Parker Ash Probe User Manual

Portable Ash Instrument Analyser
Ash Probe & AshGraffix

User Manual - Overview
VERSION HISTORY
Issue Date Author Changes

1.00 January 2017 Kevin Corcoran First publication
DISCLAIMER
This document is provided “as is” without any representations or warranties, express or implied. Parker Hannifin
Manufacturing Limited makes no representations or warranties in relation to this User Guide or the information and
materials provided herein. Although we make a reasonable effort to include accurate and up to date information,
Parker Hannifin Manufacturing Limited does not warrant that the information in this User Guide is complete, true,
accurate or non-misleading.
The contents of this document shall not be copied, disclosed, or utilised without the written permission of Parker
Hannifin Manufacturing Limited.
TRADEMARK ACKNOWLEDGEMENTS
Microsoft®, Windows® and Excel® are registered trademarks of Microsoft Corporation in the United States and other
countries.
Bretby Gammatech
Parker Hannifin Manufacturing Limited Tel: +44 (0)114 224 0000
Instrumentation Products Division Europe Email: info@bretbygammatech.com
President Park, President Way Web: www.parker.com/ipd
Sheffield, S4 7UR
United Kingdom
Ash Probe & AshGraffix Overview 2 Issue 1.00

CONTENTS
VERSION HISTORY 2
DISCLAIMER 2
TRADEMARK ACKNOWLEDGEMENTS 2
CONTENTS 3
1 INTRODUCTION 5
1.1 MANUAL FORMAT 5
2 DESCRIPTION, MAINTENANCE AND OPERATION 6
2.1 EQUIPMENT DESCRIPTION 6
2.1.1 PROBE 6
2.1.2 ASHGRAFFIX DISPLAY UNIT 6
2.1.3 DISPLAY UNIT BATTERY CHARGER 6
2.1.4 ASH PROBE/DISPLAY UNIT CABLE 7
2.1.5 DATA DOWNLOAD CABLE 7
2.1.6 ASH PROBE UTILITY SOFTWARE 7
2.1.7 CALIBRATION SAMPLES GATHERING EQUIPMENT 7
2.1.8 OPERATOR’S MANUALS 7
2.2 CARE AND MAINTENANCE 8
2.2.1 PROBE 8
2.2.2 ASHGRAFFIX DISPLAY UNIT 8
2.2.3 FAULT FINDING 8
2.3 GENERAL PRINCIPLES OF OPERATION 9
2.4 CALIBRATION PROCEDURE 10
2.4.1 USING THE CALIBRATION SLEEVE 10
3 DISPLAY UNIT OPERATION 12

3.1 OVERVIEW 12
3.2 HOME SCREEN DISPLAY 13
3.3 PROBE READING MAIN SCREEN 15
3.4 MODES OF OPERATION 15
3.4.1 PILES MODE 15
3.4.2 TRUCKS MODE 16
3.5 TAKING READINGS IN PILES MODE 16
3.5.1 INSERTING THE PROBE 17
3.5.2 TAKING THE READING 18
3.6 TAKING READINGS IN TRUCKS MODE 19
3.6.1 SETTING UP A NEW TRUCK RECORD 20
3.6.2 INSERTING THE PROBE 20
3.6.3 TAKING THE READINGS 21
3.7 DATA DISPLAY 23
3.7.1 PILE/TRUCK 23
3.7.2 MENU 24
3.7.2.1 Save/Export Data 24
3.7.2.2 Show Data for All Piles 24
3.7.2.3 Show Samples for Current Pile 25
3.8 EXPORT DATA 26
3.9 PROGRAM MENU 27
4 ASH PROBE UTILITY SOFTWARE 29
4.1 PROGRAM DESCRIPTION 29
4.2 PC REQUIREMENTS 29

1 INTRODUCTION
The Ash Probe is a portable device simple to use device for measuring the ash content of coal in the field, whether it
be piles of coals or delivery trucks. It measures the natural gamma radiation produced by the impurities that form
the ash content and once suitably calibrated to the coal sources being measured, can determine the accuracy of the
ash content to 1% or better.
The Bretby Gammatech Ash Probe has been a world leader in portable coal quality monitoring for over 10 years,
with the unit accepted around the world as a standard in its field. The new version, incorporating the AshGraffix
display unit, follows on from that success and gives the unit a modern, multi-lingual, touch screen interface, making
the unit simpler to use and more feature rich, whilst still retaining the fundamental qualities of accurate ash content
measurement from its predecessor.
1.1 MANUAL FORMAT
The manual is broken into five sections that covers all aspects of operation of the system.
Part 1 is this introduction to the manual
Part 2 describes the Ash Probe and AshGraffix, gives operational procedures and guidance on routine maintenance.
Part 3 provides guidance on the use of the AshGraffix Display Unit with details of the menu structure.
Part 4 provides details on how to download data from the AshGraffix onto a PC or configure the unit from a PC using
the companion Microsoft Windows application software.

2 DESCRIPTION, MAINTENANCE AND OPERATION
This section of the manual describes the individual piece of equipment that make up the Ash Probe and the relevant
maintenance and operation of those items.
2.1 EQUIPMENT DESCRIPTION
The Ash Probe system is comprised of the main battery powered AshGraffix display unit (from which the system is
controlled and results viewed), the actual probe used to be inserted into the coal piles and the cables used to
interconnect the two parts as well as connect to an external PC for data upload. Also include is a mains charger for
charging the display unit. The AshGraffix system can operate for over 8 hours typical operation on a full charge.
Other equipment is provided, as described below, to facilitate the calibration of the unit or provide optional
features.
2.1.1 PROBE
The probe consists of a stainless steel tube (53 mm diameter, 640 mm long) with a hard, anodised aluminium
pointed nose fitted at one end and an end cap of the same material fitted at the other end (a stainless steel nose
cone can be used where the coals are exceptionally hard and/or abrasive). Attached to the end cap is a LEMO six-
way socket for the connection of the cable from the display unit. Just below the end cap are two screwed bosses for
attachment of the handles to provide a grip for pushing the probe into coal piles.
Inside the stainless steel tube is housed a scintillation crystal/photo-multiplier tube (PMT) assembly and its
associated electronics. A carrying case is also provided for transportation and storage. The probe does not contain a
battery, as it is powered from the display unit. The total weight of the Probe is 2.9kg. The probe should be treated as
a delicate instrument, with extreme care being taken when in use, and always storing it in its carrying case when not
in use.
2.1.2 ASHGRAFFIX DISPLAY UNIT
The AshGraffix Display Unit is housed in a black metal case (220 mm x 168 mm x 55 mm), which has a protective
carrying case allowing the unit to be carried using the built in carrying strap. The main part of the console features a
7 inch high resolution TFT touch-screen display. On the side panel is a LEMO six-way socket for connection to the
probe, external PC or battery charger, a push-button switch with inbuilt LED indicator and also an industrial USB
socket to allow connection of a memory stick for data transfer.
The language of the text in the display unit can be selected from a list which currently includes: English, Spanish,
French, Polish, Russian, Turkish and Vietnamese. More languages can be added upon request.
2.1.3 DISPLAY UNIT BATTERY CHARGER
The Display Unit Battery Charger is a three stage plug-in unit for use on an 85 to 240-volt ac supply. It connects to
the LEMO connector on the side of the AshGraffix and takes approximately 4 hours to fully charge a unit from flat.
A bi-colour LED indicator on the charge indicates the state of the charging cycle. The meaning of the indicator
modes is explained on the front of the charger but the main indications are as follows:
 LED flashes slowly in yellow – pre-charge sequence

 LED flashes rapidly in green – rapid-charge sequence
 LED flashes slowly in green – main charging sequence

 LED fully on in green – charging complete
2.1.4 ASH PROBE/DISPLAY UNIT CABLE
The cable, which is normally 3 metres long, has a LEMO 6-way plug attached at each end. One plug is right angled for
connecting to the Display Unit while the other is straight for connecting to the probe. Cables of other lengths can be
supplied on request. Cold climate cables can also be supplied on request.
The wiring for the cable is shown in Appendix A of this guide.
2.1.5 DATA DOWNLOAD CABLE
The cable, which is 2 metres long, has a LEMO 6-way plug attached at one end, and a USB (type A) plug the other.
This cable is used to download data to a PC or allow remote configuration using the supplied Ash Probe Utility
software. A cable with a 9 way D type plug for direction connection to an RS232 serial port is also available as an
option.
The wiring for the RS232 serial cable is shown in Appendix A of the User Manual.
2.1.6 ASH PROBE UTILITY SOFTWARE
This Windows application software, supplied on a CD or memory stick (with associated manual), can be used to
download data from an Ash Probe display unit and save to disk file as a generic spreadsheet (Comma Separated
Values or CSV format) which can be read by most office applications. The software also allows the display unit
parameters and calibration data to be viewed and edited using the connected PC rather than the on-board touch-
screen interface.
2.1.7 CALIBRATION SAMPLES GATHERING EQUIPMENT
The equipment consists of a stainless steel tube (240 mm diameter by 600 mm long) with a row of serrated teeth on
one end and two screw-on handles at the other. The device is used to push into the coal in order to extract the coal
sample around the probe. A stainless steel scoop is also provided to remove the coal.
2.1.8 OPERATOR’S MANUALS
This manual and the associated Ash Probe Utility Software manual are supplied on CD along with the Ash Probe
Utility software application.

2.2 CARE AND MAINTENANCE
2.2.1 PROBE
IMPORTANT: The probe contains a very delicate crystal device which is easily damaged by physical impact. Great
care must be made not to drop or cause excessive vibration of the probe.
The crystal/photo-multiplier assembly and associated electronics are housed in a series of aluminium and mu-metal
joined up tubes. All the external surfaces of the assembly are covered with a 5mm layer of rubberised foam prior to
inserting in the stainless steel outer tube. The shock protection is necessary to safeguard the photo-multiplier tube,
which has a thin walled glass barrier mounted internally. For this reason, the ash probe should be treated as a
delicate instrument, with extreme care being taken when in use and always storing it in its carrying case when not in
use (which will offer some additional shock as well as thermal protection). Dropping the probe on a hard surface will
almost certainly result in serious damage. Also, never attempt to drive the probe into coal with a heavy object such
as a hammer. Hand pressure applied evenly to both handles should be the maximum force ever applied. If the coal is
compacted, use a spade to loosen it first. (Bretby Gammatech cannot be held responsible for any damage sustained
from improper use).
Before final assembly into the probe housing, the crystal/PMT assembly is temperature cycled between +35°C and -
10°C, to ensure that the unit can be used at temperatures within this range. Large temperature gradients however,
could be damaging to the crystal assembly and so should be avoided. In cold weather conditions, it is advisable to
store the probe in an unheated room to reduce the temperature difference when being used in a freezing cold coal
pile. Storing the probe in its carrying case when not in use will help to reduce the temperature gradients.
While in use, take care to ensure that dirt does not enter the LEMO connectors (on the probe and on the display
unit), and always wipe the probe to remove coal particles and moisture before storing in its case.
2.2.2 ASHGRAFFIX DISPLAY UNIT
As with the probe, the display unit should also be treated as a delicate instrument, although, the temperature
gradient restrictions on the probe do not apply.
The battery life of the display unit is displayed in a battery icon in the top right corner of the display as a percentage
figure. This is normally shown in green but will be shown in red as the percentage drops to 20% and below. At this
point the unit should be connected to the mains charger supply. To do this, insert the charger LEMO plug into the
LEMO socket on the console and connect the charger to the mains supply. A fully charged good condition battery
should give 8 to 10 hours typical operation. It is recommended that when not in use, the display unit be left on
charge. When not in use for extended periods, it is suggested that the battery be disconnected from the charger, but
that the unit is stored with the battery in a fully charged state.
2.2.3 FAULT FINDING
The display unit is equipped with a self-diagnostic function, which will attempt to determine which component if at
faulty in the event of a problem.
This involves using the Test Probe function, which will guide the user through the diagnostic process and determine
whether the problem lies with the probe itself (not producing counts of radiation), the cable (broken cable or short
circuit) or the display unit itself (faulty circuitry).
See section Error! Reference source not found. Test Probe of the User Manual for full details.

If a cable is deemed to be faulty, it may be worth using a resistance/continuity meter to check that each pin of the
LEMO connector on one end of the cable is connected to the corresponding pin on the LEMO connector at the other
enable of the cable. The meter can also be used to check that there are no connections between pins on one end
and adjacent pins (i.e. a short circuit in the cable).
2.3 GENERAL PRINCIPLES OF OPERATION
This section of the manual describes the main principles of using the Ash Probe and AshGraffix display unit. The
details of the functions and AshGraffix user interface are covered in detail in Section 3 of this document.
There are two different modes of operation of the AshGraffix; Piles Mode and Trucks Mode. The default Piles mode
is designed to be used when the probe is being used to measure large piles of coal and many samples are to be taken
from around a pile to determine the overall average ash content. The Trucks mode, however, operates slightly
differently and is designed to be used when trucks of coal are being delivered and when only a few samples from the
carried coal will be used to calculate the overall average ash content.
When preparing to insert the Ash Probe into a pile or a truckload of coal, either to determine the ash content of the
coal or to measure the gamma counts for a calibration, the same general rules apply. These are as follows:
 Where possible select a pile of coal of reasonable proportions, i.e. minimum 10 tons.
 Avoid places in a pile or truck that are adjacent to (within 0.5 metres) the truck sides, concrete or brick walls
or any other objects. If there is a concrete floor, ensure that after insertion, the tip of the probe is in excess
of 0.5 metre above the ground. This is to avoid picking up background radiation from these surfaces.
 Avoid peninsulas of coal. Select positions on the pile that provide access to the main body of the coal. The
final position of the tip of the probe after insertion should be in excess of 0.5 metre from any coal interface.
 Avoid compacted coal where possible. If excessive force is necessary to insert the probe to its required
depth, select another location within the pile or loosen the coal with a spade first.
 When inserting the probe, the elevation of the tube should be normal to the surface of the coal. If the
minimum distance above the floor (as described above) cannot be achieved, the elevation should be
modified to achieve this distance.
After having found a suitable location to use the probe, attach the two handles to the probe body and push the
probe into the coal to a depth of 600 mm. At this depth the array of four screws just below the handles should be
level with the coal surface.
Plug in the cable between the Ash Probe and the Display Unit and press the On/Off switch and when the screen
shows the home screen (displays shows one large icon and three small ones to access the main functions), press the
large icon to access the probe measurement screen.

In the case of piles of coal, check that the required pile name/reference is indicated on the Display Unit, and that the
relevant calibration has been selected. In the case of trucks, the user will be prompted to enter details of the truck
to be measured prior to taking the first reading.
Press the START button on the touch-screen to start the counting procedure to obtain the gamma counts for the pile
or truckload of coal.
When the counting has been completed, the average gamma counts per second for that reading should be stored
unless there is a reason to discard the reading (perhaps it is significantly different to other sample readings due to
proximity to another surface say).
Select another position in the pile or truck, insert the Ash Probe, and repeat the above steps. If more than one
reading is taken in a pile or truck, the programme will average all the gamma counts in the pile or truck to calculate
the overall pile or truck ash content.
For more details on taking readings, see sections 3.5 or 3.6 depending upon the modem of operation.
2.4 CALIBRATION PROCEDURE
The purpose of a calibration is to establish the coefficients for a particular gamma/ash correlation that may be
associated with coal from a particular seam or area. The display unit can store 100 different sets of calibration
coefficients, and the user can select a specific calibration set to suit a given coal type or source being measured if
more than one source is used at site(s).
It is important during a calibration to use coals from the source that represents the whole range of ashes likely to be
sensed by the ash probe in practise. As a general rule, the wider the ash range the more stable the coefficients.
The calibration procedure largely consists of taking the readings from the Ash Probe with the probe inserted into a
variety of different piles from the same coal seam/source (and different locations within those piles) and taking coal
samples from each location. The physical samples should then be analysed in a laboratory to get definitive ash
content readings for each sample. The procedure for taking a sample using the Ash Probe is described in sections
3.5/3.6. All the readings should be associated with a unique “pile” on the Display Unit so that they are grouped
together for easy access to in data downloads.
The readings taken for that pile, can then be downloaded to a PC into a spreadsheet (by memory stick or using the
included Ash Probe Utility software and associated data cable). The collection of readings recorded by the ash probe
each contain the measured “counts-per-second” values from the sensor and it is this value that is plotted on a graph
(as the x axis) against the laboratory derived ash content values associated with each reading (on the y axis). This
will give a series of plots that will follow a roughly straight line on the graph. The calibration coefficients for this
source of coal are derived from this graph.
2.4.1 USING THE CALIBRATION SLEEVE
Having gone through the procedure for inserting the probe into a pile, as described in detail in section 3.5/3.6 of this
manual, an activity measurement is taken (see section 3). Once the activity measurement is complete and the data
stored, the cable is detached from the probe end, and the two handles unscrewed. The Calibration Tube, with
handles attached, is placed centrally over the end of the probe at the same elevation angle, and with a combination
of directly pushing and oscillating rotary motions is forced into the coal until the lower edge of the top rim just
touches the coal. It is essential that the calibration tube be maintained at the same elevation angle as the probe
ensuring that the probe remains centrally positioned within the calibration tube. This will guarantee that the sample

of coal extracted for analysis will be the same coal sensed by the Ash Probe. The Probe is withdrawn from the coal,
and with the shovel provided, the first 150mm of coal is removed and discarded. The remainder of the coal down to
the bottom of the Calibration Tube is then dug out and put into an empty plastic bag. This sample of coal should be
labelled with the appropriate sample number and pile name, and kept for ash analysis.
The above procedure should then be repeated when gathering data for further calibration sample points. The user
should aim to collect data for at least 15 calibration sample points, more if several different sources of coal are to be
checked with the Ash Probe System.
IMPORTANT NOTE: It is vital that the date and time stamp are taken from the AshGraffix display unit and added to
the label of the sample to be sent to the lab so that the laboratory derived ash figured can be directly related to
each sample on the display unit so that the plotted calibration graph is correct.

3 DISPLAY UNIT OPERATION
3.1 OVERVIEW
The heart of the Ash Probe is the AshGraffix Display Unit, which contains the main electronics and user interface. The
front panel consists of a 7 inch TFT touch screen display. The side panel consists of a power switch (with built in
green LED indicator) and a LEMO style connector for connecting the probe. This connector is protected by a dust cap
that lifts up on a hinge. This socket is also used to connect a battery charger or the data/PC interface cable. The side
panel also includes a USB (Type A) socket for connecting memory sticks to export data to (or to restore previously
backed up data).
When the unit is powered on, the opening screen will be displayed whilst the system is loaded. Once ready, touch
the screen at any location to move onto the Home screen display.
By default, to save power, the screen will dim after 150 seconds of no activity. After 5 minutes of no activity the
screen will be turned off completely. Touching the screen or, optionally, moving the display unit, will restore the
display to full brightness. These power saving features can be disabled or altered by the user to suit. See Section
Error! Reference source not found. for details).
The text of the display can be configured to be shown in several languages. At the time of publication, this included:
English, Spanish, French, Russian, Turkish, Polish and Vietnamese. Other languages may be added at a later stage.

3.2 HOME SCREEN DISPLAY
When the unit it powered up, the main Home screen display will be shown (after the launch screens have been
displayed), allowing the user to access the main system functions via four touch-screen icons (taking readings,
showing data, exporting data and configuration).
The functions accessed by each icon are described below:
The largest icon gives access to the primary function of taking probe readings. On
pressing the icon, the user is taken to the probe readings pages (Section 3.3).
This displays a graph of the samples collected so far for the currently selected pile or
truck. It also can be used to view graphs for other piles/trucks and also to access the Data
Facilities menu. This provides facilities for viewing the data and allowing samples to be
removed or data to be exported.
This function gives direct access to the Export Data facility, which allows all collected data
to be exported as a spreadsheet file on an external USB memory stick. Data can also be
stored internally on the unit’s own flash memory. A special cable can be used which
allows the internal memory to appear as an eternal disk drive on a computer allowing any
data stored internally to be retrieved.
This function gives access to the system menu, where all other facilities can be accessed
and where the system configuration can be viewed and changed. The Data Facilities and
Export functions can also be accessed from this menu.

This icon is not shown on the home screen but is instead displayed on most other screens, allowing quick
access back to the Home screen from any point in the program menu.

3.3 PROBE READING MAIN SCREEN
This screen is the main screen for the primary function of taking measurements of ash content from piles or trucks.
It is accessed by selecting the large icon on the Home screen display.
On entry it shows the current calculated ash content as the average of all the samples taken for the current pile or
truck.
The main panel on the screen also shows the current Pile or Truck, the number of samples taken so far (for the
selected pile/truck) and the calibration being used.
Below the display panel are three touch screen buttons.
 START – Press this button to take a reading. For details see sections 3.5/3.6.
 Pile/Truck - Select/Edit the details of the current pile or truck (depending on the mode of operation). Use
this button to set up the pile or truck before taking the sample readings. See sections 3.5 and \3.6for details.
This final touch-screen button is actually the Home key icon, which returns to the Home screen display.
In additional to the information panel and function buttons, the top of the screen features the current time in the
top left corner and the battery life as a percentage display in the top right corner. These two displays are common to
almost all screens in the system.
3.4 MODES OF OPERATION
The display unit is designed to be used in one of two ways depending on the type of readings being taken. One
method is designed to be used with piles of coal where many samples would be taken from a single pile to get a
more accurate average value for the pile. The other is for use with trucks, where deliveries are being made and the
unit will take fewer samples of a particular truck to get the average for that delivery.
3.4.1 PILES MODE
This mode is the default mode of operation and is used where large piles of coal are to be measured. In this mode, it
is more likely that many samples will be taken from each pile to gain a more accurate average of the entire pile.
The system allows the user to define 99 separate piles. Each pile can have up to 99 individual samples/readings and
data can be exported to an external PC by data interface (using the Ash Probe Utility software) or to memory stick.

A user may takes readings from different piles and can switch between selecting different piles to store readings
against at any time.
3.4.2 TRUCKS MODE
This mode is designed to be used at sites where deliveries of coal are made/received by vehicles such as trucks. As
such, the operation of taking samples is slightly different as fewer samples of any truck will be taken due to the
smaller overall size of the associated amount of coal within the truck.
Also, there are likely to be far more trucks that need to be recorded and as such, the system can store the readings
from up to 600 trucks with up to 12 samples for each truck.
When readings are taken, they are all associated with the current truck until the operation is finished. At which
point, the truck data is closed for that particular vehicle and the user must create a completely different truck to
start taking samples from the next vehicle.
3.5 TAKING READINGS IN PILES MODE
The most common way of using the unit is to take readings in piles mode. In this mode, a series of readings should
be taken from all over the pile to determine the average ash content of the entire pile. The more samples taken, the
more accurate the calculated average readings will be.
The first stage in taking a reading or set of readings therefore, is to select and set up the details of the pile to be
measured, so that all readings can be identified at a later stage. Of course, once the pile details have been
entered/selected, then this process does not need to be repeated until a different pile is to be measured.
To set up the pile, press the Pile button on the main screen display to show the Pile To Use screen. From here, a pile
can be selected from the list of the available ones (there are 99 piles available). Use the Up and Down arrow buttons
to either select an empty sot to define the details of a new pile (usually identified by having the name No Name Set)
or an existing pile to which more readings are to be added to. Press Edit when the desired pile is highlighted to
create or change the details of the selected pile.
NOTE: An existing pile can be selected, which can then be re-used for a new pile, deleting the previous samples for the
original pile. This might also be useful when an existing pile is being re-measured at a different date and therefore all
previous readings need to be discarded so as not to affect the new average ash calculation.

The details that can be edited for each pile are:
 Name The name of the pile used to identify it to the rest of the program and in the exported data. Touch
the data entry area of the panel to display a QWERTY touch-screen keypad to allow data entry.
 Calibration – The calibration created specifically for the source of the coal in the pile to be measured. There
can be up to 100 calibrations to cater for the unit being used with many different coal sources. In many
cases, there will only be a single calibration used for the unit.
In additional to the fields above, the user can also press the Clear Data For This Pile button, which removes the
name and readings previously taken for this pile, effectively returning the pile the pool of unused ones to be used for
new sets of readings.
Once the desired parameters have been set, select the Save button to return to the Piles List and then press Select
to return to the main screen, ensuring that the chosen pile is selected for use.
With the pile set up, the actual readings can now be taken.
3.5.1 INSERTING THE PROBE
IMPORTANT: The probe should be treated as a delicate instrument. Extreme care should be taken when in use and
it should be stored in its carrying case when not in use.
When selecting a location to insert the probe in order to take a reading, bear in mind the following points:
 Avoid places that are adjacent to (within 0.5 metres) concrete or brick walls or any other objects. If there is a
concrete floor, ensure that after insertion, the tip of the probe is in excess of 0.5 metre above the ground.
minimum distance above the floor cannot be achieved, the elevation should be modified to achieve this
distance.
 Attach the two handles to the probe body and push the probe into the coal to a depth of 600 mm. At this
depth the array of four screws just below the handles should be level with the coal surface. DO NOT USE
ANOTHER IMPLEMENT, SUCH AS A HAMMER TO FORCE THE PROBE INTO THE PILE.
 Plug in the cable between the Ash Probe and the Display Unit

3.5.2 TAKING THE READING
Once the probe has been inserted, connected to the display unit and the pile set up, press the START button to take
a reading. This will display the screen as shown below:
The screen is updated each second and continues to update until the unit determines that the signal is stable enough
to be recorded. This is usually determined by the Sigma (standard deviation) figure reaching a user defined minimum
level and the sampling having been active for a minimum of 60 second (a period of less than 60 seconds is not
deemed long enough to get a true figure, even if the variance is minimal).
The updates also can be stopped by user pressing the STOP or Abort buttons or when the maximum reading time has
elapsed. In these cases, the user is asked whether or not to save the reading determined so far (apart from the Abort
button, which abandons the current reading immediately).
The fields displayed are:
 Seconds – The number of seconds that the reading has been measured for so far. The user set s a maximum
value that this value can reach after which the reading is stopped if it hasn’t already been stopped by the
Sigma reaching the selected value or the user pressing the Stop or Abort buttons.
 Count – The count of pulses detected by the probe for the previous second
 Average Count – The average counts per second since the reading was initiated
 Sample – The sample number of the current pile that is being read
 Ash – The average ash calculated from the calibration set associated with the currently selected pile and the
average counts per second.
 Sigma – The standard deviation (square root of the variance) of the readings being taken from the average.
The lower the value, the more stable the readings are. Over time, this value should decrease as the average
becomes more representative. When this value reaches a minimum level, as defined by the user, the reading
is halted as it is deemed stable enough to be representative.
When the reading is complete (through the sigma level being reached, the maximum time having been passed or the
user having pressed the STOP button, the screen below is shown, which gives the user the opportunity to SAVE the
reading or abort without saving, should the reading appear to be invalid or out of kilter with other samples (possibly
due to the probe not being correctly inserted or picking up data from an unrelated source).

Pressing either SAVE or Abort returns the user to the main screen display, where the average ash figure will have
been updated accordingly (if the last reading was saved that is).
3.6 TAKING READINGS IN TRUCKS MODE
The alternative operating mode for the Display Unit is Trucks Mode. This is primarily designed for use when coal
carrying vehicles are being received or dispatched carrying loads.
The big difference between modes is that the user will only be able to take readings for a particular truck at the time
the truck arrives/departs and can only take a limited number (twelve) of samples for any given truck. Once the set of
readings for a vehicle have been completed, then the truck cannot be “selected” in the same way as a pile in order
to add more readings.
In total, there are 600 “slots” for truck data, each having up to 12 samples (as opposed to 99 piles with up to 99
samples each in Piles mode).
The first step to take the samples in this mode is to press the Start button. This will display a pop-up window
prompting the user to set up a new Truck record or to continue saving readings to the currently selected truck
record.
If continuing to add more readings/samples from the same truck, ensure the probe has been placed appropriately
and press Continue. The unit will then start to take the reading as described in section 3.6.3. Prior to pressing the
New button, the probe should be inserted into position reading to take a measurement, as described in section 3.6.2
below.

Selecting New takes the user to a page to set up the details for a new truck, as described below.
3.6.1 SETTING UP A NEW TRUCK RECORD
This page allows the user to enter a Name (or reference number) for the truck, select the set of calibration
coefficients to use and also to clear any previous data held for this record (allowing old records to be reused).
The details that can be edited for each truck are:
 Name The name, registration index or other reference number of the truck used to identify it to the rest of
the program and in the exported data. Touch the data entry area of the panel to display a QWERTY touch-
screen keypad to allow data entry.
 Calibration – The calibration created specifically for the source of the coal in the truck to be measured.
There can be up to 100 calibrations to cater for the unit being used with many different coal sources. In
many cases, there will only be a single calibration used for the unit.
In additional to the fields above, the user can also press the Clear Data For This Truck button, which removes the
name and readings previously taken for this record, effectively returning the record to the pool of unused ones to be
used for new sets of readings.
Once the desired parameters have been set, select the Save button to continue to take the reading as described in
section 3.6.3.
3.6.2 INSERTING THE PROBE
The probe should be treated as a delicate instrument. Extreme care should be taken when in use and it should be
stored in its carrying case when not in use.
When selecting a location to insert the probe in order to take a reading, bear in mind the following points:
 Avoid places that are adjacent to (within 0.5 metre) the sides of the truck or any other objects.

minimum distance above the floor cannot be achieved, the elevation should be modified to achieve this
distance.
 Attach the two handles to the probe body and push the probe into the coal to a depth of 600 mm. At this
depth the array of four screws just below the handles should be level with the coal surface.
 Plug in the cable between the Ash Probe and the Display Unit
3.6.3 TAKING THE READINGS
Once the probe has been inserted into the coal and the truck record created/selected, then pressing the Save
button on the truck details edit screen or Continue on the Select Truck window, displays the window below and
initiates the first reading.
The screen is updated each second and continues to update until the unit determines that the signal is stable enough
to be recorded. This is usually determined by the Sigma (standard deviation) figure reaching a user defined minimum
level and the sampling having been active for a minimum of 60 second (a period less than 60 seconds is not deemed
long enough to get a true figure, even if the variance is minimal).
The updates also can be stopped by user pressing the STOP or Abort buttons or when the maximum reading time
has elapsed. In these cases, the user is asked whether or not to save the reading determined so far (apart from the
Abort button, which abandons the current reading immediately). The Home key will also abort the current reading
and return to the main Home screen.
The fields displayed are:
 Seconds – The number of seconds that the reading has been measured for so far. The user set s a maximum
value that this figure can reach after which the reading is stopped if it hasn’t already been stopped by the
Sigma reaching the selected level or the user pressing the Stop or Abort buttons.
 Count – The count of pulses detected by the probe for the previous second
 Average Count – The average counts per second since the reading was initiated
 Sample – The sample number of the current truck that is being read
 Ash – The average ash calculated from the calibration set associated with the currently selected truck and
the average counts per second.
 Sigma – The standard deviation (square root of the variance) of the readings being taken from the average.
The lower the value, the more stable the readings are. Over time, this value should decrease as the average

becomes more representative. When this value reaches a minimum level, as defined by the, the reading is
halted as it is deemed stable enough to be representative.
 Overall Average Ash – The average ash content calculated from this and any previous readings for the
selected truck.
When the reading is complete (through the sigma level being reached, the maximum time having been passed or the
user having pressed the STOP button, the screen below is shown, which gives the user the opportunity to SAVE the
reading or Discard it without saving should the reading appear to be invalid or out of kilter with other samples
(possibly due to the probe not being correctly inserted or picking up data from an unrelated source). The Abort
button will exit the window without saving the latest reading, although any previous readings will be retained.
Once Save or Discard are pressed, then screen below is shown allowing the user to relocate the probe and take
another reading by pressing REPEAT or to End the collection of readings for this truck and return to the main screen
display.

3.7 DATA DISPLAY
The Data icon on the Home screen display will show the samples graph, which displays the
measured ash for each of the individual samples of the currently selected pile or truck. The graph
will be automatically scaled to cope with the number and range of the samples.
A red line is draw across the graph, which depicts the average ash value based upon all the samples.
The use of a graph allows the user to easily see the range of readings that make up the average and to easily spot
erroneous readings which may be skewing the overall result. These could be the result of foreign material near the
probe at the time of measurement or perhaps the metal of a truck container being detected during the reading.
The Menu facility can be then used to show the samples in a table which allows individual samples to be removed by
the user if deemed to be inappropriate. Returning to the graph page will re-draw the graph with the edited data.
3.7.1 PILE/TRUCK
The Pile or Truck button is used to select a different pile/truck to display the samples for. Scroll bars to the side of
the list of piles/trucks allow the user to move the list and selection if the number of items in the list is too big to
display on the screen.

Pressing the Select button will choose the highlighted item in the list and return to the graph, which will be re-drawn
to show all the samples taken for the selected item.
3.7.2 MENU
The Menu button displays function buttons to allow access to the data display and exporting facilities, including the
ability to export the data to disk or memory stick, list the samples and allow data to be excised and also to show the
overall figures for all piles/or trucks that have been recorded by the device.
3.7.2.1 Save/Export Data
This function is used to export the data from one or all piles/trucks to a USB memory stick or to the internal memory
(which can be read by a PC using a suitable cable).
This function is identical to the Export Data function that can be accessed from the Home screen and is explained in
detail in Section 3.8 of this document.
3.7.2.2 Show Data for All Piles
This function shows a list of all the piles or trucks recorded in the system, showing the overall ash content of each
one.

Each entry in the list shows the name of the pile or truck, the overall ash percentage calculated from the samples
taken for that pile/truck, the variance (Err) between the samples (the lower the number the better), the total
number of samples used to derive the ash figure and the reference number of the set of calibration coefficients used
to perform the calculations.
The Details button is used to show the details of the individual samples taken for the highlighted pile/truck, as
described in Section 3.7.2.3 below.
The Export function allows the data to be exported using the Export Data function as described in section 3.8 below.
If a pile/truck is highlighted, then the Export function will default to only exporting the data for that specific item
(although the user can change this within the function page). If no entry in the list is highlighted, then the Export
function will default to exporting data for all piles/trucks.
3.7.2.3 Show Samples for Current Pile
This page allows the user to view the individual samples for the selected pile/truck.
Each sample that has been recorded for this pile/truck is shown together with the calculated ash percentage for that
figure as well as the base counter per second, recorded by the ash probe and from which the ash is calculated.

The display also shows the actual set of calibration coefficients used to calculate the ash just below the list of
samples.
The name of the pile/truck and the date/time at which the last sample was record is shown at the top of the list.
The functions available on this page are:
 Change Pile/Truck – This function displays a list of the piles/trucks recorded by the unit, allowing a different
one to be selected to show the samples for.
 Change Calibration – This allows the user to change the set of calibration coefficients used to derive the
individual ash percentages from the recorded counts per second for each sample.
 Clear All/Sample – This button allows an individual sample to be removed from the list, for example when it
appears to be an erroneous figure that is skewing the overall average ash figure for the pile/truck. If no
individual sample is highlighted, then this button is used to clear all the samples for that pile/truck, which
allows the pile to re-used, for example when data for a pile is being re-recorded at a later date.
3.8 EXPORT DATA
The Export Data button displays a function page that allows the data from all piles/trucks or a
selected pile or truck to be exported to a USB memory stick or to an internal disk file (which can
be accessed using an optional cable linked to a PC).
Data is exported as a spreadsheet in order to analyse the data offline using a package such as Microsoft ® Excel.
The main data that is exported is the overall ash content reading of each of the piles or trucks. Additionally, the
details of the individual samples that were taken for each pile can be included, as can the details of the sets of
calibration coefficients stored and used to carry out the calculations.
NOTE: Aside from this function, data can be downloaded from the unit using the Ash Probe Utility Software
program for Windows PC computers and the provided data cable. See Section 4 for details.
The format of the exported data is Comma Separated Values format (CSV) file, which can be interpreted by almost
all spreadsheet and database programs.
The fields on the page are as follows:

 File Name – The name of the filename to create. Pressing the text entry box will display a QWERTY keyboard
to allow the name to be entered. The name should normally include the file extension .CSV to enable the file
to be easily identified and loaded correctly to other programs. The file will actually be stored in the root
directory of the selected device (memory stick or internal disk).
 Include Calibrations - If selected (represented by a green square for the field), then the output file will
contain a table listing all the calibrations and their coefficient values stored in the unit.
 Include Samples - If selected, then the details of the individual sample readings used to calculate the overall
average ash content for each pile/truck will be included for each pile in the output file.
 Pile(s)/Truck(s) – This selection field determines if data for just one particular pile/truck will be exported or
if data for all the piles/trucks recorded by the unit will be exported.
 Internal Disk/Memory Stick – Selects whether the output file will be stored to the unit’s internal memory or
to an external memory stick plugged into the USB port.
Pressing the Save button will create the output file according to the selected parameters.
3.9 PROGRAM MENU
The Configuration/Menu button on the Home screen gives access to all the additional functions
of the unit involved with setup and configuration, accessing and viewing data as well as
maintenance and general information.
The page contains a number of buttons that access the individual configuration and function pages
The individual functions are described in detail in the following chapters, but briefly the functions are:
 Data Display/Output- View and export the collected readings for all or individual piles/trucks
 Calibrations – Edit the names and coefficients of any of the calibration sets.
 Configuration- General configuration functions, including setting the operating mode, interface language,
password access, power save options, clearing data files and other program options.
 Test Probe – Diagnostics function that will test a connected probe and help troubleshoot any problems
detected.
 Backup/Restore – Save or restore the settings and data from the unit to an internal backup or onto an
external memory stick.

 About – Display general information about the program and view contact details for the local
supplier/agent.

4 ASH PROBE UTILITY SOFTWARE
IMPORTANT NOTE: For the very latest information on the Ash Probe Utility Software, consult the user manual on
the installation CD which may be more up to date that the instructions contained within this document.
The Ash Probe Utility, APU, is a software application for use with the Bretby Gammatech Ash Probe and Lab Ash
portable coal quality monitoring systems.
It allows the data recorded by the Display Units to be downloaded to a spreadsheet file for viewing/editing on a PC.
With the AshGraffix systems, the viewing and configuration of the unit’s parameters can also be made using this
utility software.
4.1 PROGRAM DESCRIPTION
The APU software connects to an Ash Probe or Lab Ash Display Unit using a serial communication cable, which allows
data to be passed between the software and the Display Unit.
The cable and software is supplied by Bretby Gammatech as part of the Ash Probe package. The cable itself is either
an RS232 serial cable with a 9 pin D type connector on the computer side or a USB serial cable, which connects
directly from a computer USB port to the AshGraffix Display Unit.
In the case of a USB connector, a suitable software driver is required for the cable, which can be installed when the
application itself is installed. The driver is included on the installation CD and can be installed manually at any later
point if required.
NOTE: When using an RS232 cable, if the computer does not have an RS232 serial port, it will need a USB to RS232
convertor, which will also require a driver to be installed. Please follow the manufacturer’s instructions to install this.
The software allows the computer to interrogate the unit and provide full configuration facilities and also to
download the readings data from the unit and present this in the generic spreadsheet format , Comma Separated
Values (CSV), which can be read by most spreadsheet and database applications.
4.2 PC REQUIREMENTS
The APU software requires a PC with the following minimum specification:
 Microsoft Windows XP/Vista/7/8 Operating System

 10MB Free Disk Space
 1 free USB port or RS232 serial port.
The program also requires Microsoft .Net Framework 3.5 to be installed. This will be downloaded from Microsoft
and installed automatically during the APU software installation if it is not already present on the PC.
If a USB to RS232 serial port convertor is used, then the associated driver for that convertor cable must be installed.
If a USB cable is supplied by Bretby Gammatech, then the driver can be installed during the APU software
installation, where the option is given to install it or the driver can be installed directly from the APU Installation CD
at a later stage.
Some computers running the Windows 7 or 8 operating system may already have the driver installed by default.

Parker Worldwide
Europe, Middle East, Africa HU – Hungary, Budaörs UK – United Kingdom, Warwick
Tel: +36 23 885 470 Tel: +44 (0)1926 317 878
AE – United Arab Emirates, parker.hungary@parker.com parker.uk@parker.com
Dubai
Tel: +971 4 8127100 IE – Ireland, Dublin ZA – South Africa, Kempton Park
parker.me@parker.com Tel: +353 (0)1 466 6370 Tel: +27 (0)11 961 0700
parker.ireland@parker.com parker.southafrica@parker.com
AT – Austria, Wiener Neustadt
Tel: +43 (0)2622 23501-0 IL – Israel
parker.austria@parker.com Tel: +39 02 45 19 21 North America
parker.israel@parker.com CA – Canada, Milton, Ontario
AT – Eastern Europe, Wiener
Neustadt IT – Italy, Corsico (MI) Tel: +1 905 693 3000
Tel: +43 (0)2622 23501 900 Tel: +39 02 45 19 21 US – USA, Cleveland
parker.easteurope@parker.com parker.italy@parker.com Tel: +1 216 896 3000
AZ – Azerbaijan, Baku KZ – Kazakhstan, Almaty
Tel: +994 50 2233 458 Tel: +7 7273 561 000 Asia Pacific
parker.azerbaijan@parker.com parker.easteurope@parker.com
AU – Australia, Castle Hill
BE/LU – Belgium, Nivelles NL – The Netherlands, Oldenzaal Tel: +61 (0)2-9634 7777
Tel: +32 (0)67 280 900 Tel: +31 (0)541 585 000
parker.belgium@parker.com parker.nl@parker.com CN – China, Shanghai
Tel: +86 21 2899 5000
BG – Bulgaria, Sofia NO – Norway, Asker
Tel: +359 2 980 1344 Tel: +47 66 75 34 00 HK – Hong Kong
parker.bulgaria@parker.com parker.norway@parker.com Tel: +852 2428 8008
BY – Belarus, Minsk PL – Poland, Warsaw IN – India, Mumbai

Tel: +48 (0)22 573 24 00 Tel: +48 (0)22 573 24 00 Tel: +91 22 6513 7081-85
parker.poland@parker.com parker.poland@parker.com JP – Japan, Tokyo
CH – Switzerland, Etoy PT – Portugal Tel: +81 (0)3 6408 3901
Tel: +41 (0)21 821 87 00 Tel: +351 22 999 7360 KR – South Korea, Seoul
parker.switzerland@parker.com parker.portugal@parker.com Tel: +82 2 559 0400
CZ – Czech Republic, Klecany RO – Romania, Bucharest MY – Malaysia, Shah Alam
Tel: +420 284 083 111 Tel: +40 21 252 1382 Tel: +60 3 7849 0800
parker.czechrepublic@parker.com parker.romania@parker.com
NZ – New Zealand, Mt Wellington
DE – Germany, Kaarst RU – Russia, Moscow Tel: +64 9 574 1744
Tel: +49 (0)2131 4016 0 Tel: +7 495 645-2156
parker.russia@parker.com SG – Singapore
parker.germany@parker.com
Tel: +65 6887 6300
DK – Denmark, Ballerup SE – Sweden, Spånga
Tel: +46 (0)8 59 79 50 00 TH – Thailand, Bangkok
Tel: +45 43 56 04 00
parker.sweden@parker.com Tel: +662 186 7000
parker.denmark@parker.com
SK – Slovakia, Banská Bystrica TW – Taiwan, Taipei
ES – Spain, Madrid
Tel: +421 484 162 252 Tel: +886 2 2298 8987
Tel: +34 902 330 001
parker.spain@parker.com parker.slovakia@parker.com
FI – Finland, Vantaa SL – Slovenia, Novo Mesto South America
Tel: +358 (0)20 753 2500 Tel: +386 7 337 6650 AR – Argentina, Buenos Aires
parker.finland@parker.com parker.slovenia@parker.com Tel: +54 3327 44 4129
FR – France, Contamine s/Arve TR – Turkey, Istanbul BR – Brazil, Sao Jose dos Campos
Tel: +33 (0)4 50 25 80 25 Tel: +90 216 4997081 Tel: +55 800 727 5374
parker.france@parker.com parker.turkey@parker.com
CL – Chile, Santiago
GR – Greece, Athens UA – Ukraine, Kiev Tel: +56 2 623 1216
Tel: +30 210 933 6450 Tel: +48 (0)22 573 24 00
MX – Mexico, Toluca
parker.greece@parker.com parker.poland@parker.com
Tel: +52 72 2275 4200
© 2017 Parker Hannifin Corporation. All rights reserved. Ash Probe User Manual-Overview Issue 1.00
Parker Hannifin Manufacturing Ltd.

Instrumentation Products Division,
Europe
President Park, President Way
Sheffield S4 7UR
Tel: +44 (0) 114 224 0200
www.parker.com/ipd

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Portable Ash Instrument Analyser

Ash Probe & AshGraffix

Issue Date Author Changes

Ash Probe & AshGraffix Overview 2 Issue 1.00

1.1 MANUAL FORMAT 5

2 DESCRIPTION, MAINTENANCE AND OPERATION 6

2.1 EQUIPMENT DESCRIPTION 6

2.1.2 ASHGRAFFIX DISPLAY UNIT 6

2.1.3 DISPLAY UNIT BATTERY CHARGER 6

2.1.4 ASH PROBE/DISPLAY UNIT CABLE 7

2.1.5 DATA DOWNLOAD CABLE 7

2.1.6 ASH PROBE UTILITY SOFTWARE 7

2.1.7 CALIBRATION SAMPLES GATHERING EQUIPMENT 7

2.1.8 OPERATOR’S MANUALS 7

2.2 CARE AND MAINTENANCE 8

2.2.2 ASHGRAFFIX DISPLAY UNIT 8

2.2.3 FAULT FINDING 8

2.3 GENERAL PRINCIPLES OF OPERATION 9

2.4 CALIBRATION PROCEDURE 10

2.4.1 USING THE CALIBRATION SLEEVE 10

3 DISPLAY UNIT OPERATION 12

Ash Probe & AshGraffix Overview 3 Issue 1.00

3.2 HOME SCREEN DISPLAY 13

3.3 PROBE READING MAIN SCREEN 15

3.4 MODES OF OPERATION 15

3.4.1 PILES MODE 15

3.4.2 TRUCKS MODE 16

3.5 TAKING READINGS IN PILES MODE 16

3.5.1 INSERTING THE PROBE 17

3.5.2 TAKING THE READING 18

3.6 TAKING READINGS IN TRUCKS MODE 19

3.6.1 SETTING UP A NEW TRUCK RECORD 20

3.6.2 INSERTING THE PROBE 20

3.6.3 TAKING THE READINGS 21

3.7 DATA DISPLAY 23

3.7.2.1 Save/Export Data 24

3.7.2.2 Show Data for All Piles 24

3.7.2.3 Show Samples for Current Pile 25

3.8 EXPORT DATA 26

3.9 PROGRAM MENU 27

4 ASH PROBE UTILITY SOFTWARE 29

4.1 PROGRAM DESCRIPTION 29

Ash Probe & AshGraffix Overview 4 Issue 1.00

1.1 MANUAL FORMAT

Part 1 is this introduction to the manual

Ash Probe & AshGraffix Overview 5 Issue 1.00

2.1 EQUIPMENT DESCRIPTION

2.1.2 ASHGRAFFIX DISPLAY UNIT

2.1.3 DISPLAY UNIT BATTERY CHARGER

 LED flashes slowly in yellow – pre-charge sequence

Ash Probe & AshGraffix Overview 6 Issue 1.00

2.1.4 ASH PROBE/DISPLAY UNIT CABLE

The wiring for the cable is shown in Appendix A of this guide.

2.1.5 DATA DOWNLOAD CABLE

2.1.6 ASH PROBE UTILITY SOFTWARE

2.1.7 CALIBRATION SAMPLES GATHERING EQUIPMENT

2.1.8 OPERATOR’S MANUALS

Ash Probe & AshGraffix Overview 7 Issue 1.00