Buhler GAS 222.35 AMEX, GAS 222.21 AMEX Installation And Operation Instructions Manual
Gas Analysis
Sample gas probes
GAS 222.35 AMEX
Installation and Operation Instructions
Original instructions
BE460058
08/2019
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20
E-Mail: analyse@buehler-technologies.com
Internet: www.buehler-technologies.com
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20
Internet: www.buehler-technologies.com
E-Mail: analyse@buehler-technologies.com
Read this instruction carefully prior to installation and/or use. Pay attention particularly to all advises and safety instructions to prevent injuries. Bühler Technologies can not be held responsible for misusing
the product or unreliable function due to unauthorised modifications.
All rights reserved. Bühler Technologies GmbH 2019
Document information
Document No......................................................... BE460058
Version.........................................................................08/2019
GAS 222.35 AMEX
Table of Contents
1 Introduction..................................................................................................................................................................................................................... 2
1.1 Intended Use......................................................................................................................................................................................................... 2
1.2 Type Plate............................................................................................................................................................................................................... 2
1.3 Scope of Delivery.................................................................................................................................................................................................. 2
1.4 Ordering instructions ........................................................................................................................................................................................3
1.5 Product Description............................................................................................................................................................................................ 3
2 Safety instructions.........................................................................................................................................................................................................4
2.1 Important advice ................................................................................................................................................................................................. 4
2.2 General Hazard Warnings ................................................................................................................................................................................5
3 Transport and storage .................................................................................................................................................................................................. 7
4 Installation and connection........................................................................................................................................................................................8
4.1 Installation site requirements.........................................................................................................................................................................8
4.2 Installation ............................................................................................................................................................................................................8
4.3 Installing the Inlet Filter ....................................................................................................................................................................................8
4.4 Insulation...............................................................................................................................................................................................................8
4.5 Connecting the Gas Line....................................................................................................................................................................................9
4.5.1 Blowback Connection ......................................................................................................................................................................... 9
4.5.2 Connecting the Gas Line .................................................................................................................................................................... 9
4.5.3 Connecting the calibrating gas line (optional)..........................................................................................................................10
4.6 Connecting the Blowback and Pressure Vessel (Optional) ...................................................................................................................10
4.7 Electrical connections ......................................................................................................................................................................................10
4.7.1 Heated pressure vessel (optional) ..................................................................................................................................................11
5 Operation and Control.................................................................................................................................................................................................13
5.1 Before Start-Up ...................................................................................................................................................................................................13
6 Maintenance.................................................................................................................................................................................................................. 14
6.1 Maintaining the filter element ......................................................................................................................................................................15
6.1.1 Replacing the Inlet Filter .................................................................................................................................................................. 15
6.2 Blowback of the in-situ filter (within the process stream).................................................................................................................... 16
6.2.1 Manual Blowback (Without Blowback Control) ........................................................................................................................16
6.2.2 Automatic Blowback (External Blowback Control)...................................................................................................................16
6.3 Maintenance Schedule .....................................................................................................................................................................................17
7 Service and repair......................................................................................................................................................................................................... 18
7.1 Troubleshooting ................................................................................................................................................................................................ 18
7.2 Spare Parts and Accessories ...........................................................................................................................................................................19
8 Disposal...........................................................................................................................................................................................................................20
9 Appendices......................................................................................................................................................................................................................21
9.1 Technical Data .................................................................................................................................................................................................... 21
9.2 Connection Diagram ........................................................................................................................................................................................ 21
9.3 Connection diagram heated pressure vessel............................................................................................................................................22
9.4 Flow diagram......................................................................................................................................................................................................22
9.5 Dimensions ......................................................................................................................................................................................................... 23
9.6 List of chemical resistance..............................................................................................................................................................................24
9.7 User book (Please make copies) .................................................................................................................................................................... 25
10 Attached Documents...................................................................................................................................................................................................26
iBühler Technologies GmbHBE460058 ◦ 08/2019
GAS 222.35 AMEX
GAS 222.35 AMEX
100105177 462223516633000999999 001
Cl. 1, Div. 2, Gps. B, C, D, T3
CSA Certificate: 1728394
Install per drawing 46/115-Z01-06-4
115-230 V; max. 360W @ 230V
at -20 up to 80 °C; max. 6 bar
Manufacturer and address
Year: 2019
Type designation
Order no., Item no.
Blast protection marking
CSA certificate number
Drawing number
Item description
Year of manufacture
1 Introduction
1.1 Intended Use
The sample gas probe is intended for installation into gas analysis systems in commercial applications.
Sample gas probes are among the main components in a gas conditioning system.
– Therefore also note the related drawing in the data sheet in the appendix.
– Before installing the device, verify the listed technical data meet the application parameters.
– Further verify all contents are complete.
Please refer to the type plate to identify your model. In addition to the job number/ID number, this also contains the article
number and model designation.
Please note the specific values of the device when connecting, and the correct versions when ordering spare parts.
Passing through gases
Flammable gases above the UEL may only be blown back with inert gases. Flammable gases from 25% LEL and up to the UEG
may be blown back provided the operator ensures the blown back gas is not and cannot be explosive. For safety reasons we recommend only using inert gases in these cases as well.
Blowing back explosive atmospheres (range from UEG to OEG) with the probes is prohibited due to possible adiabatic compression (high blowback pressure against contaminated filter). The operator is responsible for compliance with these conditions taking into account his risk assessment.
1.2 Type Plate
Example:
1.3 Scope of Delivery
– 1 x Sample gas probe
– 1 x Flange gasket and screws
– Product documentation
– Connection and mounting accessories (only optional)
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1.4 Ordering instructions
The item number is a code for the configuration of your unit. Please use the following model key:
4622235 1 6 6 X 3 X 0 0 X 9 X 9 9 9 Product Characteristics
1)
Ex temperature classes
3 T3
4 T4
Sample probe power supply
3 115 / 230 V
Calibration gas connection
0 No calibration gas connection
1 6 mm
2 6 mm + check valve
3 1/4"
4 1/4" + check valve
Blowback with air reservoir
2)
Air reservoir heating
1 Yes
9 No
Compressed air valve/valve voltage information
0 Manual
1 120 V 60 Hz
2 240 V 60 Hz
9 None (if no blowback requested)
Pneumatic drive for ball valve
9 N/A
Control valve for pneumatic drive
9 No control valve
1)
Please note, using certain accessories may limit gas probe use in Ex areas! Observe the respective operating manuals, accessory
compatibility charts, and data sheets to ensure proper technical product design!
2)
In the case of flammable gases, always use inert gas for blowback. Probe blowback prohibited when using explosive sample
gas!
1.5 Product Description
The probe is equipped with self-regulating PTC heating cartridges and a temperature contact.
Probe Description
GAS 222.35 AMEX Probe with retractable inlet filter and blowback connection
Accessories Please refer to the data sheet at the end of this manual for accessories for this probe
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DANGER
WARNING
CAUTION
NOTICE
2 Safety instructions
2.1 Important advice
This unit may only be used if:
– the product is being used under the conditions described in the operating- and installation instructions, used according to
the nameplate and for applications for which it is intended. any unauthorized modifications to the device will void the warranty provided by Bühler Technologies GmbH,
– the limits in the data sheet and the instructions must be observed,
– the temperature switch is being operated on an intrinsically-safe circuit,
– the controller itself is installed outside the explosive area,
– Monitoring equipment / protection devices must be connected correctly,
– service and repairs not described in these instructions is performed by Bühler Technologies GmbH,
– using genuine replacement parts.
– Regulation IEC/EN60079-14 must be observed when erecting electrical systems in explosive areas.
– Additional national regulations pertaining to initial operation, operation, maintenance, repairs and disposal must be ob-
served.
– These operating instructions are a part of the equipment. The manufacturer reserves the right to change performance-, spe-
cification- or technical data without prior notice. Please keep these instructions for future reference.
Signal words for warnings
Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.
Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not
avoided.
Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property or
minor or medium injuries if not avoided.
Signal word for important information to the product.
Warning signs
These instructions use the following warning signs:
Warns of a general hazard General notice
Warns of voltage Unplug from mains
Warns not to inhale toxic gasses Wear respiratory equipment
Warns of corrosive liquids Wear a safety mask
Warns of explosive areas Wear gloves
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2.2 General Hazard Warnings
The maximum surface temperature of the probes solely varies by operating conditions
temperature, ambient temperature, fluid flow rate). For use
ings.
The equipment must be installed by a professional familiar with the safety requirements and risks.
Be sure to observe the safety regulations and generally applicable rules of technology relevant for the installation site. Prevent
malfunctions and avoid personal injuries and property damage.
in explosive areas
please particularly note the related hazard warn-
(steam temperature, sample gas inlet
The operator of the system must ensure:
– Safety notices and operating instructions are available and observed,
– The respective national accident prevention regulations are observed,
– The permissible data and operational conditions are maintained,
– Safety guards are used and mandatory maintenance is performed,
– Legal regulations are observed during disposal,
– compliance with national installation regulations.
Maintenance, Repair
Please note during maintenance and repairs:
– Repairs to the unit must be performed by Bühler authorised personnel.
– Only perform conversion-, maintenance or installation work described in these operating and installation instructions.
– Always use genuine spare parts.
Always observe the applicable safety and operating regulations in the respective country of use when performing any type of
maintenance.
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
DANGER Toxic, corrosive gas/condensate
Sample gas/condensate may be hazardous to health.
a) If necessary, ensure a safe gas/condensate discharge.
b) Always disconnect the gas supply when performing maintenance or repairs.
c) Protect yourself from toxic/corrosive gasses/condensate when performing mainten-
ance. Wear appropriate protective equipment.
DANGER Explosion hazard
Life and explosion risk may result from gas leakage due to improper use.
a) Use the devices only as described in this manual.
b) Regard the process conditions.
c) Check tubes and hoses for leakage.
DANGER Danger to life and explosion during installation and maintenance
The unit must not be worked on (assembly, installation, maintenance) in explosive atmospheres.
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DANGER
Use in explosive areas
Flammable gasses and dust could ignite or explode. Avoid the following hazard sources:
Application area!
Never operate the gas probe outside the specifications. Extracting gases or gas mixtures
which are also explosive in the absence of air is prohibited.
Electrostatic charge (sparking)!
The equipment may only be used where normal operating conditions do not frequently
produce flammable, electrostatic discharge.
Always clean plastic housing parts and decals with a damp cloth.
Sparking!
Protect the equipment from external blows.
Flame propagation!
If the process holds a risk of flame propagation, install a flame arrestor.
Adiabatic compression (explosion hazard)
Adiabatic compression may cause high gas temperatures during blowback.
back if gases are explosive. Only use nitrogen (inert gas) to blowback
Dust:
If possible, take the electrical components which must be opened for repair to a dustfree room. If unable to do so, prevent dust from entering the housing.
Ignition of dust layers!
When using the device in a dusty environment, routinely clean dust from all components.
The ignition temperature resp. smouldering temperature of flammable dusts resp. dust
layers present must be considerably higher than the maximum surface temperature of
the probe (observe applicable standards and statutory regulations).
Never blow-
flammable
gas
.
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3 Transport and storage
Only transport the product inside the original packaging or a suitable alternative.
The equipment must be protected from moisture and heat when not in use. They must be stored in a covered, dry and dust-free
room at a temperature between -20°C to 50°C (-4°F to 122°F).
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4 Installation and connection
4.1 Installation site requirements
Sample gas probes are intended for flange mounting.
– Installation site and installation position are determined based on requirements specific to the application.
– If necessary, the connection piece should be slightly tilted toward the centre of the channel.
– The installation site should be protected from the weather.
– In addition, adequate and safe access for installation and future maintenance work should be provided. Particularly follow
the uninstalled size of the probe tube!
If the probe is transported to the installation site in pieces, it will first need to be assembled.
4.2 Installation
DANGER Danger to life and explosion during installation and maintenance
The unit must not be worked on (assembly, installation, maintenance) in explosive atmospheres.
DANGER Explosion hazard
When used in explosive areas
Flammable gasses and dust could ignite or explode.
Never operate the gas probe outside the specifications. Extracting gases or gas mixtures
which are also explosive in the absence of air is prohibited.
DANGER Explosion hazard due to ignition of dust
When using the device in a dusty environment, routinely clean dust from all components.
The ignition temperature resp. smouldering temperature of flammable dusts resp. dust
layers present must be considerably higher than the maximum surface temperature of
the device (observe applicable standards and statutory regulations).
If possible, take the electrical components which must be opened for repair to a dustfree room. If unable to do so, prevent dust from entering the housing.
DANGER Explosion hazard due to flame propagation
Severe injuries and damage to the system
If the process holds a risk of flame propagation, install a flame arrestor.
4.3 Installing the Inlet Filter
The inlet filter, if necessary with matching extension, must be screwed in. The probe is then attached to the mating flange using
the included seals and screws.
4.4 Insulation
On heated probes completely insulate any exposed flange areas and, if applicable, the connection piece to absolutely prevent
thermal bridges. The insulating material must meet the application requirements and be weatherproof.
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4.5 Connecting the Gas Line
The sample gas line must be carefully and properly connected using a suitable fitting.
This table provides an overview of the sample gas probe connections:
Probe
GAS 222
Reservoir
PAV01
Ball valve
pneumatic drive
Control valve
3/2-way solenoid
valve
Connecting flange
1)
DN65/PN6/
DN3“-150
2)
Sample gas inlet G3/4
Sample gas outlet NPT 1/4
Blowback connection G3/8
Test gas connection
1)
Tube Ø6 mm
Tube Ø1/4
2)
Filling port NPT 1/4
Condensate G1/2
Bypass NPT 1/4
Control air G1/8 G1/4
NPT 1/4
Tab.1: Gas Probe Connections (Varies by Model)
1)
Varies by version.
2)
Only GAS 222.xx ANSI and GAS 222.xx AMEX
WARNING Gas emanation
Sample gas can be harmful to the health!
Check the lines for leaks.
4.5.1 Blowback Connection
If the probe has a G3/8 blowback connection, without factory installed blowback device it will be open. The blowback connection
must be sealed gas-tight prior to start-up.
DANGER Toxic, corrosive gasses
Explosive or toxic gases can develop due to a leaking or open blowback connection.
4.5.2 Connecting the Gas Line
Please note the following items when connecting the sample gas line (NPT 1/4") on heated probes to prevent thermal bridges:
– Choose the shortest possible screw connection.
– Shorten the connection pipe for the sample gas line as much as possible. To do so, remove the insulation around the sample
gas line. This is done by loosening the fixing bolts.
CAUTION Fragile
The insulation is fragile. Handle with care, do not drop.
After connecting the sample gas line it must be braced and secured with the clamp.
Long sample gas lines may require additional support clamps along the way to the analysis system! Once all lines have been
connected and checked for leaks, carefully reinstall and secure the insulation.
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WARNING Gas emanation
Sample gas can be harmful to the health!
Check the lines for leaks.
4.5.3 Connecting the calibrating gas line (optional)
Connecting the calibrating gas line requires a Ø6 mm or Ø1/4” pipe fitting.
If the calibrating gas connection was ordered with check valve, a Ø6 mm or Ø1/4” pipe can be connected directly to the check
valve.
4.6 Connecting the Blowback and Pressure Vessel (Optional)
The air lines must be connected carefully and properly, using suitable fittings.
If the probe is equipped with pressure vessel for efficient blowback (optional), a manual shut-off valve (ball valve) must be installed in the air supply, immediately upstream from the pressure vessel.
On probes used to sample flammable gas, nitrogen (inert gas) must be used for blowback. Blowback of explosive gases is prohibited.
NOTICE
The operating pressure of the compressed air (inert gas) required for blowback must always be higher than the process pressure.
Required pressure differential min. 3 bar (44 psi).
DANGER Broken pressure vessel
Gas leak, danger due to flying parts.
Maximum operating pressure of the pressure vessel 10 bar (145 psi)!
The operating pressure reduces based on the operating voltage (see solenoid valve type
plate).
DANGER Adiabatic compression during gas blowback (explosion hazard)!
Adiabatic compression may cause high gas temperatures and must be checked by the
user.
Gas blowback may result in high gas temperatures due to adiabatic compression. This
can cause flammable gases to ignite spontaneously.
a) Blowback of explosive atmosphere / gases is prohibited.
b) Flammable atmosphere / gases (non-explosive) may only be blown back with nitro-
gen (inert gas).
4.7 Electrical connections
WARNING Hazardous electrical voltage
The device must be installed by trained staff only.
CAUTION Wrong mains voltage
Wrong mains voltage may damage the device.
Regard the correct mains voltage as given on the type plate.
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CAUTION Equipment damage
Cables damaged
Do not damage the cable during installation. Install a strain relief for the cable connection. Secure the cable against twisting and loosening. Please note the temperature resistance of the cables (> 100°C/212°F).
The probe includes two cubic plugs per EN 175301-803 (ex DIN43650) and a junction box. The plugs are prewired to the junction
box. For safety reasons this connection must not be modified. The electrical connections must only be run to the terminals of the
junction box.
The power supply for the two heating cartridges (mains supply 115/230V, 50/60 Hz) and the connection for the thermal alarm
contact are provided via the terminal strip in the junction box. Per EN 60079-14 and -15, connection for the alarm output must
be connected energy-limited (U
– Only use cables with a temperature resistance of >100°C to connect to power.
– Make sure the connecting cable has sufficient strain relief (match cable diameter to the seal on the cubic plug).
– Please note, the heating system briefly has high starting currents (max. 6A). Use a suitable fuse (8A). When connecting,
please also observe the applicable Ex protection regulations.
NOTICE
The thermal alarm contact must be connected energy-limited!
(U
= 30 V, I
max
= 30 V, I
max
max
= 100 mA). Please see the enclosed terminal diagram for the connection.
max
= 100 mA)
WARNING High voltage
Damage to the device in case of insulation testing
Do not proceed insulation tests with high voltage
to the device as a whole!
Electric strength test
The necessary tests of all assemblies required to be tested were carried out at the factory (test voltage 1 kV or 1.5 kV depending
on component).
To check the electric strength again yourself, only do so on the respective individual components.
– Now perform the electric strength test against earth.
4.7.1 Heated pressure vessel (optional)
A heated blowback vessel may optionally be used for blowback. Heated via self-regulating PTC heating cartridge to protect
against frost.
The electrical (mains connection 115/230 V AC) connects via the junction box per the enclosed terminal diagram at the end.
– Only use cables with a temperature resistance of >100°C to connect to power.
– Make sure the connecting cable has sufficient strain relief (match cable diameter to the seal on the junction box).
– When connecting, also observe the applicable Ex protection regulations and general warnings in these operating instruc-
tions.
CAUTION Equipment damage
Cables damaged
Do not damage the cable during installation. Install a strain relief for the cable connection. Secure the cable against twisting and loosening. Please note the temperature resistance of the cables (> 100°C/212°F).
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