Table Of Contents - ABB ProKiln GAC400 Operating Instruction

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

Table of contents

1 General ........................................................................ 3
About these operating instructions ...................................... 3
Notifying service ........................................................................ 3
2 Safety .......................................................................... 4
General information and instructions ................................... 4
Warnings ...................................................................................... 4
Intended use ............................................................................... 5
Improper use ............................................................................... 5
Basic safety rules ....................................................................... 5
Overview of dangers ................................................................. 7
Protective installations .......................................................... 10
Requirements to be met by personnel................................ 12
Personal safety equipment .................................................... 12
Warranty provisions ................................................................ 13
Cyber security disclaimer ....................................................... 13
Software downloads ............................................................... 13
Manufacturer's address ......................................................... 13
Service address ........................................................................ 13
3 Design and function ................................................ 14
Overview .................................................................................... 14
Mode of functioning and operation .................................... 15
Components ............................................................................. 18
Control system ......................................................................... 26
User interfaces ......................................................................... 28
Access permissions ................................................................. 28
Default operation parameter settings ............................... 30
4 Product identification ............................................ 34
Name plates .............................................................................. 34
Warning signs on the system ................................................ 34
5 Transport and storage ............................................ 36
Safety instructions .................................................................. 36
Transport ................................................................................... 36
Unpacking the system ............................................................ 38
Scope of delivery ...................................................................... 38
Storing the system .................................................................. 39
6 Installation .............................................................. 40
Safety instructions ................................................................. 40
Introduction ............................................................................. 40
Overview of instruction steps .............................................. 40
Checking site conditions........................................................ 41
Installing the probe retractor/flange shutter ................... 42
Installing the probe .................................................................44
Installing the compressed-air supply ..................................48
Installing the control cabinet ................................................48
Installing the water system and cooling panel .................48
Installing the heated sample 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 instructions.................................................................. 56
Overview of instruction steps ............................................... 57
Installation check ..................................................................... 57
Cooling water ........................................................................... 58
Air supply ................................................................................... 58
Activation of the probe gas sampling system.................. 59
Working on the cooling module ........................................... 62
Checking the pneumatic system ......................................... 62
Starting frequency converter and adapting control
parameters ............................................................................... 63
Checking/correcting operating parameters .................... 64
Inserting the probe and switching to automatic mode . 64
9 Operation ................................................................. 66
Safety instructions.................................................................. 66
Monitoring automatic mode ................................................ 67
Checking general condition .................................................. 69
Adapting the cleaning procedure of the probe ................ 69
Using the EMERGENCY-STOP switch .................................. 71
Human Machine Interface (HMI) ........................................... 71
10 Diagnosis / error messages ................................... 73
Automatic processes............................................................... 73
Irregularities and corrective action ...................................... 73
HMI error displays ................................................................... 74
Handling error messages ...................................................... 78
11 Maintenance ............................................................ 80
Introduction.............................................................................. 80
Maintenance schedule............................................................. 81
Equipment layout plan ........................................................... 83
Acquiring spare parts and wear parts ................................ 98
Safety instructions for maintenance work ........................ 98
Maintenance work ................................................................. 100
12 Decommissioning .................................................. 124
Safety instructions.................................................................124
Shutting down the system ...................................................124
13 Dismounting and disposal .................................... 126
Safety instructions................................................................. 126
Disassembling the system ................................................... 127
Disposing of the system ....................................................... 127
14 Specification .......................................................... 128
Dimensions and weights ...................................................... 128
Sound emissions .................................................................... 128
15 Additional documents ........................................... 129
16 Appendix .................................................................130
Return form ............................................................................ 130