OPERATING INSTRUCTIONS
Gas Sample Probe SP®
SP180-H
Gas sampling and gas conditioning technology 2.7a-ME
Dear customer,
we have made up this operating manual in such a way that all necessary information about the
product can be found and understood quickly and easily.
Should you still have any question, please do not hesitate to contact M&C directly or go through your
appointed dealer. Respective contact addresses are to be found in the annexe to this operating
manual.
Please also contact our homepage www.mc-techgroup.com for further information about our
products. There, you can read or download the data sheets and operating manuals of all M&C
products as well as further information in German, English and French.
This Operating Manual does not claim completeness and may be
subject to technical modifications.
© 03/2013 M&C TechGroup Germany GmbH. Reproduction of this
document or its content is not allowed without permission from M&C.
®
SP
is a registered trade mark.
2nd Edition: 07/2013
2 Gas sampling and gas conditioning technology 2.7a-ME
Content
1 General information ....................................................................................................................... 4
2 Declaration of conformity ............................................................................................................. 4
3 Safety instructions ........................................................................................................................ 5
4 Warranty ......................................................................................................................................... 5
5 Used terms and signal indications .............................................................................................. 6
6 Introduction .................................................................................................................................... 7
6.1 Serial numbers ......................................................................................................................... 7
6.2 Power supply ............................................................................................................................ 7
7 Technical Data ............................................................................................................................... 8
8 Applications ................................................................................................................................... 8
9 Description ..................................................................................................................................... 9
10 Probe construction ........................................................................................................................ 9
11 Reception ..................................................................................................................................... 10
12 Preparation for Installation ......................................................................................................... 11
13 Mounting ....................................................................................................................................... 11
13.1 Connection of the heated sample line .................................................................................... 12
13.2 Connection of the test gas line ............................................................................................... 13
14 Electrical Connection .................................................................................................................. 13
15 Starting Up ................................................................................................................................... 14
16 Maintenance ................................................................................................................................. 14
17 Switching Off ................................................................................................................................ 16
18 Spare parts list ............................................................................................................................. 17
19 Appendix ...................................................................................................................................... 17
List of illustrations
Figure 1 Dimensions and construction of the SP180-H ................................................................... 10
Figure 2 Mounting of the SP180-H ................................................................................................... 12
Figure 3 Electrical connection diagram ............................................................................................ 14
Figure 4 Opening of the insulation cap ............................................................................................. 15
Figure 5 Replacing the filter element ................................................................................................ 16
2.7a-ME Gas sampling and gas conditioning technology 3
Head Office
M&C TechGroup Germany GmbH Rehhecke 79 40885 Ratingen Germany
Telephone: 02102 / 935 - 0
Fax: 02102 / 935 - 111
E - mail: info@mc-techgroup.com
www.mc-techgroup.com
1 GENERAL INFORMATION
The product described in this operating manual has been examined before delivery and left our works
in perfect condition related to safety regulations. In order to keep this condition and to guarantee a
safe operation, it is important to heed the notes and prescriptions made in this operating manual.
Furthermore, attention must be paid to appropriate transportation, correct storage, as well as
professional installation and maintenance work.
All necessary information a skilled staff will need for appropriate use of this product are given in this
operating manual.
2 DECLARATION OF CONFORMITY
CE - Certification
The product described in this operating manual complies with the following EC directives:
EMV-Instruction
The requirements of the EC directive 2004/108/EC “Electromagnetic compatibility“ are met.
Low Voltage Directive
The requirement of the EC directive 2006/95/EC “Low Voltage Directive“ are met.
The compliance with this EC directive has been examined according to DIN EN 61010.
Declaration of conformity
The EU Declaration of conformity can be downloaded from the M&C homepage or directly requested
from M&C.
4 Gas sampling and gas conditioning technology 2.7a-ME
3 SAFETY INSTRUCTIONS
Please take care of the following basic safety procedures when mounting, starting up or
operating this equipment:
Read this operating manual before starting up and use of the equipment. The information and
warnings given in this operating manual must be heeded.
Any work on electrical equipment is only to be carried out by trained specialists as per the regulations
currently in force.
Attention must be paid to the requirements of VDE 0100 (IEC 364) when setting high-power electrical
units with nominal voltages of up to 1000 V, together with the associated standards and stipulations.
Check the details on the type plate to ensure that the equipment is connected to the correct mains
voltage.
Protection against touching dangerously high electrical voltages:
Before opening the equipment, it must be switched off and hold no voltages. This also applies to any
external control circuits that are connected.
The device is only to be used within the permitted range of temperatures and pressures.
Check that the location is weather-protected. It should not be subject to either direct rain or moisture.
The device must not be used in hazardous areas.
Installation, maintenance, monitoring and any repairs may only be done by authorized personnel with
respect to the relevant stipulations.
4 WARRANTY
If the equipment fails, please contact M&C directly or else go through your M&C authorised dealer.
We offer a one year warranty as of the day of delivery as per our normal terms and conditions of sale,
and assuming technically correct operation of the unit. Consumables are hereby excluded. The terms
of the warranty cover repair at the factory at no cost or the replacement at no cost of the equipment
free ex user location. Reshipments must be send in a sufficient and proper protective packaging.
2.7a-ME Gas sampling and gas conditioning technology 5
5 USED TERMS AND SIGNAL INDICATIONS
This means that death, severe physical injuries and/or important
material damages will occur in case the respective safety measures
DANGER!
are not fulfilled.
This means that death, severe physical injuries and/or important
material damages may occur in case the respective safety
WARNING!
measures are not fulfilled.
This means that minor physical injuries may occur in case the
respective safety measures are not fulfilled.
CARE!
CARE!
Without the warning triangle means that a material damage may
occur in case the respective safety measures are not met.
ATTENTION!
This means that an unintentional situation or an unintentional status
may occur in case the respective note is not respected.
These are important information about the product or parts of the
operating manual which require user’s attention.
NOTE!
SKILLED STAFF
These are persons with necessary qualification who are familiar with
installation, use and maintenance of the product.
6 Gas sampling and gas conditioning technology 2.7a-ME
6 INTRODUCTION
M&C gas sample probes provide direct insitu ultra-fine filtration during continuous gas sampling for
analytic measurements. In this way, part of the necessary maintenance work for a system is
concentrated on a single point. This filter technology has the major advantage that dust mixtures
consisting of ultra-fine and coarse dusts can be optimally retained with the least possible maintenance
work.
Optimal adaptation of the sample probe to processing conditions and to measurement work is a
necessary condition for a measurement system to work smoothly. Basically, the gas sample should be
kept to a necessary minimum. This is made possible thanks to optimised downstream gas processing
using M&C components. Only in this way it is possible to reduce maintenance to a minimum while
ensuring maximum availability.
6.1 SERIAL NUMBERS
The nameplates bearing the serial number are located in the electrical connection box.
Always quote the device's serial number when making enquiries and ordering replacement parts.
6.2 POWER SUPPLY
The probe can be operated on alternating current in the range from 110 to 240V.
2.7a-ME Gas sampling and gas conditioning technology 7
3
2
7 TECHNICAL DATA
Gas Sample Probe Series SP® SP180-H
Part No. 02S1800
Weather protection shield yes
Mounting outdoors yes
Sample tube Type SP210/SS, stainless steel 316Ti, length 1 m* optional*
Sample temperature max. 600 °C*
Sample pressure 0.4 to 2 bar abs.
Ambient temperature -20 °C to +60 °C
Recommended for dust loadings up to 1 g/m
Filter chamber volume 70 ml
Filter element S-2K, filter porosity 2 μm, ceramic
Probe heating temperature +180 °C self-regulating
Ready for operation after 2 hours
Temperature alarm contact, alarm point <160 °C, NO
Temperature alarm, contact rating 250V-3A AC, 30V-3A DC
Connection sample outlet 1/4"-NPT inside, with 6 mm (DN4/6) Swagelok tube connector
Power supply 110 up to 240V 50 / 60Hz
Power consumption start up: 400VA, usual: 100VA, (fuse 6A)
Electrical connection terminals max. 2,5 mm
1,5
Electrical equipment standard EN 61010, EN 60335-1
Degree of protection IP54, EN 60529
Mounting flange DN65 PN6,B stainless steel 316Ti
Material of sample contacting parts SS 316 / 316Ti, FPM, ceramic
Weight 7,5 kg
Option
Part No.: 02 S 9200 Insitu probe tube out of stainless steel 316Ti type SP210/SS,
connection G3/4" o, ø 10/12, length 1 m*, incl. flange gasket.
* Standard, other versions on request.
*
, cable glands 1 x M20x1,5 and 1 x M16 x
P und T90 at flow of:
P pressure loss with new filter element S-2K:
T90 time-without sample tube/prefilter- 4,0 2,5 <1,0
100 200 500
4 7 15
8 APPLICATIONS
Nl/h
mbar
Sec.
The electrically heated M&C gas sample probe SP180-H is used for continuous gas sampling in
processes with dust densities of up to 1g/m³, operating pressure of up to max. 6 bar abs.,
temperatures of up to a maximum of 600°C or for high gas humidity. Thanks to its compact design it
requires only limited space. The gas sample probe SP180-H is equipped with a new protective cover
and can be used for outdoor mounting.
8 Gas sampling and gas conditioning technology 2.7a-ME
9 DESCRIPTION
The sample probes are designed for easy installation, reliable operation and trouble-free maintenance.
Advantages are:
Gas sampling with dust-laden processes;
Low volume, fast response time;
Filter elements can be changed without tools and without disconnecting the (heated) sample
line;
The filter chamber can be easily cleaned;
The probe tube can be cleaned without dismantling the probe;
Self-regulated electrical heating with undertemperature alarm contact;
Different probe tubes and pre-filters as option;
With calibration gas connection as standard.
The 75 mm ceramic filter element with a porosity of 2µm and a large surface is located in the heated
stainless steel filter housing of the probe. The gas sample probe is heated up to +180°C using a
special self-regulated heating element. No thermostat or temperature limiter is necessary. A separate
thermo switch is provided for under temperature monitoring (< 160°C, NO).
10 PROBE CONSTRUCTION
The probe head with its new all-round enclosing heat insulating protection cover forms a unit with the
filter housing, the standard mounting flange DN65 PN6 and the laterally mounted junction box.
A mounting clamp and a tube connector are located on the underside of the probe for the connection
of heated M&C sampling lines with external diameters of 40mm to a max. 55mm and a tube diameter
of 6mm.
We are pleased to help you finding a suitable heated M&C sample line for your application.
The sample gas outlet at the probe is provided for tube 6mm (DN4/6).
The stainless steel sampling tube of one meter length (part No.: 02S9200) can optional be provided
and is connected to the G 3/4” thread of the mounting flange. The maximum operating temperature for
the stainless steel sampling tube is 600C. The modular system of our sample probes allows the
usage of all M&C sample tubes and prefilters with G 3/4” connection thread. This guarantees an
optimal adaptation to the process conditions.
2.7a-ME Gas sampling and gas conditioning technology 9
The following cross-sectional drawing shows the probe SP180-H.
Figure 1 Dimensions and construction of the SP180-H
11 RECEPTION
The gas sample probe normally is delivered in two packaging units:
1. The gas sample probe with the required screws, nuts and flange sealing.
2. Sample tube with gasket.
The gas sample probe should be removed carefully from the packaging and checked immediately for
completeness against the delivery note.
Check the goods for any damage incurred during transport and if necessary inform your transport
insurer of any damage.
10 Gas sampling and gas conditioning technology 2.7a-ME
12 PREPARATION FOR INSTALLATION
Select the optimal sampling point in accordance with the generally applicable guidelines or
consult the competent persons.
Locate the sampling point in such a way that there is adequate space for inserting and
removing the probe and pay attention to the insertion length of the probe tube.
Make certain that the probe is easily accessible so that you can carry out any subsequent
maintenance work without trouble.
Locate the probe connections in such a way that the connections' temperature is always above
the acid dew point in order to avoid corrosion and blockage problems. If this is not possible, a
heated SP35/SP30 probe tube is recommended for cold connections.
If the ambient temperature in the area of the connections is >80°C as a result of radiated heat,
a radiated-heat deflector must be mounted to protect the probe.
The connection's mounting flange connection should comply with DN65 PN6. If other
connection sizes are required, a special adapter flange /S010 can be supplied as an option.
Before mounting, the probe must be adapted to the existing operating conditions.
The existing operational parameters are to be checked accordingly prior to commencing mounting
work:
weatherproof mounting position
Under / over pressure situation
Process temperature
Dust loading
Dust composition - grain size
Gas composition
Which parameters should be
measured, e.g. O
, CO, SO2, NOX,..,
2
Required amount of gas
Necessary T90 time
13 MOUNTING
_____present _____set
mbar bar
°C, Min. °C, Max.
g/m³
µm
corrosive toxic explosive
Vol.% mg/Nm³ ppm
l/hr,
Min.
l/hr,
Max.
sec.
M&C SP180-H probes are designed for stationary use and if properly selected and mounted a long
service life and minimum maintenance are guaranteed. It is advisable to mount the probe in an
operational position which is at a 10% inclination to the process. See also Figure 2 for the following
description.
Screw either the probe tube directly into the ¾" inner thread in the flange of the probe with
the ¾" flat gasket and tighten.
For mounting of the SP180-H at the sampling flange loosen the metal clamp around the heat
insulating protection cover and remove the cover .
If the probe connection does not correspond to the standard flange connection DN65 PN6, an
optionally supplied adapter flange should be mounted to the probe (see Figure 2).
If the heated probe tube type SP30/35 is used then the probe is to be screwed to its flange
(with welded threaded bolt). First insert the flange seal between the two flanges.
Attach the flange seal to the probe connection.
Insert mounted probe tube into the connection piece and fasten the probe using the screws
and nuts supplied.
2.7a-ME Gas sampling and gas conditioning technology 11
After mounting of the probe at the sampling flange put the heat insulating protection cover
over the probe flange again and secure it with the metal clamp .
A preferred mounting position is to have the probe with its sample gas outlet
pointing downwards, although this is not absolutely necessary for perfect
functioning.
NOTE!
Figure 2 Mounting of the SP180-H
13.1 CONNECTION OF THE HEATED SAMPLE LINE
In order to connect the sample line, a threaded tube connector for dimension Ø 6x1mm is
available – other dimensions on request.
Open metal clamp .
Introduce the tube connection piece into the bolted pipe joint and connect.
If a PTFE tube is used as sample line, a carrying bracket must under all circumstances be
inserted in the end of the tube in order to prevent the tube being pressed together.
The temperature-resistant, stainless steel connector supplied by M&C has a double-blade
ring system to ensure reliable sealing. After tightening the nut of these connector by hand, it
should then be tightened exactly 1¼ of a turn using a flat spanner and are then properly
mounted.
Put the heated sample line to the open metal clamp and close it.
Make sure that the connection is leakproof !
NOTE!
12 Gas sampling and gas conditioning technology 2.7a-ME
13.2 CONNECTION OF THE TEST GAS LINE
For connection of the test gas line a threaded tube connector for dimension Ø 6x1mm
(DN4/6) is available (see Figure 1)
If a PTFE tube is used as sample line, a carrying bracket must under all circumstances be
inserted in the end of the tube in order to prevent the tube being pressed together.
The temperature-resistant, stainless steel connectors supplied by M&C has a double-blade
ring system to ensure reliable sealing. After tightening the nuts of these connectors by hand,
they should then be tightened exactly 1¼ of a turn using a flat spanner and are then properly
mounted.
14 ELECTRICAL CONNECTION
WARNING!
When connecting the equipment, please ensure that the supply
voltage is identical with the information provided on the model type
plate.
Attention must be paid to the requirements of IEC 364 (DIN VDE
0100) when setting high-power electrical units with nominal
voltages of up to 1000 V, together with the associated standards
NOTE!
and stipulations.
In any case we recommend the use of temperature resistant cable !
A main switch and matching fuse must be provided externally!
The main circuit must be equipped with a fuse corresponding to
the nominal current (over current protection); for electrical details
see technical data.
It is recommended to use the low temperature alarm. In case of an
alarm the flow can be stopped and the components downstream
the probe are safe for demage.
The junction box is mounted on the side of the probe. The wiring plan is located in the lid of the
junction box. Two separate cable glands are available for the mains and the signal cable.
Carry out the following steps:
Remove the lid of the junction box;
Insert the mains cable (min. 3 x 1.5 mm
2
) through the cable gland and connect it to the
appropriate terminals as shown below;
Insert the signal cable through the other cable gland and connect it to the appropriate terminals
as in the wiring below;
Screw lid back on;
2.7a-ME
Gas sampling and gas conditioning technology
13
Figure 3 Electrical connection diagram
15 STARTING UP
Before starting up check whether the mains power supply voltage corresponds with the information
stated on the probe's nameplate.
Switch on mains power supply. The total heating-up time is approximately 2 hours. After about
1 hour the probe is already sufficiently heated for the temperature to have exceeded the
temperature failure alarm value (160°C), but it still takes about another hour until operating
temperature is reached.
The sample gas can now be extracted via the probe after this minimum heating-up time of 2
hours.
16 MAINTENANCE
The safety measures specific to the plant and process are to be consulted prior to any maintenance
work!
Prior to carrying out maintenance work on electrical parts, mains
WARNING!
voltage should be disconnected from all poles!
This also applies to any external control circuits which may be
connected.
It is difficult to give any recommendations as to a particular maintenance cycle. Depending on your
process conditions, a meaningful maintenance cycle must be elaborated for the specific application.
14
Gas sampling and gas conditioning technology 2.7a-ME
An indication that probe-maintenance may be necessary could be shown by a constant decline in the
amount of sample gas in the analysis system.
Probe maintenance is restricted essentially to replacing filter elements and checking seals:
Aggressive condensate is possible.
WARNING!
Wear protective glasses and proper protective clothing!
High surface temperatures!
Wear protective gloves!
Remove insulation cap by pressing it together (see Figure 4);
CARE!
Don‘t use green retaining strap for removal of the insulation cap
because it hereby will be damaged !
Figure 4 Opening of the insulation cap
2.7a-ME
Gas sampling and gas conditioning technology
15
Loosen probe lid by turning handle left and pull it out with o-rings , filter element sealings
, filter element with filter element holder and filter’s knurled screw ;
Screw out the filter’s knurled screw
Check filter element seals
Check lid o-rings
Clean filter chamber; It is also possible to rod through the probe tube in order to remove
deposits.
Remounting happens in reverse order. To lock the lid put locking against the studs and turn
handle
right.
and change if necessary;
and replace if necessary;
and renew filter element ;
Figure 5 Replacing the filter element
17 SWITCHING OFF
Before switching off, i.e. switching off the heating, the probe be flushed with inert gas or air in order to
avoid condensation of aggressive components from the process gas
.
16 Gas sampling and gas conditioning technology 2.7a-ME
18 SPARE PARTS LIST
Wear, tear and replacement part requirements depend on specific operating conditions.
The recommended quantities are based on experience and they are not binding.
Gas sample probe SP180-H
(C) Consumable parts
(R) Recommended spare parts
(S) Spare parts
Part No. Indication
90 S 0015
93 S 0045
93 S 0020
93 S 0025
90 S 2080
90 S 2077
90 S 2075
93 S 2105
93 S 2110
Recommended quantity being in
operation [years]
C/R/S
Ceramic filter element S-2K, 2 µm, 75 mm
Viton - gasket (30)
O-ring lid sealing (39) Material: Viton.
O-ring lid sealing (55) Material: Viton.
Novapress gasket 3/4" (blue), max. 600°C R 1 2 3
Novapress flange gasket DN65PN6 (67mm i.) R 1 1 1
flange gasket set for DN65 PN6 B, consisting of Novapress
gasket (67mm i.) and screws set M12
Min. temperature contact <160°C R - - 1
Cartridge heater HLPSR, 100mm, 110-240V 100W R 2 2 4
C 6 12 18
R 4 8 12
R 2 4 6
R 2 4 8
S 1 1 1
1 2 3
19 APPENDIX
Further product documentation can be seen and downloaded from our home page:
www.mc-techgroup.com
Sample tubes series SP, Document: 2.14 and 2.15
Prefilter series SP, Document: 2.7
2.7a-ME Gas sampling and gas conditioning technology 17
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