M&C TechGroup SP2000-H320-S2 Operator's manual
Operating Manual
Gas Sample Probe Series SP ®
Version SP 2000-H320/S, SP2000-H320/S1,
SP2000-H320/S2
Gas sampling and gas conditioning technology 2-1.1.4-ME
This Operating Manual does not claim completeness and may be subject to technical modifications.
© 01/2006 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.
1st Edition: 01/06
2
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.
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Contents
1 General information ............................................................................................................... 5
2 Declaration of conformity ..................................................................................................... 5
3 Safety instructions ................................................................................................................. 6
4 Warranty ................................................................................................................................. 6
5 Used terms and signal indications ....................................................................................... 7
6 Introduction ............................................................................................................................ 8
6.1 Patented probe model ..................................................................................................... 8
6.2 Serial number .................................................................................................................. 8
7 Application ............................................................................................................................. 9
8 Technical data ........................................................................................................................ 9
9 Description ........................................................................................................................... 10
9.1 Construction of the probe .............................................................................................. 10
10 Receipt of goods and storage ............................................................................................ 11
11 Preparation and installation ................................................................................................ 11
12 Mounting ............................................................................................................................... 12
12.1 Dismounting the filter housing cover and checking the filterelement ............................ 13
12.2 Temperature regulator .................................................................................................. 15
12.3 Scope of sampling tubes and prefilters ......................................................................... 15
12.4 Mounting of the probe with extension tube or prefilter .................................................. 16
13 Supply connections ............................................................................................................. 18
13.1 Mounting the sample line .............................................................................................. 18
13.2 Connection of the test gas feeding line ......................................................................... 18
13.3 Connecting the condensate evacuation ........................................................................ 19
13.4 Electrical connection ..................................................................................................... 20
13.4.1 Version SP2000-H320/S with internal capillary tube thermostat .......................... 20
13.4.2 Version SP2000-H320/S1 with electronic temperature controller ........................ 21
13.4.3 Version SP2000-H320/S2 with 2 electronic temperature controllers ................... 22
14 Starting up ............................................................................................................................ 24
14.1 Adjustment of the set value temperature ...................................................................... 25
14.1.1 Version SP2000-H320/S ...................................................................................... 25
14.1.2 Version SP2000-H320/S1 .................................................................................... 25
14.1.3 Version SP2000-H320/S2 .................................................................................... 26
14.2 Test gas feeding ........................................................................................................... 26
14.2.1 Option test gas feeding return valve .................................................................... 26
14.2.2 Option 3/2-Way ball valve /3VA320 ..................................................................... 27
15 Closing down ....................................................................................................................... 27
16 Maintenance and repair ....................................................................................................... 27
16.1 Replacement of the Standard Filter element and control of the seals ......................... 28
16.2 Replacement of the heating cartridge and the thermostat ............................................ 29
17 Spare parts list ..................................................................................................................... 32
18 Connection and mounting data .......................................................................................... 33
19 Annex .................................................................................................................................... 33
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List of Illustrations
Figure 1 Probe construction eg. version SP2000-H320/S1 ............................................................. 11
Figure 2 Mounting possibilities ......................................................................................................... 12
Figure 3 Schematic drawing of the filter housing cover ................................................................... 13
Figure 4 Dismounting of the filter housing lid ................................................................................... 14
Figure 5 Filter element receiving part............................................................................................... 14
Figure 6 Mounting the sample tube or pre-filter ............................................................................... 17
Figure 7 Connection tube on GL adapter ......................................................................................... 18
Figure 8 Connection of test gas line and condensate evacuation ................................................... 19
Figure 9 Electrical connection SP2000-H320/S with thermostat ...................................................... 20
Figure 10 Electrical connection SP2000-H320/S1 with electronic controller eg. type 703G ............. 21
Figure 11 Electrical connection SP2000-H320/S2 with electronic double controller 703G ............... 23
Figure 12 Set value adjustment on Version SP2000-H320/S ............................................................ 25
Figure 13 Schema of test gas (calibration gas) feeding via return valve ........................................... 27
Figure 14 Mounting notice for probes with fibre glass filter element F-0,1GF 150 ............................ 29
Figure 15 Positioning of the thermostat and heating cartridge .......................................................... 30
Figure 16 Positioning of the fixing screws and cable gland ............................................................... 30
Figure 17 Connection box with heating cartridge and thermostat sensor ......................................... 31
Figure 18 Mechanical stop of the thermostat .................................................................................... 31
Figure 19 SP2000-H/Filter elements ................................................................................................. 34
Figure 20 High temperature sample tube max. 1800°C .................................................................... 35
Figure 21 Electrically heated sample tube SP30-H1.1/-H2 ............................................................... 36
Figure 22 SP2000-H320/S ................................................................................................................ 37
Figure 23 SP2000-H320/S1 .............................................................................................................. 38
Figure 24 SP2000-H320/S2 .............................................................................................................. 39
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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 as well as DIN
57721 for the voltage test of heating elements.
Declaration of conformity
The EU Declaration of conformity can be downloaded from the M&C homepage or directly requested
from M&C.
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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 probes SP2000-H320S, SP2000-H320/S1 and SP2000-H320/S2 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 via your appointed M&C 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 device. 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 sent in a sufficient and proper protective
packaging.
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DANGER!
This means that death, severe physical injuries and/or important
material damages will occur in case the respective safety measures
are not fulfilled.
WARN ING !
This means that death, severe physical injuries and/or important
material damages may occur in case the respective safety measures are not fulfilled.
CAUTION!
This means that minor physical injuries may occur in case the respective safety measures are not fulfilled.
CAU TIO N!
Without the warning triangle means that a material damage may
occur in case the respective safety measures are not met.
ATT ENT ION
This means that an unintentional situation or an unintentional status
may occur in case the respective note is not respected.
NOTE!
These are important information about the product or parts of the
operating manual which require user’s attention.
SKILLED STAFF
These are persons with necessary qualification who are familiar with
installation, use and maintenance of the product.
5 USED TERMS AND SIGNAL INDICATIONS
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NOTE!
Please always indicate the serial number of the equipment when you have
questions or in case of ordering spare parts.
8
6 INTRODUCTION
A great problem during extractive and continuous gas analysis are the escort substances of the gas
such as dust, water vapour and also gas components that build up corrosive acids in connection with
condensed water vapour.
It may also occur that solid particles are precipitated when the gas is cooled down. Consequently, the
downstream conditioning device would be choked.
In order to realize a measurement easy to maintain, the dust must be separated and the condensing
of water vapour must be prevented. Thus, you avoid a caking of the dust and the water as well as the
developing of acid. The filter and connected lines will not be choked and the probe material in contact
with the gas will not be attacked by eventual acids. To prevent the subsequent precipitation of solid
particles, they, too, must be separated and removed.
The heated M&C sample probes as for example those of series SP 2000-H.... provide a solution for
this problem. Adequately adapted to the process conditions, these probes guarantee a minimum of
maintenance. During the continuous gas sampling for the analytical measurement, the M&C sample
probes are already filtering the fine dust directly on the sampling point and, if necessary, separate
and remove the solid particles. This way, a great extent of maintenance work on the analysing system is avoided.
Principally, the quantity of the sampled gas should be as low as possible in order to keep the necessary maintenance work to a minimum and to grant a maximum availability. This objective can be
achieved via a subsequent optimized gas conditioning system with components of M&C.
6.1 PATENTED PROBE MODEL
The patented gas sample probe SP2000....., designed in modular construction, is produced by
M&C TechGroup Germany GmbH, D- 40885 Ratingen. [PATENT-NO.: 41 11 377]
6.2 SERIAL NUMBER
The type plates with the serial numbers are to be found where the electrical connection box is placed.
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Gas sample probe Type
SP2000-H320/S
SP2000-H320/S1
SP2000-H320/S2
Part number
20S5000 (a)
20S5005 (a)
20S5010 (a)
Temperature regulation
Thermostat
FeCu-Ni (Regulator optionally)
FeCu-Ni (Regulator optionally)
Probe heating
max. 320 °C
Ambient temperature
+5 °C to +60 °C ** optionally with GFK protective housing -20 °C to +60 °C
Sealing material
Graphite
Material probe flange sealing
Novapress
Sampling tube/Pre filter
Optionally
Sampling pressure max.
0,4 –2 bar* abs.
Volume of filter chamber
120 cm3
Porosity
S – 2K150 = ceramic*, 2 micron, /F-0,1GF150 = Glass fibre** 0,1 micron
/F-3SS150** 3 micron, /FW = Glass fibre-filter cotton**
Ready for work
after 2h
Connection gas outlet
Threaded hose coupling DN 4/6
Connection test gas
Pipe connection Ø 6 mm with blind plug, optionally Ø ¼“ (a)
Power Supply
230V 50/60Hz, 800W, optionally 115V 60Hz (a)
Electrical connection
Terminals max. 2,5 mm2, terminal range 0,75 – 4mm
Standard of electrical equipment
EN 61010, EN 60519-1
Mounting flange
DN 65 PN 6, Form B, 1.4571*, > DN or ANSI possible**
Weight
17 kg
Filter element Type
Filter porosity
Material
S-2K 150
2µm
Ceramic *
S-3SS 150
3µm
Stainl. Steel 1.4401
S-0,1GF 150
0,1µm
Glass fibre
FW
--------
Glass wadding
7 APPLICATION
The probes type SP2000-H320/S.. are used for continuous gas sampling in processes with high dust
load and high temperatures and/or high gas humidity where additionally solid particles may precipitate. M&C has developed these probes for eg. continuous gas sampling in waste gas of DENOX
plants (SCR) where NH3 is added to the flue gas in order to reduce the NOX content. With temperatures of <300 °C, ammonium salts are produced due to the chemical reaction of NH3 and SO2/SO3 in
the flue gas. This salification will choke in a very short time the filters and sample lines.
8 TECHNICAL DATA
* = Standard ** = Option
* = Standard
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9 DESCRIPTION
The probes have been designed for easy mounting, safe operation, easy maintenance and a great
variety of applications.
The main features of this probe are: changing the filter element without tools and without necessity of
dismounting the sample line, easy cleaning of the filter housing, cleaning of the sample tube without
dismounting the probe. The big surface filter element is placed inside a heated filter receiving part of
stainless steel.
The M&C gas sample probe SP2000-H320/S is based on the standard sample probe SP2000-H320.
The temperature regulation of the gas sample probe SP2000-H320/S is made via an integrated capillary sensor thermostat adjustable from 50 to 320 °C including an excess temperature limiter and
alarm in case of insufficient temperature. Optionally, the gas sample probe can be delivered with a
thermocouple FeCu-Ni instead of the thermostat regulator. In this case, an external temperature
regulator is not necessary (eg. 703).
According to the application, it is possible to add sample tubes and pre-filters of different sizes and
versions out of the modular system of M&C probe accessories. All these options are to be mounted
before the probe. In the outlet of the probe, the sample gas is lead via a heated connection adapter
into a non-heated (SP2000-H320/S and SP2000-H320/S1) or into a heated (SP2000-H320/S and
SP2000-H320/S1) collection vessel. Inside the vessel that is made of glass and filled with glass balls
to enlarge the surface, the chemical reaction of the sample gas takes place and the solid particles
and salts are deposited.
On the versions SP2000-H320/S and SP2000-H320/S1 the condensate collected in the collection
vessel is pumped out by the peristaltic pump SR25.1G. The condensate effects that the existing solid
contaminations are withdrawn and transmitted outside. Because of the heated connection adapter
and the hot gas flow, the operating temperature inside the collection vessel is increased compared to
the ambient temperature.
Due to the fact that the gas components are solved to a negligible extent in the warm condensate,
the application of this sampling technique in DENOX systems with a low content of NH3 (normally a
few ppm) allows the analyse of SO2 and NOX without important losses. These will be a few ppm only
and can normally be neglected. In order to examine exactly the extent of the losses, you can feed test
gas on the gas sample probe and determine the eventual measuring fault that can be calibrated afterwards.
On version SP2000-H320/S2 the collecting vessel is equipped with a heater in order to avoid chemical reactions of the sample gas components below a defined temperature as well as to avoid freezing
of the condensate in case the vessel is mounted outside. A heated sample line 3/4-M for max. 200 °C
operating temperature can be connected onto the gas outlet of the collection vessel. The collection
vessel is equipped with a heat isolating protection cover.
9.1 CONSTRUCTION OF THE PROBE
The complete probe is made up of the heated filter part and a sample tube or pre-filter. The filter receiving part with the surrounding heating jacket is fitted together to a unit with the standard mounting flange DN65 PN6 and the electrical connecting box mounted laterally .
The heat insulated covering cap is placed on the stainless steel angle plate of the mounting
flange and is fixed with 2 fastening clamps. Thanks to the covering cap, the heat is distributed regularly over the probe heating and serves at the same time as weather and contact protection. In the
probe outlet the connection adapter with the collecting vessel is mounted. A mounting clamp is
available for the connection of the heated line. On the probes SP2000-H320/S and SP2000-H320/S1
a peristaltic pump SR25.1 is mounted below the collecting vessel in order to evacuate the condensate.
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1
2
5
4
3
6
NOTE!
The equipment should be stored in a protected, frost-free room!
Figure 1 Probe construction eg. version SP2000-H320/S1
10 RECEIPT OF GOODS AND STORAGE
The gas sample probe and any special accessories should be removed carefully from the packag-
ing 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.
The gas sample probe is normally delivered in two packaging units:
1. The gas sample probe with the screws, nuts and flange seal required for mounting;
2. Sample tube or pre-filter, if applicable with extension tube.
11 PREPARATION AND INSTALLATION
Select the optimal sampling point in accordance with the generally applicable guidelines of
consult the competent persons.
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Adapter-
R 2"-threaded
to flange size
Seal according
Mounting fitting
20 S 9005
Seal 3/4"
90 S 2080
90 S 2077
DN65PN6
Seal
20 S 9004
flange
Options Probe Mounting
12
Locate the sampling point in such a way that there is adequate space for inserting and remov-
ing 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.
Make sure that the bleeder connection at site is made up and insulated so that the connec-
tion’s temperature is always above the dew point or above the acid dew point in order to avoid
corrosion and blockage problems as well as washing out effects. If this is not possible, a
heated sample tube SP35 / SP30 is recommended for cold connections.
If the ambient temperature in the area of the connections is >80°C due to radiant heat, then a
rediant heat reflection plate must be mounted to protect the probe.
The mounting flange connection of the connection piece should comply with DN65 PN6. If
other connection sizes are required, a special adapter flange can be supplied as option. Instead of a flange connection mounting, the probe can also be mounted using a R2” adapter
on a corresponding threaded sleeve connection. The required minimum flange size or the
minimum connection piece diameter depends on the outside diameter of the used sample
tube or pre-filter.
Figure 2 Mounting possibilities
12 MOUNTING
The M&C probes SP2000-H320/S.. are designed for stationary use and guarantee a long service life
and a minimum of maintenance provided they are properly selected and mounted. The required position is horizontally.
Gas sampling and gas conditioning technology 2-1.1.4-ME
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