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AB B M E A S UR E ME N T & AN A LY T I C S | DATA S H EE T

SCK
Sampling system for dry gas sampling at
rotary cement kiln gas exit and calciner gas exit
2 SCK SAMPLING SYSTEM | DS/SCK-EN REV. A

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Measurement made easy
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• Complete sampling system comprising only three
pre-assembled modules
• Pre-assembled tubes and bus cables significantly
reducing the system installation time
• Robust system design
• Standardized interfaces to ABB’s and third-party
manufacturers’ analyzer systems
• Pneumatically driven probe retractor with dust cover
and automatically or manually driven oven flap
• Robust, water cooled gas sampling probe types
• Probe type H with automatic mechanical cleaning
• Automatic probe retraction in case of compressed air
or power supply failure
• Automatic cyclic cleaning of probe and filter
• Closed cooling water circuit with speed-controlled
heat exchanger
• Continuous monitoring of cooling water pressure,
temperature and flow
• Control unit with color touch panel featuring
comprehensive operation, diagnosis and maintenance
capabilities
• Graphic trend displays for predictive maintenance
purposes
• Password-protected menu levels adapted for the needs
of different user groups in the cement plant
• Various tools for remote operation and remote diagnosis
available
• User interface in national languages available on request
 SCK SAMPLING SYSTEM | DS/SCK-EN REV. A 3

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Application and system overview

Application System overview

The SCK sampling system is designed for sampling of hot ce- The SCK sampling system comprises the following modules:
ment flue gas with a high dust load for gas analysis. Usage sites
 Probe retractor 1 with pneumatic motor and chain-driven
are the rotary cement kiln gas exit and the calciner gas exit in dry
water-cooled probe type H or type 60S 2
process clinker kilns. The system is suitable for applications in
rough environmental conditions.  Control unit 3 with industrial controller incl. color touch panel
The SCK sampling system is preferably combined with ABB’s ACX  Cooling unit 4 with speed-controlled heat exchanger and cool-
analyzer system. The combination of SCK with analyzer systems ing water circulation pump
of third-party manufacturers is also possible.
 Compressed-air tank 5 (optional)
4 SCK SAMPLING SYSTEM | DS/SCK-EN REV. A

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Retractor
1 2 3 4 5 6

7 12 11 10 9 8 7
1 Pneumatic box 7 Transport brackets (dismounted at installation site)
2 Emergency stop button ‘probe action’ 8 Gas sampling probe type H (see p. 5) or type 60S (see p. 6)
3 Pneumatic motor 9 Internal heated sample gas line
4 Terminal box for system-internal electric cables connections 10 Flashing lights ‘probe action’
5 Heated connection box for sample gas line connection 11 Cable drag chain
6 Automatically (pneumatically) or manually driven oven flap 12 Probe cleaning unit

Description Pneumatic box

Pneumatic equipment for compressed-air conditioning and con-
The retractor with its pneumatic chain driver carries the gas sam- trol of:
pling probe in a double beam construction. It is used to insert – Probe movement
and retract the probe to defined front or rear positions to scrape – Oven flap opening/closing
off possible material deposits or encrustations. – Plunger movement (for probe type H)
The integrated automatically (pneumatically) or manually driven Connection of external compressed air
oven flap closes the sampling opening when the probe is retraced, Terminal box
thus preventing hot and toxic gases to exhaust from the oven and Connection of system-internal power supply and signal cables
cause damage to man and machinery.
Heated connection box
The integrated cable drag chain bundles the tubes and cables for Connection of an external unheated or heated sample gas line
smooth probe movements. (see system technical data, page 10)
The probe is automatically retracted when Color
 Cooling water temperature is too high Light gray (RAL 7035)

 Cooling water flow or pressure is too low Degree of protection

IP54 to EN 60529
 Cooling water circulation pump failure occurs
Dimensions
 Compressed-air failure occurs see page 14
 Power supply failure occurs Standard retractor lengths:
4500 mm (177.2 in) for probe length L = 1.5 to 2.5 m (59.1 to
Technical data 98.4 in)
5500 mm (216.5 in) for probe length L = 3.0 to 3.5 m (118.1 to
Double beam construction 137.8 in)
– Chain drive Option: Retractor length adjusted to the probe length; retractor
– Pneumatic motor length is approx. probe length L + 2 m (L + 78.7 in).
– Probe carrier with installed gas sampling probe
– Automatically (pneumatically) or manually driven oven flap Weight
Max. 600 kg (1322 lb) incl. probe
– Dust cover
Mounting
Cable drag chain
– Hanging mounting (see page 16)
– Cooling water tubes
– Electric cables – 6 fixing points, required bearing capacity 10000 N each
– Pneumatic tubes
– Self-regulating heated sample gas line
 SCK SAMPLING SYSTEM | DS/SCK-EN REV. A 5

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Gas sampling probe type H
6
5

1 1 3
18 4 4
202 2 535 350 L
1105
L+1105

1 Control air connection G ¼ in 5 Bleeding for cooling water circulation

2 Sample gas connection G ¼ in 6 Flange DN 150, PN 10
3 Compressed air connection for pipe nozzle with 18 mm outer diameter L Installation length
4 Cooling water connections G 1 in

Description Technical data

The water-cooled gas sampling probe type H is installed in kilns, Material
where extremely hard encrustations are to be expected. Cooling tube: Stainless steel 1.4541 (AISI 321)
Inner gas pipe: Stainless steel 1.4436 (AISI 316)
By using the probe type H, long measuring periods without inter-
ruptions are possible: The pneumatically driven plunger which is Probe length
welded on the filter tip mechanically breaks the encrustations at L = 1.5/2.0/2.5 m (59.1/78.7/98.4 in) preferably for use at calciner
the probe gas entry without interruption of the measurement. gas exit
L = 3.0/3.5 m (118.1/137.8 in) preferably for use at cement kiln gas
After a preset number of plunger movements, the probe is auto-
exit
matically retracted. Thereby, possible material deposits are
scraped off. After re-insertion filter and tube tip are purged with Weight
compressed air. Through the automatic probe movement and Approx. 95 kg (210 lb) for probe length L = 3.0 m (118.1 in)
purging it is assured that the probe tube is practically free of de-
posits and the filter is free of dust.
6 SCK SAMPLING SYSTEM | DS/SCK-EN REV. A

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Gas sampling probe type 60S
~60

1 2 3
A

~70
ø60,3

A
ø89

35
90

L3 L2 3

L1

1 Sample gas inlet ports L1 Probe tube length

2 Thickened shank of probe tube L2 Length of thickened shank:
3 Cooling water connections 800 mm for L1 ≤ 2000 mm, 1300 mm for L1 ≥ 2500 mm
L3 200 mm with reinforced protection tube

Description Technical data

The water-cooled gas sampling probe type 60S is installed in Material
kilns where less hard encrustations are to be expected. Cooling tube: Stainless steel 1.4541 (AISI 321)
Inner gas pipe: Stainless steel 1.4571 (AISI 316Ti)
By using the probe type 60S with two sample gas openings at
the side of the probe tip, an effective pre-dedusting of the sam- Probe length
ple gas is achieved at the tip thus reducing the frequency of the L = 1.5/2.0/2.5 m (59.1/78.7/98.4 in) preferably for use at calciner
automatic back purging actions. gas exit
L = 3.0/3.5 m (118.1/137.8 in) preferably for use at cement kiln gas
After a preset number of back purging actions of the filtering
exit
unit and the sample pipe, the probe is automatically retracted.
Thereby, possible material deposits are scraped off. After re-in- Weight
sertion filter and tube tip are purged with compressed air. Approx. 45 kg (100 lb) for probe length L = 3.0 m (118.1 in)
Through the automatic probe movement and purging it is as-
sured that the probe tube is practically free of deposits and the
filter unit is free of dust.
 SCK SAMPLING SYSTEM | DS/SCK-EN REV. A 7

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Cooling unit

1 Temperature sensor (return) 11 Surge tank

2 Cooling water return (brass, pipe connector 1 in) 12 Fan motor heat exchanger
3 Check valve 13 Heat exchanger
4 Shut-off valve cooling water 14 Cooling water pump
5 Cooling water inlet (brass, pipe connector 1 in) 15 Analog input module
6 Cooling water feed (brass, pipe connector 1 in) 16 CAN bridge
7 Pressure controller 17 Terminal strip power supply for motor and pump
8 Temperature sensor (feed) 18 Terminal box
9 Safety relief valve outlet (brass, pipe connector 1 in) 19 Cable glands and cable feed-through
10 Safety relief valve cooling water pressure 20 Flow controller

Description Technical data

Due to the prevailing conditions a cooling of the gas sampling Cooling water circuit
probe is mandatory. The cooling unit is used to provide and mon- – Capacity (first fill) 50 to 60 l (13 to 16 gal [US], 11 to 13 gal [UK])
itor the cooling water supply. The cooling water circuit is com- – Pressure 1 to 2 bar (14.5 to 29 psi)
pletely closed thus minimizing cooling water consumption and – Controlled temperature 75 to 85 °C (167 to 185 °F)
avoiding scaling. – Circulation 5 to 6 m3/h (2.9 to 3.5 cfm)
– Drinking water quality, anti-freeze agent necessary at ambient
The cooling unit contains the speed-controlled heat exchanger
temperature < 0 °C (32 °F)
and the cooling water supply pump as well as analog sensors for
monitoring the cooling water temperature, flow and pressure. Cooler block material
Copper/brass for corrosion-proof operation
Color
Light gray (RAL 7035)
Degree of protection
IP54 to EN 60529
Dimensions
see page 15
Weight
Approx. 250 kg (550 lb)
Mounting
Ground mounting (see page 17)
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Control unit
1 2

SCK
4 3

1 Maintenance switch (lockable)

2 Color touch panel
3 Buzzer
4 Main switches

Description Technical data

The control unit comprises the control system including the dis- Modules
play and operator control unit for monitoring and operating the – Industrial controller with display and operator control unit
gas sampling system. Electrical power supply and all signals for – Color touch panel with special-hardened glass surface
the entire gas sampling system are fed-in and distributed in the – Maintenance switch (lockable)
control unit. – Buzzer
– Main switches
The control program offers different levels which are partly pass-
– Input and output terminals
word-protected. Various locking mechanisms prevent possible
– Automatic fuses
sampling probe damages caused by erroneous operation or fail-
– Power supply
ure of single modules.
– Frequency controller

Operation Material
Sheet steel
Probe movement and cleaning are controlled either in automatic
mode or in manual mode. The program sequences are menu- Color
driven and provide: Light gray (RAL 7035)

 Operation (automatic or manual probe retraction/insertion, Degree of protection

oven flap opening/closing, probe cleaning, etc.) IP54 to EN 60529

 Diagnosis (cooling water parameters, trend displays, status Dimensions

messages, etc.) see page 15

 Set-up for process optimization (timers, limit parameters, etc.) Weight

Approx. 75 kg
 Login levels to allow authorized access only (operators, techni-
cians, etc.) Mounting
Wall mounting (see page 18)
 Support via help texts
 SCK SAMPLING SYSTEM | DS/SCK-EN REV. A 9

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Pneumatic and piping diagram

1 Safety relief valve outlet (bulkhead union brass with pipe connector 1 in)
2 Cooling water inlet (bulkhead union brass with pipe connector 1 in)
3 Cooling water feed (bulkhead union brass with pipe connector 1 in)
4 Cooling water return (bulkhead union brass with pipe connector 1 in)
5 Cooling water tube (25/39x7 mm 30 m incl. in delivery)
6 Compressed air tube (PA 18/14x2 mm 25 m incl. in delivery)
7 Heated sample gas line TBL-01 with PTFE bore 4/6x1 mm
8 Condensate outlet
9 Bulkhead union ‘compressed air to tank’ for tube 18/14 mm
10 Bulkhead union ‘compressed air from tank’ for tube 18/14 mm
11 Bulkhead union ‘compressed air inlet’ for tube 18/14 mm
12 Bulkhead unions ‘external pneumatic emergency stop’ for tube 6/4 mm
13 Elbow union with pipe connector 1 in ‘cooling water feed’
14 Elbow union with pipe connector 1 in ‘cooling water return’
15 Connector for sample gas line TBL-01 with SS flange ‘sample gas outlet#
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System technical data
Connections Declaration of conformity
Power supply Electrical safety
Control unit The regulations of European directive 2006/95/EC for low voltage
230/400 VAC supply lines: 4.0 mm2 (AWG10) are complied with.
UPS 230 VAC supply lines (option): 2.5 mm2 (AWG12)
Electromagnetic compatibility
Control unit to retractor
The regulations of European directive 2004/108/EC for EMC are
230 VAC supply lines: 1.5 mm 2
(AWG14)
complied with.
230 VAC supply lines (for probe type 60S): 1.5 mm2 (AWG14)
24–30 VAC supply lines (for probe type H): 2.5 mm2 (AWG12) Machinery
24 VDC supply lines: 1.0 mm2 (AWG18) The regulations of European directive 2006/42/EC for machinery
Control unit to cooling unit are complied with.
400 VAC supply lines: 1.5 mm2 (AWG14)
24 VDC supply lines: 1.0 mm2 (AWG18)
Signal interfaces
– Relay contacts (max. load 110 VDC/230 VAC, 1.5 A)
– Profibus DP slave RS485 (optional)
– Modbus (optional, for connection to ACX analyzer system)
Power supply and signal interfaces diagram see page 12
System bus CANopen
2 cables attached to the control unit and to the retractor for con-
nection to the cooling module, length = 15 m (49.2 ft) each
Compressed-air connections (at retractor)
Fittings, diameter 18 mm (0.7 in, supplied)
Cooling water connections (at cooling unit)
1 in (supplied)
Sample gas line to the analyzer system
The sampling system can be prepared for connection of an un-
heated gas sample line or a self-regulating heated sample gas
line, depending on application.
Requirements on a heated sample gas line: No flange connection,
outside diameter of isolation 45 to 48 mm (1.77 to 1.89 in), out-
side diameter of inner core 6 mm (0.24 in), length of nipple max.
30 mm (1.18 in), temperature-resistant up to 150 °C (302 °F).

Accessories
Cooling water tube
25/39x7 mm, length = 30 m (98.4 ft, can be cut as required), incl.
fittings, weight approx. 40 kg (88 lb, included in delivery)
Compressed-air tube
PA 18/14x2 mm, length = 25 m (82 ft, can be cut as required), incl.
fittings (included in delivery of optional compressed-air tank)

Acoustic emission
Retractor and cooling module
approx. 89 dB(A)
 SCK SAMPLING SYSTEM | DS/SCK-EN REV. A 11

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Requirements at the installation site
Power supply Ambient conditions
Operating voltage Ambient temperature
230/400 VAC, ± 10 %, 50 Hz (fuses 3 x 20 A required), 5 to 45 °C (41 to 113°F), −20 to 45 °C (−4 to 113 °F) with anti-freeze
3-phase connection (5 wires, N-conductor necessary) agent in the cooling water
or Compressed air tank (option): −10 to 50 °C (−14 to 122 °F)
230/400 VAC, ± 10 %, 60 Hz (fuses 3 x 20 A required),
Transport and storage temperature
3-phase connection (5 wires, N-conductor necessary)
5 to 55 °C (41 to 131 °F), −20 to 55 °C (−4 to 131 °F) after draining
or
and drying all parts in contact with cooling water or condensate
3 x 208 VAC, ± 10 %, 60 Hz incl. transformer (fuses 3 x 20 A
required), 3-phase connection (4 wires) Relative air humidity
Other voltages on request ≤ 75 % annual average, for a short time up to 95 %, infrequent
and slight condensation possible
Power consumption
Max. 6 kVA Installation location
Installation location altitude max. 2000 m (6562 ft).
Option ‘UPS’
The control unit must be installed at a low-vibration location and
230 VAC or 120 VAC, ± 10 %, 50 to 60 Hz (fuse 1 x 6 A required)
protected from direct sunshine, dust and rain.

Compressed air supply Process gas conditions

Purpose
Pressure
For movement and cleaning of the gas sampling probe
±3 kPa (0.435 psi) related to atmospheric pressure
Requirements
Temperature
Compressed air free of dirt, oil and water droplets, 6 bar positive
Max. 1300 °C (2372 °F)
pressure, dried to 5 °C (9 °F) below ambient temperature
Recommendation: Instrument air (dew point −40 °C [−40 °F]) Dust load
Max. 2000 g/m3 (874 grain/ft3)
Consumption
Approx. 3 m3/h (1.7 cfm) at standard conditions Gas velocity at sampling point
Max. 20 m/s (65 ft/s)
Emergency tank
A compressed-air tank with a capacity of at least 250 l (66 gal [US],
55 gal [UK]) must be installed near the sampling system. This
emergency tank is necessary to supply sufficient compressed air
for retracting the probe from the kiln in case of a compressed-air
or power supply failure. The tank can be provided by the customer
or by ABB.

Cooling water supply

Purpose
For cooling of the gas sampling probe
Requirements
Drinking-water quality
Anti-freeze agent (approx. 20 l [5.3 gal (US), 4.4 gal (UK)], without
anticorrosion agent, oil-free) must be added if the ambient tem-
perature is < 0 °C (32 °F).
Capacity
First fill 50 to 60 l at 1 to 2 bar (13 to 16 gal [US] or 11 to 13 gal [UK]
at 14.5 to 29 psi)
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Power supply and signal interfaces
 SCK SAMPLING SYSTEM | DS/SCK-EN REV. A 13

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Power supply and signal interfaces (legend)
 14

700 Gas sample probe not mounted!

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600

500

400

300

200

100

0
Retractor: Dimensions

1000

900

800

700

600

500
SCK SAMPLING SYSTEM | DS/SCK-EN REV. A

400

300

200

100

700 500 2500 300

4500 1) / 5500 2)

1) Length for 2.5 m retractor for probes 1.5 m, 2.0 m and 2.5 m All dimensions in [mm]
2) Length for 3.5 m retractor for probes 3.0 m and 3.5 m
 SCK SAMPLING SYSTEM | DS/SCK-EN REV. A 15

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Cooling unit: Dimensions

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Control unit: Dimensions
RETRACTOR FOR MAX. 2.5m PROBE 10,000 N 10,000 N 10,000 N
16

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800 1500 1500 700

18
Ø

RETRACTOR FOR MAX. 3.5m PROBE

800 2000 2000 700

Retractor: Mounting

MOUNTING RETRACTOR

5-30 °

18
Ø
Mounting pipe
Heat resistant steel
Dim. 219.10 x 6.30 mm
Length = 1 to 1.5 m
(supply by customer)
SCK SAMPLING SYSTEM | DS/SCK-EN REV. A

R1
40

Counterflange Ø 320 mm
acc. EN 2573, DN 200, PN6

bolt circle 280 mm

(supply by customer)

All dimensions in [mm]

8x 18
 SCK SAMPLING SYSTEM | DS/SCK-EN REV. A 17

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Cooling unit: Mounting
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Control unit: Mounting
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ABB Automation GmbH
Measurement & Analytics
Stierstädter Str. 5
60488 Frankfurt am Main
Germany
E-mail: cga@[Link]

[Link]/analytical
DS/SCK-EN Rev. A 03.2019

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We reserve the right to make technical changes or modify the contents of this document
without prior notice. With regard to purchase orders, the agreed particulars shall prevail.
ABB does not accept any responsibility whatsoever for potential errors or possible lack of
information in this document.
We reserve all rights in this document and in the subject matter and illustrations contained
therein. Any reproduction, disclosure to third parties or utilization of its contents – in whole
or in parts – is forbidden without prior written consent of ABB.

© Copyright 2019 ABB 3KXG141003R1001