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ProKiln GAC400

PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A

Example 2: Maintenance Request menu - overview table

Maintenance request - Error

Probable Cause

Measures

T01 Probe Heat TAH

Probe sample tube heating temperature high

Check process and water temperature

T01 Probe Heat TAL

Probe sample tube heating temperature low

Check process and water temperature

T02 Heated hose TAH

Heated hose temperature high

Check heated hose connection and hose for damages

T02 Heated hose TAL

Heated hose temperature low

Check heated hose connection and hose for damages

T03 Heated valve TAH (Option)

Heated valve temperature high

Check heated valve connection and hose for damages

T03 Heated valve TAL (Option)

Heated valve temperature low

Check heated valve connection and hose for damages

T10 Water tank TAL

Water tank temperature low

Check process and ambient temperature and if anti-freeze has
been added

L11 Water tank LAL

Water tank level low

Check refill valve of potable water to the tank

F12 Water flow FAL

Water flow low

Check water system for leakages and lime deposits

T01 Ai Error

Probe sample tube temperature sensor error

Check cable connection

T02 Ai Error

Heated hose temperature sensor error

Check cable connection

T03 Ai Error

Heated valve temperature sensor error

Check cable connection

T10 Ai Error

Water tank temperature sensor error

Check cable connection

T11 Ai Error

Water temperature forward temperature sensor error

Check cable connection

T12 Ai Error

Water temperature return temperature sensor error

Check cable connection

F12 Ai Error

Flow sensor error

Check cable connection

-1S3 Main supply

General power OFF

Check Main switch -1S3 in control cabinet

-35Q3 Fuse M1 motor

Power supply for frequency drive

Check circuit breaker -35Q3 in control cabinet

-35Q19 fuse M1 Break

Power supply for M1 Motor break

Check circuit breaker -35Q19 in control cabinet

-10T8 24V CC

Fuse for control cabinet 24VDC

Check fuse -10T8 in control cabinet

-10T2 24V Emergency stop

Fuse for emergency power 24VDC

Check fuse -10T2 in control cabinet

-10T14 24V Retractor

Fuse for retractor power 24VDC

Check fuse -10T14 in control cabinet

-11T12 24V PC

Fuse for probe cooling power 24VDC

Check fuse -11T12 in control cabinet

-50S15 Service Mode

Switch for Service/Operation Mode

Shift to Operation mode

-45Q3 H1 fuse

Power supply for Probe heating

Check circuit breaker -45Q3 in control cabinet

-46Q3 H2 fuse

Power supply for Heated hose

Check circuit breaker -46Q3 in control cabinet

-47Q3 H3 fuse

Power supply for Heated valve

Check circuit breaker -47Q3 in control cabinet

-101S2 M1 safety switch

Switch for Probe Safety ON/OFF

Shift to ON

-152F3 M20 fuse

Power supply for Heat Exchanger Fan M20

Check circuit breaker -152F3 in Water cooling control cabinet

-153F3 M21 fuse

Power supply for Heat Exchanger Fan M21

Check circuit breaker -153F3 in Water cooling control cabinet

-154Q3 H10 fuse

Power supply for Water Tank Heat H10 (Option)

Check circuit breaker -154Q3 in Water cooling control cabinet

Содержание ProKiln GAC400

Страница 1: ...vironment of a cement plant The ProKiln sampling system is preferably combined with ABB s AO2000 System However the ProKiln sampling system is built to be self supporting which allows it to easily be...

Страница 2: ...ample gas line to the retractor 50 7 Electrical connections 51 Safety instructions 51 Connecting internal electric cables 51 Connecting external electric cables 54 8 Commissioning 56 Safety instructio...

Страница 3: ...rmation in this document can lead to a risk of damage to property injuries or even death In order to ensure safety all personnel handling the probe gas sampling system must have read and understood th...

Страница 4: ...e product may only be performed if expressly permitted by these instructions Information and symbols on the product must be observed These may not be removed and must be fully legible at all times The...

Страница 5: ...les These rules are intended for all persons handling the probe gas sampling system in any situation Purpose of these rules The purpose of these rules is to ensure that all persons handling the probe...

Страница 6: ...cumstances If cooling water tubes or compressed air tubes burst shut down the probe gas sampling system and secure it against being switched on again If errors are detected shut down the system and se...

Страница 7: ...the retractor or probe Do not enter the danger area around the retractor until it is at standstill and the warning lamps and buzzer are off Never stand in the danger area around the retractor when th...

Страница 8: ...spiratory protection against toxic gases Keep the time in which the duct opening is open as short as possible Hot cooling water During operation of the probe gas sampling system the cooling water in t...

Страница 9: ...ressed air tubes with no additional connector Associated warning sign in this operating instruction WARNING Pressurized system dangers Risk of injury in the area of the probe gas sampling system due t...

Страница 10: ...on The protective installations must not be disabled and must be checked for proper functioning at regular intervals The illustration below shows the location of the protective installations on the pr...

Страница 11: ...ck ensures that the duct opening is reliably closed when working near the duct opening Protective fence installation with electric lock access Location Protective fence installation with electric lock...

Страница 12: ...echanical expert Electrical maintenance personnel On mechanical parts Maintenance Troubleshooting Maintenance Shutting down Electrical expert With experience with controllers Storage personnel Correct...

Страница 13: ...rams etc to protect the product the network its system and the interface against any kind of security breaches unauthorized access interference intrusion leakage and or theft of data or information AB...

Страница 14: ...r conditioning of the analysis gas takes place in external equipment not part of the probe sampling system The following figure shows a general overview of the ProKiln GAC400 probe gas sampling system...

Страница 15: ...sampling system will run the sequence of gas sampling and probe cleaning based on set intervals 10 The probe gas sampling system will run the sequence of moving the probe in and out of the process bas...

Страница 16: ...Dr in F a 1 a6 a5 V5 1 ptional o V5 2 tional op Pos 1 Pos 0 V5 3 tional op P t urge Ven V6 Included comp air connect o p ints i n o a1 1 alv pipe connect on F g i a2 1 hose stu connection b a3 1 hose...

Страница 17: ...rature measurement Is part of monitoring the process heat input to the probe Protects the probe against overheating Is used as base temperature for process heat input T12 Probe cooling water flow out...

Страница 18: ...explained in the Description of the controller section 2 Emergency reset Reset of Emergency Stop after it has been released Indication that Emergency Stop is pushed Blue constant Indication that Emer...

Страница 19: ...downstream Heating function prevents condensation from building up 7 Heated connection box for external heated hose Connection point for heated hose leading to external gas analysis system Heating fun...

Страница 20: ...robe is in manual operation 4 Safety breaker Safety breaker for probe motor When off the main power to the motor is off and the probe is not able to move Flange Shutter To protect people and equipment...

Страница 21: ...Connects the periphery filter cleaning nozzle to one air blaster for powerful cleaning of filter sample area 6 Water cooling forward Connects the probe to the cooling panel 7 Water cooling return Con...

Страница 22: ...probe are removed by regularly moving the probe in and out using the retractor Cleaning the probe intake hole by means of centre tube nozzle connected to air blaster Incrustations on the intake hole...

Страница 23: ...parameters Water pump operation Water tank temperature Water tank water levels Cooling water flow rate Figure 8 Water panel Pos Component Function 1 Water pump Re circulate the cooling water 2 Tempera...

Страница 24: ...the actual flow which has been cooling the probe Monitoring is performed on the HMI on the control cabinet Requirements for the water supply The water supply must meet the following minimum requiremen...

Страница 25: ...the tip of the probe The compressed air system also serves to operate the optional flange shutter Requirements The compressed air must meet the following minimum requirements Category Requirement Dew...

Страница 26: ...access the control system operators will use the Human Machine Interface HMI located on the front of the control cabinet If the ProKiln GAC400 is connected to an ABB AO2000 System gas analysis system...

Страница 27: ...ervice mode Alarm status lights and sound tower Figure 14 Alarm status lights and sound tower Indication Function Meaning Green Flashing light Retractor is locked in safe position Green Constant light...

Страница 28: ...nd pressure release if available 2 Pressure alarm Alarm for low compressed air pressure 3 Ball valve Compressed air supply User interfaces Operation screen The figure below shows a typical operation s...

Страница 29: ...es Access permissions Setup for system optimization limits etc Edit tolerance ranges Network settings PID Setpoints Critical setpoints of alarms etc Important information about passwords Level 2 and 3...

Страница 30: ...for hysteresis control of water cooler fan 75 C 167 F Stop Stop temperature for hysteresis control of water cooler fan 70 C 158 F Flow See Parameter input Alarm setpoint menu on page 33 for alarm limi...

Страница 31: ...line length on site 30 sec V5 2 sample gas valve optional Open heated sample shut off valve to allow process gas to flow to gas analysis system downstream if available Not configurable Cleaning menu...

Страница 32: ...move 60 sec Parameter input PID H1 Probe heater Setup menu Figure 26 PID H1 Probe heater Setup menu Parameter input Function Default value Setp Temperature set point of sample tube inside of the prob...

Страница 33: ...ance request 150 C T03 TAH Heated shut off valve temperature high maintenance request 190 C T03 TAL Heated shut off valve temperature low maintenance request 150 C T10 TAHH Water tank temperature high...

Страница 34: ...ower supply electrical connections 7 CE mark 8 Warning triangle acc to EN 61010 observe instructions 9 European Union WEEE sign do not throw in trash Figure 30 Nameplate example Note Products that are...

Страница 35: ...rminals and main switch frequency converter wiring Warns about hot surfaces A risk of hot surfaces can be expected during operation Particular danger areas are all cooling water tubes water panel cool...

Страница 36: ...y appropriately trained personnel may transport the transport units and only with the aid of the recommended transport equipment Do not stand under suspended loads Follow the transport instructions in...

Страница 37: ...e The unpacked retractor must not be transported using a fork lift truck Cooling unit 350 kg Only store after draining all water Lifting gear may only be attached at the designated lifting points 1 se...

Страница 38: ...term max 95 occasional slight condensation is permitted Unpacking the system Instructions Perform the following steps to unpack the system 1 Remove outer packaging Transport crate Tensioning straps Ca...

Страница 39: ...of the attachments Only store after draining all water out of the internal tubes Environmental conditions Observe the following physical limits with regards to storing the various modules Module Envi...

Страница 40: ...ng and respiratory protection against toxic gases Keep the time in which the duct opening is open as short as possible Introduction This section contains a list of tasks to be performed when installin...

Страница 41: ...n or dust influx must be present Choosing the place of installation of the control cabinet Position to set up the cooling module defined No direct heat radiation or dust influx must be present Choosin...

Страница 42: ...lations 3 Lift probe retractor together with flange shutter and position in front of insertion tube flange of the kiln wall Remove the two mounted transport legs Note Store the transport legs for any...

Страница 43: ...a tool in case the probe needs to be removed from the buggy for maintenance activities 1 Retractor buggy lock 2 Probe transportation support Figure 37 Retractor buggy lock and probe transportation su...

Страница 44: ...legs Remove after installation Figure 38 How to lift the probe Lifting instructions Use only the included crane shackles for lifting Weight 1200 kg Note Figure 38 is shown without flange shutter to b...

Страница 45: ...5 Installation flanges points on the retractor flange shutter 1 Process flange at the flange shutter 3 Matching flange ASME B16 5 Slip on Welding Class 150 2 Installation flanges 4 2 on each side Figu...

Страница 46: ...sed 7 ASME B16 5 Slip On Welding Flange Kiln center lineass 150 8 8 Install flange pipe to be welded to kiln foot wall 9 Installation flange pipe 8 0 Min kiln center line height 1200 mm 47 in k Max ki...

Страница 47: ...install flange Figure 41 Customer supplied install flange ASME B16 5 Slip On Welding Flange Class 150 8 1 Length of pipe to be determined on site 2 Pipe to be cut flush with inside kiln lining bricks...

Страница 48: ...sembly screws or bolts Installing the water system and cooling panel Screws required for assembly 4 4 galvanized steel screws or stainless material M16 or bolts M16 Requirements The following requirem...

Страница 49: ...doubt Only use hoses in areas where no heat or mechanical wear occurs 1 hoses between Water panel and Cooling panel are included for install next to each other If distance is larger than the length of...

Страница 50: ...d sample gas line through the side of the junction box and fix it with the supplied holder The figure below shows the heated junction box with cover left and without cover right Heated sample gas line...

Страница 51: ...the various modules can be found in the electrical connection plan enclosed inside the control cabinet when supplied All required internal lines are pre installed in the probe retractor Cooling panel...

Страница 52: ...iew A Power supply and cable connections between units B General power supply C Uninterruptible power supply UPS D Signals from Central Control Room Analysis system to the ProKiln system E System Stat...

Страница 53: ...fan motor 230 VAC cable to probe retractor for brake probe 230 VAC cable to the retractor unit heating 24 VDC cable for safety installations 24 VDC cable to the retractor unit ProfiNet bus cable from...

Страница 54: ...leads have an adequately dimensioned protective device circuit breaker General voltage requirements 230 400 VAC 10 50 Hz fuses 3 x 20 A required 3 phase connection 5 wires N conductor necessary or 230...

Страница 55: ...ce probe retracts out of the and flange shutter closes Protective installation 1 contact closed from device probe works normally Connection option for air cannon In order to prevent dangers caused by...

Страница 56: ...ress the EMERGENCY STOP switch immediately if anyone is still in the danger area around the retractor after the warning lamps light up or the warning buzzer buzzes WARNING Pressurized system dangers R...

Страница 57: ...ressed air switch in the pneumatic box Checking the pneumatic system on page 62 8 In the control cabinet check frequency drive has no alarm Checking correcting operating parameters on page 64 9 Check...

Страница 58: ...n the water tank top cover to a side to allow anti freeze to be filled in tank 4 Release approximately 33 of the water tank capacity 5 Add the 33 of anti freeze to the water tank 6 Close the water tan...

Страница 59: ...occurs anywhere and close the covers Activation of the probe gas sampling system Requirements The connected gas analyser system must be switched on Observe the warm up time of the gas analyser system...

Страница 60: ...s sampling system on the side of the control cabinet 2 General power supply 3 UPS power supply Figure 48 Control cabinet retractor system electrical cabinet 3 Turn on the power supply for the water sy...

Страница 61: ...page 62 Starting frequency converter and adapting control parameters on page 63 Checking correcting operating parameters on page 64 Power breakers in the control cabinet The illustration below shows t...

Страница 62: ...Note Wait until the temperature of the cooling water is below 40 C Before starting to work on the system Figure 51 Water system 3 After work is completed check of any leakages before returning the pro...

Страница 63: ...he retractor are used to define the various positions needed in order for the probe to enter the kiln in the most favourable way By selecting the Encoder Menu button a window will pop up with a warnin...

Страница 64: ...Proceed as follows 1 Check that the water flow in the water cooling system is correct see Default operation parameter settings on page 30 The rotor of the water pump must run according to arrow indica...

Страница 65: ...te system is ready to sample because the probe is equipped with internal electrical heating of the gas conducting tube 11 Switch the gas sampling probe to automatic mode using the HMI Home page Result...

Страница 66: ...bout to move at any moment Press the EMERGENCY STOP switch immediately if anyone is still in the danger area around the retractor after the warning lamps light up or the warning buzzer buzzes WARNING...

Страница 67: ...water gets in the eyes despite protective glasses rinse them thoroughly under cold running water holding the eyelids open Contact medical specialist according to local regulations Monitoring automati...

Страница 68: ...the analyser if the sample gas condenses in the sample gas tube part of the SO2 dissolves in the condensation which in turn decreases the SO2 concentration measured in the analyser In the above mentio...

Страница 69: ...case Calciner gas outlet Because of the greater flow speeds in this process after start up the gas sampling probe must be checked frequently for wear at the calciner gas outlet measuring point If dist...

Страница 70: ...off any adhering material then goes back to measuring position S3 The probe never leaves the insertion tube so as to prevent any dust to be blown outside of the process Clean in AUTOMATIC mode remote...

Страница 71: ...the probe buggy until the probe has reached its end position and the warning signal goes out Result The gas sampling probe is automatically retracted out of the kiln and enters Manual mode of operatio...

Страница 72: ...menu For an overview of access permissions in the various areas of the control system please refer to the section on Access permissions Navigation The user navigates the interface at the bottom of th...

Страница 73: ...oling water circuit Air bubbles in the cooling water circuit caused by too high temperature Check the water flow Check if piping has lime deposits limiting the flow Use lime removing liquid in tank se...

Страница 74: ...intenance Request yellow or Alarm menus red The illustration above shows the Menu page with error indication at the top right corner in this example there are no active alarms therefore the system is...

Страница 75: ...OFF Check water pump switch 150S3 on side of water system control cabinet Emergency Stop Emergency Stop button has been pushed and not released and reset Release Emergency switch and push Emergency re...

Страница 76: ...aintenance Request at the top right corner of the HMI plus a green OK indication showing that the system is still operating It can also be seen that the Alarm originates from a 101S2 safety switch as...

Страница 77: ...emperature forward temperature sensor error Check cable connection T12 Ai Error Water temperature return temperature sensor error Check cable connection F12 Ai Error Flow sensor error Check cable conn...

Страница 78: ...inal box to turn off before performing any corrective action Instructions Proceed as follows to handle any errors 1 Operation Service Mode 50S15 switch must be is in the Service Mode 2 Switch system t...

Страница 79: ...probe retractor and air blaster probe blow back 11 Insert gas sampling probe into the kiln Path Main Probe Position Go S3 WARNING Gas sampling probe moves into the kiln Do not stand in the area of tr...

Страница 80: ...f the probe gas sampling system no longer works after prolonged storage in adverse conditions after severe transport stress It is recommended to have the probe gas sampling system maintained by the AB...

Страница 81: ...m cleaning the system on page 102 X Display and evaluate trend display Evaluating trend displays on page 104 X Functional test of residual current circuit breaker Checking the residual current circuit...

Страница 82: ...just the position of the probe Probe retractor Checking and tightening the drive chain on page 117 X X Cooling system Maintenance task See Inspection Maintenance intervals As required Daily Weekly Twi...

Страница 83: ...cooling flow 2 Water return Water outlet for cooling flow 1 1 Probe core 1 2 Probe base 1 3 Inspection port centre air blaster connection 1 4 Flange seal adjustable 1 8 Probe tip filter cartridge and...

Страница 84: ...Reference Designation 1 Process flow direction 2 Sample connection heated sample tube connected to filter 3 Periphery air blaster 3 x tube connection to filter periphery air blaster 4 Filter blow bac...

Страница 85: ...ipe cooling 1 2 16 2 x pt100 sensor for water cooling temperatures 1 2 17 2 x O ring inner tube cooling jacket O ring OD72 ID84 6 Viton 1 2 18 1 x O ring middle tube water separator O ring OD96 ID88 4...

Страница 86: ...n and clean out entrance 1 3 1 x O ring for inspection port 1 3 1 Swagelok straight connector 3 4 SS 1210 1 12W BT 1 3 2 Swagelok tee welded 3 4 1 3 3 Dacapo DN20 union DJ10343000 1 3 4 Dacapo DN20 un...

Страница 87: ...nozzle for air blaster Equipment Reference Designation 1 8 1 1 8 2 1 8 3 Filter female thread front D46x25 Filter body D46 42x460 Filter female thread back D46x25 1 8 4 Center nozzle for air blaster...

Страница 88: ...retractor Equipment Reference Designation 1 Control cabinet retractor control components 2 Pneumatic cabinet valves and pressure switch 2 1 Center beam 2 2 Covers 2 3 Chain support low 2 4 Chain supp...

Страница 89: ...B 3 3 Support Probe 3 4 Buggy frame 3 5 Rail attachment 3 6 Wheel plate L_B 3 7 Wheel plate R_B 3 8 Buggy beam 3 9 Chain anker_B 3 10 Wheel protection_B 3 20 V track wheel 3 21 Conical bushing 3 22 Ex...

Страница 90: ...4 6 Blaster tank air supply with ball valves valves not shown in drawing 4 20 Accumulator tank 5L 2x 4 21 Lock handle 4 22 blinding plugs 2x 4 30 Filter blow back supply 4 31 Filter blow back 4 32 Fil...

Страница 91: ...1 Support Chain 5 2 Cable tray 5 3 Support front 5 4 Base cover 5 5 Connection base with 3 1 unions for compressed air and cooling water 5 7 Heated valve box option connection box to heated sample gas...

Страница 92: ...NG SYSTEM OI GAC400 EN REV A 11 Maintenance Equipment layout plan Illustration flange shutter automatic 293 202 300 250 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 9 6 10 6 14 6 11 6 12 6 8 6 13 6 17 6 20 6 30 6 12...

Страница 93: ...44 6 3 Shutter seal 6 4 Flange front cut 6 5 Flange front stear 6 6 Shutter sides 6 7 Shutter stear 6 8 shutter rail L 6 9 shutter rail R 6 10 Shutter connect 6 11 Shutter cyl lid 6 12 Front flange 6...

Страница 94: ...94 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM OI GAC400 EN REV A 11 Maintenance Equipment layout plan Illustration water system 3 4 5 2 1...

Страница 95: ...Water return 1 union for min 1 connection to probe 3 Water from cooler 1 hose connection to cooler 4 Control cabinet water system 5 Optional water heater 7 1 Lid water tank 7 10 Water pump 7 12 Level...

Страница 96: ...ayout plan Illustration cooling system Equipment Reference Designation 8 4 2 x Emergency stop fan motors 8 11 Water to water tank 1 hose connection to water tank 8 12 Water return from water system 8...

Страница 97: ...18 Controller CPU 25 Frequency drive for retractor motor 33 HMI panel for control 34 General and UPS power 36 Warning signal tower 37 Emergency stop 46 Connections to probe retractor and cooling panel...

Страница 98: ...ve equipment Closed overalls with long trousers and long sleeves Safety shoes preferably boots covering ankles Safety gloves suitable for mechanical work Safety glasses Protective helmet If necessary...

Страница 99: ...ch the hot probe wear a face mask against heat heat proof gloves and protective welder s clothing WARNING Harmful gases jet flames Danger due to harmful gases and jet flames in the area of the duct op...

Страница 100: ...ee Safety instructions for maintenance work on page 98 Introduction The service switch puts the system into service mode If work described in the following maintenance instructions must be performed i...

Страница 101: ...MERGENCY STOP switch and turn the Safety switch 101S2 at the probe rear cabinet to OFF 8 Push Emergency Reset button 15SB 15P12 at the front of the control cabinet to allow movement of the probe 9 Tur...

Страница 102: ...clean the duct opening when the rotary kiln is in operation Wear a face mask against heat heat proof gloves and protective welder s clothing and respiratory protection against toxic gases Keep the ti...

Страница 103: ...rails in the same way Also the energy chain containing hoses must be cleaned with compressed air 4 Check condition of drive chain with regard to the following chain tension chain link wear Correct Bug...

Страница 104: ...ust be stable above 90 l min The water cooling temperature return will change depending on process and if scaling or build up occurs on the probe 3 The Trend Heat Input menu will show how much heat is...

Страница 105: ...ystem will not record any process data apart from these Alarm and event log Data can only be transferred to ABB Service if the customer removes the USB stick and sends the files to ABB for service rev...

Страница 106: ...shutting down the kiln if possible as the test procedure disables all monitoring mechanisms If it is necessary to check during operation while the kiln is running the probe retractor must be located...

Страница 107: ...pling probe moves into the kiln Do not stand in the area of travel of the gas sampling probe or probe buggy until the probe is completely inserted into the kiln and the warning lamps sounds goes out 9...

Страница 108: ...uctions for maintenance work on page 98 Introduction Sample gas paths the compressed air system and cooling water circuit must be checked for leaks on a regular basis Maintenance interval twice yearly...

Страница 109: ...ed tool Follow instructions Probe Replacing the intake filter on page 115 6 Clean the surfaces inside the probe sample inlet with a brush and a cloth making sure only minimum dust is left 7 Insert inc...

Страница 110: ...peration Mode Instructions checking the compressed air system How to check the cooling water circuit for leaks 1 Operation Service Mode 50S15 switch must be in the Service Mode 2 Switch system to manu...

Страница 111: ...em to manual mode on the HMI if this has not already been done Path Home Manual 3 Retract gas sampling probe out of the kiln Path Menu Probe Position GO S0 WARNING The probe moves out of the kiln Do n...

Страница 112: ...system to Auto mode on the HMI Path Home Auto 12 Operation Service Mode 50S15 switch must be switch back to Operation Mode Probe Removing incrustations Safety measures WARNING Dangers when performing...

Страница 113: ...aning 7 Cleaning inspection of center pipe Follow opening instructions for Inspection clean out through center pipe inspection port on page 114 Inspection of the center pipe can only be done while the...

Страница 114: ...1 in the back end of the probe 2 Remove cover 1 to access the center pipe inspection port 2 located at the end of the center pipe 3 Remove the flange of the center pipe inspection port 2 by unscrewin...

Страница 115: ...onditions must be met The probe is retracted to maintenance position S0 Safety switch probe 101S2 in OFF position to prevent any movement of the probe see Safety instructions for maintenance work on p...

Страница 116: ...it is not possible to clean anymore due to excessive clogging or if it looks damaged Part is available through ABB Service 10 Replace the filter sealing 2 with ceramic string 17cm shown below Use tap...

Страница 117: ...forming this work Wear a face mask against heat heat proof gloves and protective welder s clothing Operation Service Mode 50S15 switch must be in the Service Mode with a padlock Additionally press the...

Страница 118: ...u can pull it vertically approximately 0 5 1 cm by hand on the middle of the retractor unit 7 If the chain is too loose or if you can see wear on the chain support Increase tension with the chain tens...

Страница 119: ...should be maximum 30 cm inside the rotary kiln beyond the kiln seal after start up The gas sampling probe must not be inserted further than absolutely necessary into the rotary kiln in order to minimi...

Страница 120: ...r flange 2 on the flange shutter 1 Bolt 2 Counter flange Figure 56 Adjusting the probe flange 5 Adjusting the vertical position Release the support bolt 1 red supporting the probe to allow for adjustm...

Страница 121: ...the button Override S0 and S3 for manual operation of probe Use the push buttons Probe In 1 and Probe Out 2 on the retractor control cabinet to position the probe at the correct length of 200mm Use a...

Страница 122: ...eratures below 5 C add approximately 30 of anti freeze Anti freeze requirements If ambient temperatures below 5 C can be expected you must add anti freeze ABB recommends Glycol as anti freeze Anti fre...

Страница 123: ...water pump on the Water Cooling Pump ON OFF switch on the side of the water system control panel Let flow run for a few minutes 16 When completed stop the pump and remove all the liquid by releasing t...

Страница 124: ...eze with skin wash off the skin immediately with water and soap Contact medical specialist according to local regulations If cooling water or anti freeze gets in the eyes despite protective glasses ri...

Страница 125: ...e with national legislation 2 Remove hoses between water panel and cooler panel 23 Apply low pressure compressed air 1 bar to the heat exchanger top to force out water from the heat exchanger until no...

Страница 126: ...ation Preferably install or remove the probe when the rotary kiln is out of operation If you install or remove the probe when the rotary kiln is in operation Wear a face mask against heat heat proof g...

Страница 127: ...und they are not designed to support the complete weight of the probe and retractor Further procedure The following table shows further procedure If the system follow the following instructions is to...

Страница 128: ...as sampling system Unit HxWxL mm Weight kg Control unit 1000x800x300 75 Probe 400x4500x400 100 Retractor unit 400x4500x400 700 Water panel 1200x800x700 250 Cooling unit 1200x1700x900 300 Sound emissio...

Страница 129: ...ocuments Note All documentation declarations of conformity and certificates are available in ABB s download area www abb com analytical Trademarks PROFINET are registered trademarks of PROFIBUS PROFIN...

Страница 130: ...Company Address Contact person Telephone Fax Email Device details Type Serial no Reason for the return description of the defect Was this device used in conjunction with substances which pose a threa...

Страница 131: ...ProKiln GAC400 PROBE GAS SAMPLING SYSTEM OI GAC400 EN REV A 131 Notes...

Страница 132: ...out 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 docu...

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