Page 1 Introduction Additional Information ProKiln GAC400 The ProKiln sampling system is especially Additional documentation on ProKiln GAC400 is designed for analysis in hot cement flue gases available for download free of charge at with high content of dust and aggressive gas www.abb.com/analytical.
Page 2: Table Of Contents
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Table of contents Commissioning ............56 General ................ 3 Safety instructions..............56 About these operating instructions ........3 Overview of instruction steps ..........57 Notifying service ................ 3 Installation check ..............57 Safety ................
Page 3: General
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 1 General About these operating instructions Scope and purpose Liability These operating instructions apply to the ABB ProKiln GAC400 The manufacturer is not liable for damage and disruptions Probe gas sampling system for gas sampling at rotary cement resulting from a failure to observe these operating instructions kiln inlet, riser duct and calciner gas exit.
Page 4: Safety
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 2 Safety Warnings General information and instructions The warnings in these instructions are structured as follows: These instructions are an important part of the product and must be retained for future reference.
Page 5: Intended Use
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Intended use Basic safety rules Target group for these rules The probe gas sampling system is used to continuously monitor process gas in cement production: These rules are intended for all persons handling the probe gas •...
Page 6 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 2 Safety … Basic safety rules Operator's obligations towards personnel Procedure in the event of accidents The operator must ensure: The probe gas sampling system is designed and built in such a •...
Page 7: Overview Of Dangers
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Overview of dangers Introduction Electrical components The probe gas sampling system is designed such that the The probe gas sampling system contains electrical and live operator is protected against all dangers that can be reasonably components.
Page 8 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 2 Safety … Overview of dangers Hot surfaces Hot cooling water During operation of the probe gas sampling system surfaces and During operation of the probe gas sampling system, the cooling parts get hot.
Page 9 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Compressed-air in the pneumatic system The pneumatic system contains compressed-air. This means: • Danger of eye injuries if compressed-air escapes, e.g., if compressed-air tubes burst, when opening screw connections or inadvertently opening compressed-air tubes with no additional connector.
Page 10: Protective Installations
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 2 Safety Protective installations Introduction The probe gas sampling system is fitted with protective installations to protect the operator. All protective installations must be in place and operational during operation. The protective installations must not be disabled and must be checked for proper functioning at regular intervals.
Page 11 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Flange shutter (optional) EMERGENCY-STOP switch Location Location On the duct opening of the rotary kiln • Rear end of the retractor • Right side of control cabinet Function • Protects from jet flames, hot material, and gases from Function the duct opening.
Page 12: Requirements To Be Met By Personnel
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 2 Safety Personal safety equipment Requirements to be met by personnel General protective equipment Personnel qualifications The following general protective equipment must be worn when Personnel handling the probe gas sampling system must meet...
Page 13: Warranty Provisions
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Warranty provisions Manufacturer’s address Using the device in a manner that does not fall within the scope ABB AG of its intended use, disregarding this manual, using Measurement & Analytics underqualified personnel, or making unauthorized alterations Stierstädter Str.
Page 14: Design And Function
Any further 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: Figure 2: ProKiln GAC400 probe gas sampling system The individual modules of the probe gas sampling system have the following functions: Pos.
Page 15: Mode Of Functioning And Operation
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Mode of functioning and operation Modes of functioning Modes of operation The following process takes place in order to sample gas during The following operating modes are possible: cement production:...
Page 16 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 3 Design and function … Mode of functioning and operation Monitoring devices W te panel op i t on Cu omer w er T T10 u ply 1" urge Ven .
Page 17 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A The process is monitored by the following devices (see Figure 3 for a detailed drawing): Monitoring Monitoring device Purpose Function position Cooling water flow measurements • Protects the probe against overheating •...
Page 18: Components
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 3 Design and function Components Control cabinet The control cabinet is the central control point of the sampling system. The electric power supply and signals for the entire sampling system are connected and distributed here.
Page 19 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Probe retractor The probe retractor moves the probe, which can be up to 3500 mm long. The movement is carried out by an electrical chain drive. The retractor is emergency-supported by uninterruptible power supply (UPS). It is recommended that the UPS is provided from the site according to local regulations.
Page 20 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 3 Design and function … Components Controls on the probe retractor There are additional controls on the retractor: Figure 6: Controls on the probe retractor Pos. Designation Function Warning tower •...
Page 21 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Probe The probe is used to continuously sample the gas from the process. Figure 7: Probe Pos. Component Function Sample tube Transports the sample gas through the probe to the gas outlet.
Page 22 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 3 Design and function … Components Cleaning Cleaning procedure Mode of functioning Cleaning of insertion tube into process Customer air blaster cleans the insertion tube and removes incrustations between probe and insertion tube...
Page 23 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Water Panel The probe is made from high temperature resistant steel but, because of the extreme high temperature of a kiln inlet, it needs a cooling system to sustain the operation.
Page 24 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 3 Design and function … Components Cooling water circuit regulation Water panel cabinet The open cooling-water circuit must be connected to a potable The figure below shows the water panel cabinet: water outlet (requirements: see Installing the water system and cooling panel on page 48).
Page 25 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Cooling panel Compressed-air system The probe cooling panel serves to cool the water supply. The The compressed-air is used for probe filter blow-back and air cooling panel contains the air-to-water heat exchanger. The...
Page 26: Control System
The control system of the ProKiln GAC400 has a layout based on distributed I/O configuration connected via ProfiNet to the various units. Each unit of the complete system (control cabinet, retractor, and water unit) contains distributed I/O’s that report...
Page 27 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Operational handles of the control cabinet 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...
Page 28: User Interfaces
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 3 Design and function … Control system User interfaces Operation screen The figure below shows a typical operation screen: Figure 16: Retractor system control cabinet Pos. Component Function Emergency Stop...
Page 29 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Hierarchy of access levels The password levels are divided as follows: Menu Level 0 Level 1 Level 2 – Level 3 Any viewer Plant maintenance team Trained specialists, ABB service technicians...
Page 30: Default Operation Parameter Settings
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 3 Design and function … Access permissions Default operation parameter settings By selecting ‘change password’ the following dialog will pop-up Parameter input cooling menu and a new password can be created.
Page 31 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Parameter input cleaning Sequence menu Parameter input Probe Position Setup menu Figure 23: Cleaning Sequence menu Figure 24: Probe Position Setup menu Parameter input Function Default value Parameter input Function...
Page 32 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 3 Design and function … Default operation parameter settings Parameter input M1 Motor Control menu Parameter input PID H2 Heated hose setup menu Figure 25: M1 Motor Control menu...
Page 33 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Parameter input Alarm setpoint menu Figure 29: Alarm setpoint menu Parameter input Function Default value T01 TAH Heated probe temperature high 200 °C maintenance request T01 TAL Heated probe temperature low 170 °C...
Page 34: Product Identification
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 4 Product identification Warning signs on the system Name plates Meaning of the warning signs Note Warning signs on the gas sampling probe warn about danger The name plates displayed are examples. The device areas.
Page 35 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Figure 34: Warning signs on the cooling unit The warning signs have the following meaning: Warning sign Meaning Warns about probe movements. Also means read manual. Retractor movement can be expected during operation. Do...
Page 36: Transport And Storage
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 5 Transport and storage Safety instructions Take into consideration the following safety instructions for all actions related to transport and storage: WARNING Mechanical, thermal and material dangers Risk of injury in the area of the probe gas sampling system due to moving or falling parts, anti-freeze, lubricating oil.
Page 37 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Transporting the modules Observe the following instructions with regards to transporting the modules: Module Weight Transport condition Retractor unit including 700 to 900 kg • The retractor is delivered with two temporary transportation legs. They are removed when assembled on the location.
Page 38: Unpacking The System
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 5 Transport and storage Unpacking the system … Transport Instructions Environmental conditions Perform the following steps to unpack the system: Observe the following physical limits when transporting the 1. Remove outer packaging: modules: •...
Page 39: Storing The System
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Storing the system General storage information Environmental conditions Store in a place protected from the weather. Observe the Observe the following physical limits with regards to storing the designated storage temperatures and humidity. The transport various modules: packing, if present, should not be removed during storage.
Page 40: Installation
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 6 Installation Introduction Safety instructions This section contains a list of tasks to be performed when Take into consideration the following safety instructions for all installing the probe gas sampling system. Links are given to the...
Page 41: Checking Site Conditions
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Checking site conditions The purpose of this task is to check whether the probe gas sampling system site is correctly prepared. Instructions How to check site conditions: 1. Using the checklist, check whether the site conditions for the various modules of the probe gas sampling system are fulfilled and that preparations for installation have been completed 2.
Page 42: Installing The Probe Retractor/Flange Shutter
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 6 Installation Installing the probe retractor/flange shutter Screws required for assembly 4 + 4 + 4 suspension bolts, diameter 16 mm, material round steel 4. Position probe retractor at the designated position and S235JR (St37) install appropriate support.
Page 43 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Adjustment of the retractor After completing all installation tasks and start-up, it may be 8. Remove retractor buggy lock (, Pos. and probe necessary to change the position of the probe to ensure precise transportation support (, Pos.
Page 44: Installing The Probe
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 6 Installation Installing the probe How to lift the probe F00711 1 Crane shackle point 1000 kg 2 Transport legs – Remove after installation Figure 38: How to lift the probe Lifting instructions Use only the included crane shackles for lifting.
Page 45 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 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...
Page 46 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 6 Installation … Installing the probe How to install the probe 5052 [199 in] F00712 Probe view from top Figure 40: Standard 3 m probe, shown with insertion flange / pipe * 1 Typical install area 0 Min.
Page 47 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Customer supplied install flange 26,92 42,93 F00751 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...
Page 48: Installing The Compressed-Air Supply
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 6 Installation Installing the water system and cooling Installing the compressed-air supply panel Requirements • A minimum 270 litres air tank must be connected to the Screws required for assembly probe gas sampling system.
Page 49 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Installing the cooling water hoses Cooling water tubes or hoses are not supplied together with the system and are to be sourced locally according to local regulations. Note the following recommendations when sourcing the tubes: •...
Page 50: Installing The Heated Sample Gas Line To The Retractor
180°C to connect the probe gas sampling system to the gas analyser system, such as model TBL01-S from ABB AG. Other models are possible to use, as long as they comply with pneumatic connection size, electric connections, power supply and temperature requirements.
Page 51: Electrical Connections
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 7 Electrical connections Connecting internal electric cables Safety instructions Position of the connections Take into consideration the following safety instructions for all actions related to electrical connections: The location of the electric connections on the various modules...
Page 52 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 7 Electrical connections … Connecting internal electric cables Overview D Signals from Central Control Room / Analysis system to the ProKiln A Power supply and cable connections between units...
Page 53 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Connect the internal electrical lines Requirements Proceed as follows to connect internal electric lines with all • See the electrical connection plan on page • Finalize all internal probe gas sampling system cable cables according to flammability acc.
Page 54: Connecting External Electric Cables
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 7 Electrical connections Connecting external electric cables Using the Ethernet interface The control unit, HMI and frequency controller of the probe gas UPS voltage requirements sampling system are equipped with Ethernet interfaces. These •...
Page 55 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Connection for protective installation The probe gas sampling system is fitted with an electric signal input that integrates an external protective installation to secure the danger area around the retractor. The protective installation should be supplied locally and could consist, as an example, of a door leading to the probe or a fence surrounding it.
Page 56: Commissioning
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 8 Commissioning Safety instructions WARNING Take into consideration the following safety instructions for all actions related to electrical connections: Pressurized system dangers Risk of injury in the area of the probe gas sampling system DANGER due to pressurized pneumatic system.
Page 57: Overview Of Instruction Steps
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Overview of instruction steps Installation check Proceed as follows to install the complete system: Introduction Check the installation for correct condition before start-up. The Step Procedure Detailed instructions in chapter following section describes this procedure.
Page 58: Cooling Water
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 8 Commissioning Air supply Cooling water Requirements Requirements The compressed-air must meet the following minimum The closed cooling-water circuit must be filled with requirements: approximately 350 l of potable water. The water is filled in the tank automatically by the re-fill valve on the side of the tank.
Page 59: Activation Of The Probe Gas Sampling System
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Activation of the probe gas sampling system Turning on compressed-air 1. Open the compressed-air main supply to the probe gas Requirements sampling system on valve V8 below the connection panel of •...
Page 60 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 8 Commissioning … Activation of the probe gas sampling system Switching on the probe gas sampling system 3. Turn on the power supply for the water system on the 1.
Page 61 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Power breakers in the control cabinet The illustration below shows the power breakers in the control 7. Reset all alarms and maintenance requests cabinet. Home page ►Alarm Reset Push the Emergency Stop Reset...
Page 62: Working On The Cooling Module
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 8 Commissioning Checking the pneumatic system Working on the cooling module Requirements Requirements The Operation/Service switch is in the Service position, the • The service switch is in the ON position, the gas sampling probe is retracted from the kiln.
Page 63: Starting Frequency Converter And Adapting Control Parameters
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Starting frequency converter and adapting control parameters Introduction The frequency converter ABB model ACS380 controls the To reset the encoder zero-calibration point S0 the probe must retractor motor. In order to ensure correct speed and be moved in manual mode to the “correct”...
Page 64: Checking/Correcting Operating Parameters
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 8 Commissioning Inserting the probe and switching to Checking/correcting operating automatic mode parameters Requirements Modifying the controller operating parameters The following conditions must be met: The probe gas sampling system control system has factory Turn the Safety switch to "Off”...
Page 65 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 9. Observe the following: • horizontal and vertical alignment of the gas sampling probe in relation to the opening in the mounting flange • stability of the probe retractor fastening elements •...
Page 66: Operation
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 9 Operation Safety instructions Take into consideration the following safety instructions for all actions related to operation: WARNING Pressurized system dangers DANGER Risk of injury in the area of the probe gas sampling system Danger to life due to live parts! due to pressurized pneumatic system.
Page 67: Monitoring Automatic Mode
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Monitoring automatic mode Introduction After starting up the probe gas sampling system and inserting CAUTION the probe manually you can switch it to automatic mode. Slippery floor Automatic mode allows continuous operation of the system for Risk of falling on slippery floor due to escaped or spilled sample gas sampling.
Page 68 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 9 Operation … Monitoring automatic mode Power failure Failure of the general mains power leads to immediate Maximum reliability of SO measurement is given, retraction of the gas sampling probe out of the kiln. After •...
Page 69: Checking General Condition
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Checking general condition Adapting the cleaning procedure of the probe Condition of the probe sampling system When the probe sampling system is in operation, monitor the Cleaning processes general condition of the system on a daily basis: You can start a cleaning process as follows: •...
Page 70 If an ABB AO2000-System is connected via Modbus RTU to the The heated sample shut-off valve opens to allow flow of measuring ProKiln GAC400, it will send a signal to the probe gas sampling gas towards the gas analysis system (if available)
Page 71: Using The Emergency-Stop Switch
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Using the EMERGENCY-STOP switch Human Machine Interface (HMI) Introduction Overview The EMERGENCY STOP switch is used to interrupt probe The Human Machine Interface (HMI) is the access point for movement and probe Air blaster cleaning immediately in the information and control of the probe gas sampling system.
Page 72 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 9 Operation … Human Machine Interface (HMI) Functions of HMI main menus The following table outlines the functions of the main menus: Menu Functions Home Front screen displays current measured values, basic information, and access to menu points Operation Operating functions for start-up, maintenance, etc.
Page 73: Diagnosis / Error Messages
Irregularities and corrective action Observation Possible cause Measures Untypical running noise Heat exchanger defective Motor M1 for retractor defective Inform internal maintenance department or ABB Service Whistling noise from compressed- Compressed-air system leak See Checking for leaks on page 108 air system Probe travel is jerky •...
Page 74: Hmi Error Displays
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 10 Diagnosis / error messages HMI error displays The HMI on the front of the control cabinet displays error status. Example 1: Alarm menu All error messages do not appear directly on the HMI's Home This example shows the Alarm menu.
Page 75 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Example 1: Alarm menu - overview table Alarm – Error Probable Cause Measures T10 Water tank TAHH Water tank temperature too high, cooler not able to remove Check heat exchanger panel and clean cooling surface...
Page 76 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 10 Diagnosis / error messages … HMI error displays Example 2: Maintenance Request menu This example shows the Maintenance Request menu. In this example there is an indication of a Yellow Maintenance Request at the top right corner of the HMI, plus a green OK indication showing that the system is still operating.
Page 77 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...
Page 78: Handling Error Messages
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 10 Diagnosis / error messages Handling error messages … HMI error displays Requirements Alarm History and Active Alarms In the event of an Alarm, the probe is automatically retracted out The HMI also provides the possibility to show a list of active of the kiln until the probe reaches its safe end position S0.
Page 79 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 9. Unlock EMERGENCY STOP switch -15S7 or -150S3 by turning the back ring in the direction of the arrow. No movement must be seen. 10. Push the blue button Emergency Reset -15SB/-15P12 to allow new operation of the probe retractor and air blaster probe blow-back.
Page 80: Maintenance
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 11 Maintenance Introduction This section gives an overview of maintenance work to be performed at regular intervals. The tasks described here require special training and under some circumstances involve working on control cabinet open and powered on.
Page 81: Maintenance Schedule
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Maintenance schedule The following tables show the maintenance intervals within which to perform maintenance work, with a link to the relevant instructions: General tasks Maintenance task See... Inspection / Maintenance intervals...
Page 82 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Maintenance schedule Retractor Maintenance task See... Inspection / Maintenance intervals If necessary, remove dust and debris around chain drive Probe retractor: Checking and tightening the drive chain on page 117...
Page 83: Equipment Layout Plan
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Equipment layout plan Illustration Probe n 190 2938 3418 1.20 1.19 Equipment Pos. Designation Water forward / Water inlet for cooling flow Water return / Water outlet for cooling flow...
Page 84 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Equipment layout plan Illustration sample end 2938 29,90 137,50 Equipment Reference Designation Process flow direction Sample connection (heated sample tube connected to filter) Periphery air blaster (3 x tube connection to filter periphery air...
Page 85 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Illustration probe base – water connection flange 1.2.15 1.2.16 1.2.20 1.2.3 1.2.1 1.2.1 1.2.18 1.2.19 1.2.17 1.2.4 1.2.16 1.2.3 1.2.4 Equipment Reference Designation 1.2.1 Probe base 1.2.3 Cover rail 1.2.4 Probe cover_B 1.2.15...
Page 86 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Equipment layout plan Illustration inspection port - center nozzle air blaster Equipment Reference Designation Inspection 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...
Page 87 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Illustration filter cartridge with center nozzle for air blaster Equipment Reference Designation 1.8.1 Filter female thread, front (D46x25) 1.8.2 Filter body (D46/42x460) 1.8.3 Filter female thread, back (D46x25) 1.8.4 Center nozzle for air blaster (D46x70) 1.8.5...
Page 88 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Equipment layout plan Illustration retractor Equipment Reference Designation Control cabinet / retractor control components Pneumatic cabinet / valves and pressure switch Center beam Covers Chain support low...
Page 89 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Illustration buggy 3.20 3.10 3.10 3.20 3.22 3.21 3.20 3.20 Equipment Reference Designation Base plate Frame top_B Support Probe Buggy frame Rail attachment Wheel plate L_B Wheel plate R_B Buggy beam Chain anker_B 3.10...
Page 90 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Equipment layout plan Illustration blaster panel 01 4.33 4.31 4.35 4.30 4.32 4.34 4.20 4.21 4.20 4.20 4.20 4.22 4.21 Equipment Reference Designation Blaster panel base...
Page 91 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Illustration blaster panel 02 5.30 5.20 5.20 5.30 Equipment Reference Designation Support Chain Cable tray Support front Base cover Connection base with 3 × 1″ unions for compressed air and...
Page 92 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Equipment layout plan Illustration flange shutter - automatic 6.11 6.21 6.10 6.17 6.17 6.13 6.20 6.12 6.20 6.30 6.12 6.11 6.14 6.10...
Page 93 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Equipment Reference Designation Pipe 6" Sch 10S x 350 EN 10025-2 Shutter flange ASME B16.5, slip-on welding, Class 150 8″ EN 1.0044 Shutter seal Flange front cut Flange front stear...
Page 94 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Equipment layout plan Illustration water system...
Page 95 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Equipment Reference Designation Water forward / 1” union for min. 1” connection to probe Water return / 1” union for min. 1” connection to probe Water from cooler / 1” hose connection to cooler...
Page 96 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Equipment layout plan Illustration cooling system 8.11 8.12 8.21 8.20 8.22 1400 Equipment Reference Designation 2 x Emergency stop fan motors 8.11 Water to water tank (1” hose connection to water tank) 8.12...
Page 97 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Illustration control system 1088 Equipment Reference Designation Controller CPU Frequency drive for retractor motor HMI panel for control General and UPS power Warning signal tower Emergency stop Connections to probe retractor and cooling panel...
Page 98: Acquiring Spare Parts And Wear Parts
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance Safety instructions for maintenance work Acquiring spare parts and wear parts Take into consideration the following safety instructions for all To order spare parts or to order service, please contact your...
Page 99 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A WARNING CAUTION Heavy transport units Hot cooling water Danger of crushing when lifting or lowering the transport unit Danger of injury to skin and eyes in the event of contact with •...
Page 100: Maintenance Work
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance Maintenance work Operating the service switch Instructions How to put the system in service mode: Safety measures 1. Make sure that no-one is standing in the area of probe WARNING retractor travel.
Page 101 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 5. Perform maintenance tasks as required, always observing the operation manual. 6. Leave danger area around the retractor and close the protective installation. Check surroundings and make sure that no-one is standing in the area of probe travel before proceeding with next step.
Page 102: Checking The Condition Of The System, Cleaning The System
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Maintenance work Checking the condition of the system, cleaning the system Safety measures WARNING WARNING Dangers when checking the condition of the system or Dangers when checking the duct opening.
Page 103 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Requirements The following conditions must be met: 5. Check air blaster tanks for visible damage or leakage • The Service Mode switch is in the Service position, the gas 6. Check probe tube for signs of wear, e.g., polished metal sampling probe is completely retracted from the kiln (see surfaces.
Page 104: Evaluating Trend Displays
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Maintenance work Evaluating trend displays Introduction 3. The Trend Heat Input menu will show how much heat is going Irregularities of cooling-water rate and cooling-water into the probe. This is done by measuring the temperature temperature may indicate various errors.
Page 105: Checking The Residual Current Circuit Breaker
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 review. The customer has full control of the data and must allow it to be transferred to ABB.
Page 106: Checking Protective Installations
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Maintenance work Checking protective installations Safety measures WARNING Dangers when checking protective installations. Always take the following safety measures when performing this work: • Wear the general protective equipment.
Page 107 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Instructions: checking warning lamps and sound buzzer Perform the following steps to check warning lamps -51P15 4. While the probe is still moving and approximately one meter Buzzer, -51P11 White, -50P9 Red, -50P6 Yellow, -50P3 Green before reaching from the rear end position (S0): Press 1.
Page 108 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Maintenance work Checking for leaks Required tools Safety measures The following tools are required: WARNING For checking the compressed-air system and cooling-water Dangers when performing maintenance work.
Page 109 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Instructions: checking sample gas paths The following procedure only works if your gas analyser system 8. Open the heated sample shut-off valve V5.2 (if available) in is NOT equipped with an air-driven vacuum pump the HMI panel.
Page 110 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Maintenance work 15. After successful test: Instructions: checking the compressed-air system • Remove silicone plug and 2-3 m hose. How to check the cooling-water circuit for leaks: •...
Page 111 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Instructions: checking the cooling water circuit How to check the cooling-water circuit for leaks: 8. Push the blue button Emergency Reset -15SB/-15P12 to allow 1. Operation/Service Mode -50S15 switch must be is in the...
Page 112: Probe: Removing Incrustations
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Maintenance work 6. Sight-check the cooling-water circuit. Probe: Removing incrustations • You locate a leak, replace component and/or ensure Safety measures adequate sealing WARNING 7. Switch ON the water pump M10 at the Probe cooling switch - Dangers when performing maintenance work.
Page 113 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Instructions 1. Operation/Service Mode -50S15 switch must be in the 7. Cleaning/inspection of center pipe: Service Mode Follow opening instructions for Inspection/clean-out 2. Switch system to manual mode on the HMI (if this has not through center pipe inspection port on page 114.
Page 114 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Maintenance work Inspection/clean-out through center pipe inspection port 1. The center pipe inspection port is hidden under the probe 3. Remove the flange of the center pipe inspection port cover #1 in the back end of the probe.
Page 115: Probe: Replacing The Intake Filter
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Probe: Replacing the intake filter Instructions For extensive work on the probe tip (e.g., when replacing the Safety measures filter), maintenance position S0 provides sufficient working WARNING space. Refer to illustrations below for guidance while following Dangers when performing maintenance work.
Page 116 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Maintenance work 4. When working on the retractor and gas sampling probe, additionally actuate the EMERGENCY-STOP -15S7 or -150S3 10. Replace the filter sealing with ceramic string 17cm shown switch for reasons of safety and turn the Safety switch - below.
Page 117: Probe Retractor: Checking And Tightening The Drive Chain
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Probe retractor: Checking and tightening the drive chain Safety measures 18. Unlock EMERGENCY STOP switch -15S7 or -150S3 by turning the back ring in the direction of the arrow. No movement WARNING must be seen.
Page 118: Instructions
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Maintenance work Instructions How to check drive tension: 7. If the chain is too loose or if you can see wear on the chain 1. Operation/Service Mode -50S15 switch must be in the...
Page 119 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Probe retractor: Checking and adjusting the position of Instructions: checking the probe tip position and insertion the probe depth Due to changes entailed by the process or the system, it may be Safety measures necessary to change the position of the gas sampling probe.
Page 120 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Maintenance work Instructions: checking probe vertical and horizontal position How to check probe position: 5. Adjusting the vertical position: 1. Turn the Safety switch -101S2 at the probe rear cabinet to •...
Page 121 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Instructions: checking probe position and retractor movement How to check probe position: 5. Push the Encoder Menu button on the Probe Position setup 1. Operation/Service Mode -50S15 switch must be in the...
Page 122: Instructions
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A … 11 Maintenance … Maintenance work Anti-freeze requirements Cooling module: Checking cooling water If ambient temperatures below 5 °C can be expected, you must Safety measures add anti-freeze. ABB recommends Glycol as anti-freeze. Anti- WARNING freeze with anti-corrosive additive is not permitted.
Page 123 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 10. Stop the water pump on the Water-Cooling Pump ON/OFF 20. Insert gas sampling probe into the kiln. Path: Main ► Probe Position ► Go S3 switch on the side of the water system control panel and WARNING! Gas sampling probe moves into the kiln.
Page 124: Decommissioning
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 12 Decommissioning Safety instructions Shutting down the system Take into consideration the following safety instructions for all Introduction actions related to disassembling: These instructions describe how to shut down the gas sampling probe.
Page 125 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Instructions: Draining cooling water Proceed as follows to drain the cooling water: 1. Open the valve at the bottom of the water tank to drain the water system. Note: If anti-freeze (Glycol) had been mixed, observe disposal regulations in accordance with national legislation.
Page 126: Dismounting And Disposal
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 13 Dismounting and disposal Safety instructions CAUTION Take into consideration the following safety instructions for all actions related to dismounting and disposal: Harmful dusts Danger due to harmful dusts when cleaning the probe gas...
Page 127: Disassembling The System
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Disassembling the system Requirements Further procedure The following conditions must be met to disassemble the The following table shows further procedure: system: If the system ... follow the following instructions: •...
Page 128: Specification
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 14 Specification Note The device data sheet is available in the ABB download area at www.abb.com/analytical. Dimensions and weights The following table lists the dimensions and weights of the main...
Page 129: Additional Documents
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 15 Additional documents 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 & PROFINET International (PI) Windows is a registered trademark of Microsoft Corporation.
Page 130: Appendix
ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A 16 Appendix Return form Statement on the contamination of devices and components Repair and/or maintenance work will only be performed on devices and components if a statement form has been completed and submitted.
Page 131 ProKiln GAC400 PROBE GAS SAMPLING SYSTEM | OI/GAC400-EN REV. A Notes...
Page 132 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. © ABB 2023...

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