

line 

8 Gas output 

9 Cleaning opening 

10 Dust removal filter 

2 

Fig. 4 Connection of the coolant lines to the probe 

After removing blank flanges on the feed and return, the shut-off valves must be joined using flanges. If the 

coolant hoses are connected at the side, it is advisable to fit the 90° pipe bends after the shut-off valves and 

before the coolant hoses. 

Caution ! 

Only the supplied special gaskets should be used between all the flange joints. 

The flanges must be tightened in a crosswise manner to obtain uniform compression of the gaskets. 

The connections between the probe and the fixed-mounted venting containers is made using flexible corrugated 

hoses NW 25, 3m long. 

The question of the mounting of the venting containers is dependent on the probe traverse distance. Normally, 

this mounting point is the centre of the traverse distance and at about 50cm distance from the connecting flanges. 

This should be the highest point of the coolant line. It should be accessible during traversing using a ladder or 

similar aid. 

See the section on mounting the complete analysis equipment with the FLK Probe for determination of the 

mounting points and coolant line arrangement. 



2.4 Measuring gas connection 

A special, short hose with ERMETO unions, included in the supplied items for this purpose, is used for the 

measuring gas connection. After mounting the dust removal filter, the hose is connected between the filter and the 

probe. 

See the operating manual for the dust removal filter regarding mounting and alignment. 

2.5 Covering flange 

The covering flange seals the mounting flange to the inlet chamber or the precalcination chamber when the probe 

is inserted. 

Aussparung = recess 

Fig. 5 Covering flange 

flange 

Fig. 6 Mounting on the probe 

Legend: 1 fixing screw 3 covering 

2 gas sampling probe 4 lock nut 

Push the covering flange over the probe up to the probe mounting. Insert the probe up to the measuring position 

until the traversing is switched off by the limit switch. Push the covering flange onto the inlet connecting piece and 

centre it. Here it should be ensured that the recess on the covering flange runs exactly parallel to the runner rail. 

This prevents the covering flange from touching the limit switch during retraction and insertion. Always tighten 

opposite fastening screws alternately. Briefly insert and withdraw the probe a few times and check that the flange 

is well seated. During retraction check the distance between the covering flange and the limit switch. It must be at 

least 6mm. Readjust the covering flange if required and tighten the fastening screws. Then tighten the lock nuts. 

Note: 

Caution ! 

When the furnace or precalcination chamber is heated up, slight offsets may arise between the 

installation flange and the traversing device due to expansion. It may be necessary to readjust the 

covering flange. 

If the probe is traversed with a covering flange that is not fastened down, then it is essential to 

ensure that the flange does not jam against the limit switch or runner rail. 

Fill the space between the covering flange mounting and the cooling pipe with temperature resistant insulation 

material. 



3 Operation 


Danger ! 

The probe and coolant lines have an operating temperature of up to 220° Cel. 

The baked-on deposits on the probe can reach temperatures of over 1000° Cel. 

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. 

See the operating manual for the complete gas analysis equipment with FLK Probe for the start-up procedures. 

4 Maintenance 

The following maintenance work must be carried out by the user to maintain the probe ready for operation: 

When using the probe on the furnace inlet, checks must be made in the initial period during each insertion and 

retraction. A check should be made of whether the baked-on deposits on the probe are released by compressed 

air during insertion. This opportunity should be used to check the probe for mechanical damage (e.g. due to falling 

material deposits in the furnace inlet chamber). 

The probe and coolant line connections should also be checked for leaking coolant. 

Any leaks must be immediately repaired. 

If the baked-on deposits are not released on insertion, then the probe must be cleaned manually. 

Danger ! 

The probe and coolant lines have an operating temperature of up to 220° Cel. 

The baked-on deposits on the probe can reach temperatures of over 1000° Cel. 

With other installation locations (precalcination chamber) a regular check of the probe for damage, baked-on 

deposits and leakage on the coolant line connections must be carried out. The period between these checks 

should not exceed 14 days. 

If the sampling chamber and/or the sampling pipe becomes blocked, the probe must be cleaned manually. Once 

the screwed gland on the sampling side has been removed, the sampling pipe can be cleaned with a suitable rod 

or strong wire. 

If cleaning is no longer possible, the complete sampling pipe must be changed. 

If the ball valve becomes leaky, the tap spindle and/or seals must be replaced. 


SQ252 Electrically Heated Dedusting Filter 

Fig. 1 Electrically heated dedusting filter 


1 Introduction..................................................................................43 

1.1 General information.....................................................................43 

1.2 Personnel qualification requirements ..........................................43 

1.3 Field of application......................................................................44 

1.4 Construction.................................................................................44 

1.5 Mode of operation........................................................................46 

1.6 Technical data ..............................................................................48 

2 Installation ...................................................................................49 


2.2 Mounting on the retraction device...............................................50 

3 Operation......................................................................................52 


3.2 Start-up.........................................................................................52 

4 Maintenance................................................................................. 53 

4.1 General information..................................................................... 53 

4.2 Leakage test ................................................................................. 53 

4.2.1 Pressure test ................................................................................. 53 

4.2.2 Low pressure test......................................................................... 53 

4.2 Cleaning the filter or replacing the filter tube............................. 54 

4.3 Replacing the thermostat ............................................................. 55 

4.4 Measures for fault rectification ................................................... 55 

4.4.1 Filter does not reach operating temperature after 

about 15min................................................................................... 55 

4.4.2 No release of the measuring gas pump........................................ 55 

4.4.3 Filter becomes blocked too quickly ............................................ 55 



Note: 






application of this product can be described in this operating manual. If you require further information or if particular 




used: 
















occur. 





mounting as well as proper operation and maintenance. 






mounting, mounting, maintenance and operation of this product and who possess appropriate qualifications for their 


- training or instruction, and authorisation for installing, removing, earthing and labelling power circuits, equipment and 










The dedusting filter is used to clean the gas / dust mixture extracted from the process space. The filter is not just for use in 

conjunction with the FLK Probe, but also for other fields of application. It is particularly suitable for dry, high temperature, 

dust-laden gases (2000 mg/m 3 dust content). 

The filter is heated electrically to about 200 °C to prevent the filter pores from becoming silted up or clogged by baked-on 

deposits. 


The electrically heated dedusting filter is protected to IP55 according to DIN 40050 and is therefore dust-proof and hoseproof. 

The electrically heated dedusting filter mainly consists of the following parts (see also Figure 2): 

1. Electrical terminal box. 

2. Filter housing with heating and insulation. 

3. Compressed air connections for cleaning. 

4. Quick-release clip with tommy screw for manual cleaning of sintered-metal filter. 

5. Filter head with seals and sintered-metal filter. 

6. Measuring gas connection. 

The filter head and filter housing consist of corrosion-resistant material and are joined to a central tommy screw via a 

retaining clip. Therefore when necessary, all maintenance work such as filter replacement, filter cleaning, etc. can be carried 

out easily and in the shortest time. Sealing is provided by high temperature-resistant O-rings which also give reliable sealing 

even after disassembling many times. 

By choosing an appropriate sintered-metal cylinder with different sizes, the filter element can be adapted to the relevant 

amount of dust. 

The dedusting filter is heated by the heating element integrated into the filter housing. The maintenance of a constant internal 

filter temperature, matched to the probe operating temperature, is ensured by a thermostat with overload protection mounted 

on the filter housing. 

All connections for the filter heating, thermostat and solenoid valve are brought together in a terminal box. The connection 

for the measuring gas line to the gas sampling probe is situated in the upper part of the filter housing. 

The compressed air connection for the probe cleaning is located on the bottom of the filter housing. 

An adjustable angular screwed gland with a connecting thread M16x1.5 is provided on the filter head for the measuring gas 

output. 

The compressed air connection for the filter cleaning can also be found on the filter head. 


Legends: 

1 Electrical terminal box 

2 Filter housing with heater and insulation 

3 Compressed air connections for cleaning 

4 Quick-release clip with tommy screw 

5 Sealing plate with cup springs and nut 

6 Sintered-metal filter 

7 Filter head with seal for sintered-metal filter and housing 

8 Compressed air connection for filter purging 

9 Measuring gas inlet 

1O Measuring gas output 

Fig. 2 Construction of the electrically heated dedusting filter 




The measuring gas to be cleaned flows from above into the space between the filter body and housing and is drawn from here 

through the filter body into the internal space in the filter. It is then taken from the filter head via the measuring gas output. 

Due to an equipment arrangement that is favourable to the flow, the dust-laden gas flow is not deflected. The dust particles 

separate on the outer side of the filter and fall by gravity to the bottom of the filter housing. 

The filter is electrically heated to about 200 °Cel to prevent the filter pores from becoming silted up or clogged by baked-on 

deposits. 

A voltage-free contact (normally open) is available for locking purposes. This enables the release of the measuring gas demand 

only after the operating temperature has been reached. This prevents the formation of condensate when the filter heater fails or 

at the start of operation. 

For higher availability, cleaning of the filter from dust deposits is particularly important. 

This cleaning is carried out using compressed air. Before starting cleaning, the measuring gas line for the analysis must be 

reliably shut off with a valve. Two cleaning cycles are recommended which can be employed independent of one another or in 

combination. 

Cleaning Cycle 1 (see Figure 3, arrow labelled 1) eliminates compacted dust particles in the pores of the filter tube (Figure 

3, Item 4). Here, the compressed air flows through the hot filter tube against the direction of the gas. The compressed air 

enters the filter tube via the connection on the filter head (Figure 3, Item 82) and is diverted via the probe connection 

(Figure 3, Item 80) into the furnace. The dust, which has become lodged in the pores of the filter tube, is now deposited on 

the bottom of the filter housing. However, with the flow through the filter tube there is an unavoidable pressure drop, which 

prevents the dust particles located in the filter chamber from being fully flushed back into the furnace. 

With Cleaning Cycle 2 (see Figure 3, arrow labelled 2) the compressed air is diverted through an annular jet (Figure 3, Item 

81) uniformly over the complete internal space of the filter chamber. The high air flow rate therefore has sufficient pressure 

to blow back (Figure 3, Item 80) the dust which has collected in the filter chamber into the furnace via the probe 

connection. Simultaneously, the gas sampling pipe and the sampling chamber with opening are cleaned from dust deposits. 

The activation of the cleaning can be matched to the specific furnace conditions in conjunction with the valve combination and 

the programmable control and monitoring unit. 


Fig. 3 Cross-sectional drawing of electrically heated dedusting filter 

Legends: 1 Filter head 80 Measuring gas connection from probe 

2 Sealing gasket 81 Compressed air connection for probe flushing 

3 O-ring 82 Compressed air connection for filter flushing 

4 Filter tube 83 Measuring gas output 

5 Cup spring 84 Filter chamber 

6 Retaining washer 

7 Hexagonal nut 

8 Retaining tube 

9 Heater 


11 Mounting bracket 

12 Terminal box 

13 Thermostat 

14 Tommy screw 

15 Retaining clip 

16 T-union with M24x1.5 connection 




Electrical supply data: 

230V, 240V + 10%,-15% ; 50...60 Hz 

Power rating 400VA 

Compressed air supply data: 

6...8 bar 

Compressed air free from oil, dust and water 

Compressed air connections: Probe flushing: R 3/4" DIN 

Filter flushing: 

R 1/2" DIN 

Measuring gas connections: Measuring gas output: External thread M16x1.5 DIN 

Measuring gas input: External thread M24x1.5 DIN 

Thermostatic auxiliary contact: 

Temperature resistant -20 to +250 ºCel. 

Switching capacity max 40A at 250V, 50...60 Hz, cosϕ =1,0 

Operating temperature: 

max 210 ºCel 

Weight: 

6 kg 





The filter operating temperature is about 200 ºCel, so make sure that there is a sufficient distance to heat-sensitive parts. 

The electrically heated filter is constructed such that it can be easily mounted on the retraction device. If no retraction device is 

being used, then mounting on a mounting frame is also possible. 

The installation orientation is vertical. The measuring gas inlet must be at the top and the compressed air, measuring gas outlet 

and retaining clip must be at the bottom. 

A mounting bracket is attached to the upper cover plate. It has two elongated holes in its vertical section for M10 screws. These 

can be used to mount the filter. 

If no compressed air flushing is being used, the compressed air connections should be closed off with suitable screw-plugs. 

Fig. 4 Filter with mounting bracket 

Legends: 



3 Measuring input for probe M24x1.5 ( Version on 90° or 45° possible) 


5 Allen screws for fastening the mounting bracket 

6 Thermostat for auxiliary contact 

7 Thermostat for electrical heater 



2.2 Mounting on the retraction device 

A suitable mounting fixture with mounting holes is available on the retraction device for the FLK Probe. 

The required joining parts are included with the supplied items (supplementary pack). All connections have been implemented 

such that confusion is eliminated. 

During mounting the filter should be aligned such that the measuring gas connection is positioned at the same height as the 

probe connection. Before final mounting the PTFE pressure hose NW12 with steel braiding and TEFLON core must be 

adapted and screwed with the ERMETO M24x1.5 unions and the tapered rings. 

The mounting fixture is designed such that the filter can be correctly aligned in both height and depth. 

Note: When routing the hoses pay particular attention to the absolute sealing of the measuring gas line. See also the 

general operating manual Chapter 2.5, Mounting the probe with retraction device. 

After mounting, the other connections for compressed air, measuring gas outlet and the electrical connections must be made. 

• Connecting the valve combination to the filter: 

• Compressed air for probe flushing. Stainless steel corrugated hose 3/4" with braiding with R 3/4" unions on both 

ends 

• Compressed air for filter flushing. Stainless steel corrugated hose 1/2" with braiding with R 1/2" unions on both 

ends 

The connection from the filter to the condensate separator is implemented in TEFLON pipe or with PTFE pressure 

hose depending on the version. 

• TEFLON pipe: In this case the PTFE screw-on gland for pipe connection is screwed onto the adjustable angular 

screw gland on the filter. The PTFE angular screw-in gland is screwed into the condensate separator. These must 

joined to the TEFLON pipe such that the TEFLON pipe does not break off and runs slightly sloped to the 

condensate separator. 

Note: 

All screwed joints for the measuring gas must be sealed with TEFLON. 

• PTFE pressure hose: This PTFE pressure hose is fitted with M 16x1.5 union nuts at both ends. These are used to 

directly connect the PTFE pressure hose to the screw couplings on the filter and condensate vessel. 

If an electrically heated measuring gas line is used between the probe and analysis cabinet, then this must 

directly connected to the filter. The ERMETO couplings included in the supplied items can be used for this. 

be 

• For the electrical connection, the ready-made lead with plug is attached to the filter terminal box. 

This only needs to be plugged into the appropriate socket on the valve combination. 



1 

7 

2 

6 

11 

4 

3 

5 10 12 

8, 9 

Fig. 5 Installation of the filter on the retraction device 

Legends: 

1 FLK Probe 


3 Valve combination 




7 Measuring gas connection, probe / filter 

8 Compressed air connection, probe flushing 

9 Compressed air connection filter flushing 

10 Measuring gas connection, filter / condensate vessel 

11 Pipe bend 90º 

12 Condensate vessel 

13 Shut-off ball valve (not shown) 


Siemens 


3 Operation 


Danger ! 

The electrically heated filter has an operating temperature of up to 210° Cel. 

3.2 Start-up 

Warning! The electrically heated filter must only be operated by qualified personnel who are familiar with all the 

maintenance measures. Unauthorised operation and improperly carried out starting procedures can cause damage. 

After inspecting the electrical connections and also the connecting cable for correct routing, a check should be made of 

whether the mains voltage agrees with the voltage specified in the wiring documentation and on the name-plate. 

The leakage test should be carried out as in Section 4.2. 

After switching on the voltage, the function of the thermostat should be checked. The heater must switch off when the 

operating temperature is reached. 

The auxiliary contact for switching on the measuring gas pump must switch over at about 180 °Cel. 


Siemens 




With automatic cleaning using compressed air no regular work is needed by the user. However, checks for any damage and 

external soiling should be made in conjunction with other maintenance work and remedied if necessary. 

4.2 Leakage test 

4.2.1 Pressure test 

This test is always required after mounting as well as installation and removal of the filter head. 

• Seal off absolutely tight the measuring gas input to the filter (a blank plug can be used for this). 

• It is sufficient for a short test when using the valve combination to start the flushing and observe whether compressed 

air escapes anywhere on the filter. 

Note: With small leaks it is recommended that leak-seeking spray or soap solution is applied to the joints to 

localise any leaks. 

• This opportunity can also be used to test the joints on the measuring gas line up to the four-way valve. 

• Any leaks which are found should be rectified. 

4.2.2 Low pressure test 

Since the filter is normally under negative pressure in operation, a sealing test under negative pressure is more conclusive. 

• Close off the measuring gas input on the filter as under 4.2.1. 

• Connect a low pressure measurement sensor as close as possible to the filter output. Ensure absolute sealing tightness! 

• Produce a negative pressure of about 300 mbar by switching on the measuring gas pump. 

• Shut off the line. The low pressure must now remain almost constant (pressure drop in 5 minutes max. 2 mbar). 

• Localise any leaks and rectify them. 


Siemens 


4.3 Cleaning the filter or replacing the filter tube 

The filter should be removed and cleaned If an excessively large negative pressure occurs at the filter, or, when a valve 

combination is used, the filter flushing is often initiated by the low pressure, or at the latest after the signal "Filter / probe 

blocked" occurs. 

Careful - danger of burning ! 

Electrically heated filter has an operating temperature of up to 210° Cel. 

See Figure 3 for the procedure 

• Switch off the fuse for the filter heater or unplug the plug for the filter on the valve combination. 

• Start the compressed air flushing, if available, a few times to cool the filter. 

• Loosen and remove the hoses on the filter head at the filter end (compressed air connection, Item 82 and measuring gas 

connection, Item 83). 

• Loosen the tommy screw (Item 14) on the retaining clip (Item 15). 

• Swivel the retaining clip to the side. 

• Withdraw the filter head (Item 1) with the filter tube (Item 4) downwards. 

• Loosen the screw (Item 7), retaining it with a mandrel. 

• Remove the cup springs (Item 5) and retaining washer (Item 6). 

• Remove the filter tube (Item 4) and clean it inside and outside with a brush and compressed air. 

With obstinate soiling, the filter tube can be cleaned with a suitable chemical solvent. 

However, if the filter tube is mechanically damaged or cleaning is no longer possible, then it must be replaced. 

• Before fitting the cleaned or new filter tube, check the O-rings (Item 3) for sealing on the front side of the filter tube and 

the sealing gasket (Item 2) on the filter head, renewing them if required. 

• Replace the filter tube, place the retaining washer (Item 6) and the cup springs (Item 5) flat, tighten with screw (Item 7) 

and retain using the mandrel. Make sure that the filter tube does not become misaligned. 

• Replace the filter insert and fasten with the retaining clip and tommy screw. 

• Blow out the gas lines from the filter to the probe sampling chamber as well as the condensate vessel with compressed 

air or clean them by hand. 

• Reconnect the hoses, ensuring sealing tightness. 

• Carry out a leakage test according to Section 4.2.1. 

• Plug in the electrical connectors and switch on the heater fuse. 


Siemens 


4.4 Replacing the thermostat 

• Switch off the fuse for the filter heater or withdraw the plug for the filter on the valve combination. 

• Start the compressed air flushing a few times, if available, to cool the filter. 

• Loosen the electrical connection cable in the terminal box (Item 12) and pull back the cable. 

• Remove the thermostat after loosening the screws at the top of the filter. 

• Smear the new thermostat with heat conducting paste on the bottom and firmly screw to the filter. 

• Insert the cable into the terminal box and connect according to the wiring diagram. 

• Carry out a functional test. 

4.5 Measures for fault rectification 

4.5.1 Filter does not reach operating temperature after about 15min. 

• Check the voltages in the terminal box. 

• If there is no voltage on the heater, replace the thermostat. 

• If voltage is present on the heater, replace the heater or the complete filter housing. 

4.5.2 No release of the measuring gas pump 

• Check that the filter operating temperature is about 200 ºCel. 

• Check the voltages in terminal box. 

• If the temperature is still too low after about 15 min., carry out procedure in 4.4.1. 

• If the operating temperature is reached, but thermostat not closed for release, replace the thermostat. 

4.5.3 Filter becomes blocked too quickly 

If the filter becomes blocked soon after cleaning: 

• Check whether the release for the measuring gas pump only occurs after reaching the operating temperature. 

• Replace auxiliary-contact thermostat. Procedure as in 4.3. 

• Is there enough compressed air available for flushing? 

• Check the compressed air pressure and check supply line if necessary. 

• Is there compressed air available as required (free of oil and dry) ? 

• Check the filter tube for blocked pores (black, burnt deposits). 

Note: If oil compounds are present in the compressed air, then baked-on deposits which are difficult to 

remove occur in the filter tube. The tube can then only be replaced. 


Siemens 

SQ253 Valve Combination 


Siemens 

Fig. 1 Valve combination for mounting on the retraction device 


Siemens 



1. Introduction.......................................................... 59 

1.1 General information ............................................ 59 

1.2 Personnel qualification requirements ................ 59 

1.3 Field of application .............................................. 60 

1.4 Construction......................................................... 60 

1.5 Mode of operation................................................ 62 

1.6 Technical data ...................................................... 63 

2. Installation............................................................ 64 


2.2 Mounting on the withdrawal device................... 64 

2.2.1 Hose connections to the withdrawal 

mechanism..................................................................... 64 

2.2.2 Cable connection to the withdrawal 

device ............................................................................. 65 

2.3 Compressed air/measuring gas 

connection/ ext. cable 

connection ............................................................. 65 

3. Operation.............................................................. 66 


3.2 Start-up................................................................. 66 

3.2.1 Electrical start-up ................................................ 66 

3.2.2 Compressed air and leakage test ........................ 66 

4. Maintenance ......................................................... 67 

4.1 General information ......................................... 67 

4.2 Compressed air filter ........................................ 67 

4.3 Compressed-air solenoid valves....................... 68 

4.3.1 Replacing the valves.......................................... 69 

4.3.2 Cleaning the valve ............................................. 69 

4.3.3 Faults:................................................................. 69 

4.4 Condensate separator ....................................... 69 

4.5 Four-way ball valve........................................... 71 

4.5.1 Removing the 4-way ball valve ........................ 71 

4.5.1.1 Checking and setting the limit switches:......... 70 

4.6 Low-pressure pressure switch.......................... 71 

4.7 Electrically operated compressed air 

valve (option) ................................................................ 71 

4.7.1 Replacing the valve ........................................... 71 

4.7.2 Cleaning a valve: ............................................... 71 

4.7.3 Faults:................................................................. 71 

4.8 Pneumatically operated compressed air 

valve (option) ................................................................ 72 

4.8.1 Replacing the valve ........................................... 72 

4.8.2 Cleaning the valve:............................................ 72 

Note: 










used: 










Siemens 




Warning! 

This system is operated by electricity. When operating electrical equipment, it is unavoidable that certain 

parts of this system carry a dangerous voltage. 


occur. 





mounting as well as proper operation and maintenance. 






mounting, mounting, maintenance and operation of this product and who possess appropriate qualifications for their 


- training or instruction, and authorization for installing, removing, earthing and labelling power circuits, equipment and 








Siemens 



The valve combination is used for the automatic cleaning of FLK Gas Sampling Probes 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. 


The valve combination is designed as a compact unit (see Figure 2). All the parts required for flushing, the valve unit for the 

control of the compressed air motor (Item 4, optional), and the drive motor for the four-way ball valve (Item 10) are 

accommodated so that they are protected from dust, splashing water and from mechanical damage. A compressed air filter 

with automatic condensate drain is connected in front of the filter in the compressed air line. Maintenance-free ball tap (Items 

2) are provided for shutting off the compressed air during maintenance work. The compressed air filter and the ball tap are 

fitted on the outside so that easy operation and cleaning are possible. 

The buttons for starting and stopping the flushing are located on the front panel. 

With this construction the valve combination should only be opened in case of a fault or for maintenance work. 

A condensate vessel is fitted on the side before the four-way ball valve for retaining the condensate arising after the 

electrically heated filter. 

Note: 

If a heated line is being used for passing the measuring gas between the probe and the analysis cabinet, the 

condensate vessel (Item 9), four-way ball valve (Item 10) and low-pressure pressure switch are located in the 

analysis cabinet so that the heated line can be cleaned when flushing. 


Siemens 


Fig. 2 Valve combination 

Legends: 

1 Coupling for compressed air connection 

2 Manual shut-off ball valve 

3 Pneumatic valve for compressed air motor 

4 Electrically operated valve for compressed air motor 

5 Solenoid valves for probe flushing 

6 Solenoid valves for filter flushing 

7 Compressed air connection for probe flushing 

8 Compressed air connection for filter flushing 

9 Condensate precollector 

10 Electrically driven four-way ball valve 

11 Connection terminals for all electrical connections for the trunk 

cable to the controller 

12 measuring gas input from probe 

13 Teflon hose 

14 Measuring gas output to analyzer 




In conjunction with an PLC programmable logic controller, the compressed air valve combination carries out the appropriate 

cleaning program for the flushing of the gas sampling system. Dry compressed air, free of dust and oil, is required at 6...8 bar. 

The consumption depends on the duration of cleaning and on the compressed air pressure. 

The compressed air for the cleaning is passed via the filter (Figure 2) with automatic condensate separator. 

For safety reasons manual shut-off ball tap are provided in the filter feed for shutting off the compressed air during 

maintenance work, etc. 

The low-pressure in the measuring gas line between the measuring gas input on the probe, the four-way ball valve and the 

measuring gas pump in the analysis cabinet is measured with the pressure switch. This low pressure is a measure of the 

contamination in the probe, dust removal filter and following measuring-gas line to the measuring gas pump. With a blockage 

in these areas the measuring gas pump produces a negative pressure and if this exceeds the set limit, flushing is started 

irrespective of the set flushing interval period. 

The condensate occurring in front of the valve combination is collected in an enclosed glass vessel. 

The motor-driven four-way ball valve releases the measuring gas path when the probe is inserted and when no faults are 

present in operation. 

If a measuring cycle is started, the four-way ball valve moves to the "Closed" position. The measuring gas line is therefore 

closed, so that no compressed air can enter the analysis cabinet. Now the solenoid valves for the filter flushing (Figure 2, 

Item 6) are controlled cyclically. The compressed air is blown into the probe through the inner side of the filter in a pulsating 

manner. Shortly before the termination of the filter flushing, the solenoid valves for the probe flushing (Figure 2, Item 5) are 

also switched. This cleans the filter pipe from the outer side and also the probe. After termination of the filter / probe 

flushing, the compressed air valves are closed and the four-way ball valve turns further into the position "Blow out 

condensate". Then the solenoid valves are controlled once again so that the condensate is blown out of the condensate vessel. 

Pressure compensation with respect to atmospheric pressure then takes place in the "Test" position. 

Note: 

See the operating manuals for the PLC controller, FLK probe and electrically heated filter for further details on 

flushing. 

When using the withdrawal device with a compressed air motor, the following valves are also accommodated for the 

emergency withdrawal of the probe. 

1. Solenoid valve which opens in the unenergized state and therefore switches on the compressed air motor. 

2. Pneumatically operated valve which switches off the compressed air motor via a pneumatic limit switch when the 

probe withdraws. 

For all the electrical connections to the withdrawal device (drive motor, limit switch) and to the electrically heated filter 

(heater and thermostat) coded connectors are provided on the bottom. These enable quick mounting and rapid replacement of 

defective parts. The terminal strip in the valve combination is provided for the connection of the flexible, heat resistant trunk 

cable to the control cabinet. 




Electrical supply 

Voltage: 

110 – 230VAC + 24VDC 

Compressed air supply 

Supply pressure 

6 ... 8 bar, 

Dry, free of dust and oil 

Permissible ambient temperature: 

0 ... 60°Cel. 

Dimensions: 

630 mm x 380 mm x 210 mm 

Type of protection: IP 54 to DIN 40050 

Weight: 

25kg 

Pressure switch : 

Display range 

Two way contact 

Contact rating 

-300 ... -700 mbar 

max.: 250V AC, 1,5A / 24DC, 2A 

4-way valve: 

24 VDC 

Actuating time for 90° 

approx. 20sec 

Compressed air filter: Max operating pressure 25 bar 

Max. temperature 90 °C 

Filter element 

sintered metal 

Pore size 30 µm 

Draining 

automatic 

Solenoid valves: Max operating pressure 0...16 bar 

Max. temperature 80 °C 





The valve combination is constructed such that it can be easily mounted on the withdrawal device. If no withdrawal device is 

being used, then fixing on a mounting frame is possible. Documentation for this can be requested from the SIEMENS 

company in the relevant country. 

2.2 Mounting on the withdrawal device 

The valve combination is fastened to the four screw bolts provided on the opposite side of the drive motor on the traversing 

carriage. 

All internal connecting screws on the measuring gas line must be retightened, including the nuts on the condensate vessel 

(Figure 2, Item 11). Once the valve combination has been mounted, the hose and cable connections to the withdrawal device 

and the electrically heated filter must be made. 

Note: 

See general operating manual Chapter 2.5, Mounting the probe with withdrawal device. 

The joining hardware needed for this is included in the supplied items (supplementary pack). All connections have been 

labeled to eliminate confusion. 

2.2.1 Hose connections to the withdrawal mechanism 

These consist of: 

Connections between valve combination and electrically heated filter 

• Metal-braided hose with R 3/4" threaded joint at both ends for compressed air for the probe flushing. 

• Metal-braided hose with R 1/2" threaded joint at both ends for compressed air for the filter flushing. 

• Depending on the measuring gas connection between filter and condensate vessel (Figure 2, Items 11,20): 

PTFE pressure hose with union nuts (M16x1.5) on both ends. 

TEFLON pipe for high-corrosion version with TEFLON screwed glands. 

Note: Special attention should be paid to ensure that the PTFE pressure hose or the TEFLON pipe continuously 

slopes down to the condensate vessel. 

Connections for the compressed air motor. ( Figure 2, View A. ): 

• Compressed air feed line to the pneumatic limit switch connection M16x1.5 

Valve combination "P2" to the pneumatic limit switch "R1/P2" 

• Return line from pneumatic limit switch connection M16x1.5 

Valve combination "A" to the pneumatic limit switch "A" 

• Compressed air feed line to the compressed air motor connection M16x1.5 



2.2.2 Cable connection to the withdrawal device 

The electrical connection from the withdrawal device and the electrically heated filter are implemented in ready-made cable 

to the terminal strip in the valve combination (Figure 2, Item 14). The connections are: 

• electrically heated filter 

• limit switch, Probe Withdrawn 

• limit switch, Probe Inserted 

• Drive motor for withdrawal device 

2.3 Compressed air/measuring gas connection/ ext. cable connection 

A quick-release coupling to DIN 3483 is provided for the compressed air connection (Figure 2, Item 1). The NW20 

compressed air line must be connected to this. 

The measuring gas connection (Figure 2, Item 18) is made via the ready-made, 3.5m long PTFE pressure hose with metal 

braiding. This is directly screwed to the angular screwed joint. No further sealing with TEFLON is needed due to the conical 

nipple connection on the hose. 

The electrical connections are implemented according to the regulations of the local power supply utility and of the relevant 

country. 

The cables between the valve combination and the controller 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 M 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. See Figure 3 for 

examples. 

Note: 

See general operating manual Chapter 2.10, Electrical connections. 

< 1 > < 2 > < 3 > < 4 > < 8 > < 8 > < 9 > 

< 6 > 

Fig. 3 Suggested fastenings for holding the feed lines. 

Legends: 1 Valve combination 6 Flat bar 30 x 4 mm 

2 Fastening screw M8 7 Fastening for compressed air hose 

3 Cable retention bracket 8 Pipe clamp 

4 Fastening for measuring gas hose 9 Plastic cable protection 

5 Fastening for control cable 10 M screwed gland for control cable ( Underside ) 



3. Operation 


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. 

• 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. 

3.2.2 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. 





The user should carry out the following maintenance work so that operational readiness is ensured: 

• 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. 

4.2 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 



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 



4.3.1 Replacing the valves 

• 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 

Note: 

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. 

• Assembly takes place in the reverse sequence. 

4.3.2 Cleaning the valve 


• 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. 

Note: 

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 




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. 



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). 


Important! When setting the limit switches, pay attention to the 24VDC control voltage. 



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 


• 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 

Note: 

Pay attention to voltage and type of current according to the nameplate. 

• Clean the hose nozzles and use PTFE tape to seal the thread. 

• Screw in the hose nozzles into the new valve. 


4.7.2 Cleaning a valve: 


• 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. 


Note: 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. 



Leaky valve: 

• Procedure as in Section 4.7.2 or replace the valve. 

Fig. 7 

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. 




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. 


Fig. 8 Pneumatically operated compressed air valve 


SQ254 Heat Exchanger 

Fig. 1 Heat Exchanger 


1. Introduction........................................................................ 76 


1.2 Personnel qualification requirements ................................ 76 

1.3 Field of application ............................................................ 76 

1.4 Function description of the heat exchanger....................... 77 

1.5 Technical data ................................................................... 78 

2. Installation ......................................................................... 79 

2.1 Installation of the heat exchanger...................................... 79 

2.2 Electrical connection ......................................................... 79 

2.3 Filling up the heat exchanger with cooling liquid ............... 79 

3. Setting into operation......................................................... 80 

3.1 Safety specifications.......................................................... 80 

3.2 Preparation before first Start-up ........................................ 80 

3.3 Adjustment of temp.-controller in switch cabinet .............. 81 

3.3.1 Setpoint for temperature adjustment of the 3-WV ............. 81 

3.3.2 Setpoint for temp.adjustment of fan .................................. 81 

3.3.3 Min. limit value for start gas-sampling............................... 81 

3.3.4 Max. limit value emergency extraction of probe ................ 82 

3.4 Standard starting ............................................................... 82 

4. Setting out of operation ..................................................... 82 

4.1 Shutdown the equipment................................................... 82 

5. Maintenance...................................................................... 82 



Note: 



from the relevant purchasing agreement, which also contains the complete and solely valid warranty. These 




















Warning! 




occur. 














- training or instruction, and authorization for installing, removing, earthing and labeling power circuits, 








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. 



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) 




Operating Voltage Volt 380-480 

Frequency Hz 50/60 

Control Voltage Volt 24 V DC from control unit 

Frequency Hz 50/60 

Cooling capacity kW 65 

Circulation pump 

Power of motor kW 2.2 

Motor speed 1/min 3460 

Fan 

Power of motor kW 0,52 

Motor speed 1/min 1340 

Heat exchanger 

Inlet temperature of air °C max. 45 

Outlet temperature of air °C appr. 105 

Inlet temperature of medium °C 200 

Outlet temperature of medium °C 170 

Cooling surface m 2 25 

Cooling unit 

Weight, incl. filling kg appr. 420 

Protection type IP 54 

Cooling medium 

synthetic heat transfer liquid 

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 140 °C 

Switch temperature for start fan to be adjusted at the Temp.-controller 180 °C 

Maximum temperature to be adjusted at the Temp.-controller 220 °C 

Minimum temperature to be adjusted at the Temp.-controller 130 °C 

Minimum flow to be adjusted at the flow meter 1.5m 3 /h 

Minimum level in compensating tank over bottom 

85 mm 




2.1 Installation of the heat exchanger 

The installation platform has to be even and must endure a weight of estimated 400 kg/m 2 . 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. 



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 m 3 /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 3,6m 3 /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 



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. 



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. 


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. 


Siemens 


Siemens 

SQ255 Control Unit 

Fig. 1 FLK Control Unit 


1. Introduction.......................................................... 86 2.2 Mounting the controller cabinet......................... 89 

1.1 General information ............................................ 86 2.3 Electrical connection............................................ 89 

1.2 Personnel qualification requirements ................ 86 2.4 External cable connection ................................... 89 

1.3 Field of application .............................................. 86 3. Operation.............................................................. 90 

1.4 Construction......................................................... 87 3.1 General information ............................................ 90 

1.5 Mode of operation................................................ 88 3.2 Start-up................................................................. 90 

1.6 Technical data ...................................................... 88 3.2.1 Electrical start-up ................................................ 90 

2. Installation............................................................ 89 4. Maintenance ......................................................... 90 



Siemens 


Note: 



purchasing agreement, which also contains the complete and solely valid warranty. These warranty provisions are neither 







used: 










Siemens 







occur. 




The proper and safe operation of this device requires correct transport, storage and 

well as proper operation and maintenance. 

mounting as 






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 








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. 


Siemens 



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 Simatic S7 

2 Reset-Button / Start-Stop Purge-Button 

3 Operator Panel (OP3) 

4 Main Switch S1 (400V) 

5 Main Switch S2 (230V) 

6 Indication lamps/Lamp test 




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. 


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 





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. 



3. Operation 


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. 

• 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. 


The control cabinet is maintenance free. 



SQ256 Retraction Device 

Fig. 1 Retraction device with mounted gas sampling probe 


1 Introduction......................................................................... 95 

1.1 General information............................................................ 95 

1.2 Personnel qualification requirements ................................. 95 

1.3 Field of application ............................................................. 95 

1.4 Construction ....................................................................... 96 

1.5 Mode of operation............................................................... 96 

1.6 Technical data .................................................................... 97 

2 Installation .......................................................................... 98 

2.1 General information............................................................ 98 

2.2 Point of installation ............................................................. 98 

2.2.1 Fitting on the kiln inlet......................................................... 98 

2.2.2 Installation in the heat exchanger (precalcination 

chamber) ............................................................................ 98 

2.3 Fitting the probe entry pipe and retraction device .............. 99 

3 Operation........................................................................... 101 


3.2 Start-up.............................................................................. 101 

4 Maintenance...................................................................... 102 

4.1 Transport chain ................................................................. 102 

4.2 Guide rollers ...................................................................... 103 

4.3 Chain wheel....................................................................... 104 

4.4 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 



Note: 



from the relevant purchasing agreement which also contains the complete and solely valid warranty. These 




















Warning! 




occur. 














- training or instruction, and authorization for installing, removing, earthing and labelling power circuits, 








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. 




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. 


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. 




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 

6AM-FRV-5A 

6 ... 8 bar 

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 





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). 



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 



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. 


3 Operation 


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. 




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 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 ). 



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. 



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. 

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 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: 

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 

BP 

CALYPSOL 

KLÜBER 

MOBIL 

SHELL 

Type of oil 

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. 



• 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.

FLK Gas Sampling System - MPIP - Free

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