M&C TechGroup SP3200 Operator's manual

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Operating Manual

Gas sample probe Series SP

Version SP3200V /.../HEX5-x.08

Version SP3200 /.../RS/HEX5-x.08

II 3 GD

Gas sampling and gas conditioning technology 2-1.3.9-ME

Contents

1 Equipment standard ........................................................................................................................... 3

2 Safety information .............................................................................................................................. 3

3 Information on the use in hazardous areas ...................................................................................... 4

4 Guarantee ............................................................................................................................................ 4

5 Terms and signals used in this manual .............................................................................................. 4

6 Application .......................................................................................................................................... 5

7 Description .......................................................................................................................................... 5

8 Options ................................................................................................................................................ 7

8.1 Backflush unit type /RS ................................................................................................................................................... 9

8.2 Option /R, /BB and /BBF for test gas feeding or backflushing via check valve R 1/4“, BB 3/8“

or BBF 3/8“ ........................................................................................................................................................................... 9

8.3 Option /CC, /CCF test gas feeding before or behind the probe filter to be selected by the user ..... 10

8.4 Option /C/I test gas feeding via check valve behing the probe filter with pneumatic stop

valve of the probe outlet to the process ............................................................................................................... 10

8.5 Option 2-Way ball valve............................................................................................................................................... 10

8.6 Option spun glass cartridge FW ............................................................................................................................... 10

8.7 Option /3VA test gas feeding and backflushing VIA 3/2-Way ball valve ................................................... 10

8.8 Ball valve drive MS1 ...................................................................................................................................................... 11

8.9 Option /2X second sample gas outlet on the probe ......................................................................................... 11

8.10 Option /PT100 ADditional PT100 with terminal box for external temperature control ....................... 11

8.11 Probe heating .................................................................................................................................................................. 12

9 Technical Data ................................................................................................................................... 12

10 Receipt of goods and storage .......................................................................................................... 15

11 Preparations for installation ............................................................................................................ 15

12 Mountage .......................................................................................................................................... 16

13 Electrical connection .........................................................................................................

................ 20

14 Starting-up ........................................................................................................................................ 21

15 Maintenance ...................................................................................................................................... 21

15.1 Replacement of the filter element ........................................................................................................................... 22

15.2 Replacement of the preliminary filter ..................................................................................................................... 22

15.3 Cleaning of the probe .................................................................................................................................................. 22

16 Shutdown .......................................................................................................................................... 23

17 Spare parts list ................................................................................................................................... 23

18 Annex ................................................................................................................................................. 23

Figures

Figure 1 Probe SP3200(V) without options with preliminary filter V20 .................................................................... 6

Figure 2 Schematic view of the options for backflush and test gas feeding .......................................................... 8

Figure 3 Function scheme of the option 3/2-way ball valve /3VA........................................................................... 11

Figure 4 Schematic drawing of the filter housing cover ............................................................................................. 17

Figure 5 Removal of the filter housing cover .................................................................................................................. 18

Figure 6 SP3200 RS, HEX5-1.08 .............................................................................................................................................. 24

Figure 7 SP3200 RS, HEX5-2.08 .............................................................................................................................................. 25

This Operating Manual does not claim to be complete and is subject to technical changes. ©02/2004 M&C TechGroup GmbH. Reproduction of this document or its content is not allowed without permission from M&C.

3. Edition: 07/2013

2 Gas sampling and gas conditioning technology 2-1.3.9-ME

1 EQUIPMENT STANDARD

The equipment standard of the gas sample probe and the options correspond to the safety requirements of EC Directive 94/9/EG. The respective type of protection depends on the variant (see table 4).

Manufacturer: M&C TechGroup GmbH Rehhecke 79

40885 Ratingen – Germany Tel.: 02102/935-0 E-Mail: info@mc-techgroup.com www.mc-techgroup.com

2 SAFETY INFORMATION

Please observe the following fundamental safety precautions when using the device:

 Read these operating instructions carefully before start-up and use of the device! The

information and warnings given in these operating instructions must be heeded.

 The declaration of conformity must strictly be observed (see enclosure).  Work on electrical equipment may only be carried out by qualified personnel in ac-

cordance with the regulations actually valid.

 When erecting high-voltage power installations with rated voltages up to 1000 V, the

requirements of VDE 0100 and its associated standards and regulations must be observed.

 For use of the device in hazardous areas, the relevant national and international

standards and regulations must be observed.

 The device must be connected to a mains supply with the same voltage as specified

on the rating plate.

 Protection against contact with high electrical voltages:

The device must be safely isolated from the mains supply before it is opened. The same applies to any connected external control circuits.

 Only use the device within the permissible temperature ranges.  Check that the location of the device is weatherproof. Do not expose it directly to rain

or liquids.

 Installation, maintenance, control and eventual repairs may only be carried out by

authorized personnel. Such work must be carried out in accordance with the applicable rules and regulations.

2-1.3.9-ME Gas sampling and gas conditioning technology 3

3 INFORMATION ON THE USE IN HAZARDOUS AREAS

Please see the identification of the individual variants in table 4.

Detailed information and a copy of the declaration of conformity are contained in the appendix to these operating instructions. The devices must be installed and used in accordance with the conditions and installation instructions given in the EX-Certificate (see appendix). Only then, a safe operation in hazardous areas is guaranteed.

Any changes to the standard configuration with unspecified parts or parts not authorised by M&C as well as repair or service work with unspecified parts leads to an immediate loss of ex-certification.

- In case of any doubt, please contact directly M&C or your M&C franchise dealer.

4 GUARANTEE

In the event of a device failure, please contact M&C directly or your M&C franchise dealer. The device is covered by a one-year warranty starting from the day of delivery according to our normal terms and conditions of sale and assuming a technically correct use of the unit. Wearing parts are not covered by the warranty. The warranty includes free repair at our factory or free replacement of the device which must be sent to us carriage paid and correctly packed.

5 TERMS AND SIGNALS USED IN THIS MANUAL

QUALIFIED

PERSONNEL

The term QUALIFIED PERSONNEL denotes people who are familiar with the installation, start-up, maintenance and operation of the product and have the necessary qualification by training or instruction.

The warning and notice symbols mean important information on the product or specific parts of these operating instructions to which special attention should be paid.

This symbol emphasizes important information on the product or specific parts of these operating instructions referring to use in hazardous areas.

4 Gas sampling and gas conditioning technology 2-1.3.9-ME

6 APPLICATION

The probes of type SP3200V.. and SP3200.. are used for continuous gas sampling in dust-laden processes or processes with high temperatures (according to table 5, chapter 10) or high gas moisture. The modular construction of the probes and the variety of possible options guarantee optimum adaptation of the probes to complex process and environmental conditions. The probes of the type SP3200V.. and SP3200.. are available in both, an unheated and an electrically heated version.

The probes must not be used for sampling of gases or gas mixtures that could be explosive, even in absence of air or which change safety-relevant material properties. The gases or gas mixtures must also not contain any solid particles that could generate ignitable friction or percussion sparks in combination with the materials of the probe. It is not allowed that during operation potential sources of ignition (e.g. smouldering or burning particles, glowing embers, foreign objects) are brought into the gas sample probe.

7 DESCRIPTION

The probes type SP3200(V).. have been designed for easy use, long life and uncomplicated service and maintenance. The internal filter element can be replaced without the need of tools or dismounting of the sample line. After having removed the internal filter element, both the filter chamber and the sample tube can be cleaned easily.

SP3200V and SP3200 (combustible gases and dust):

The gas sample probes type SP3200V.. and SP3200.. are suitable for the sampling of gases and installation in hazardous areas of zone 2 or 22 (combustible gases and dust). The only difference between both types is the sealing material of the filter housing. Version SP3200 has got a filter housing sealing out of graphite for special types which are heated above 185°C. Version SP3200V has got filter housing seals of Viton for special types which are heated below or up to 185°C. The probe housing and all options are suitable for use in hazardous areas of zone 2 or 22 (combustible gases and dust). Please read the identification in table 4.

The probe SP3200(V).. must not be used for gas sampling in zone 0/1.

The filter system of type SP3200(V).. is suitable for dusts of a fineness of up to 2 μm.

Behind the filtration, i.e. at the outlet of the gas sample probe, the sample gas is free of dust. This means that in the absence of explosive sample gas downstream analysers can be used without any special protective measures.

2-1.3.9-ME Gas sampling and gas conditioning technology 5

The following figure shows the basic version of the gas sample probe SP3200(V) with prefilter.

Figure 1 Probe SP3200(V) without options with preliminary filter V20

SP3200V / SP3200:

In case the gas-dust mixture to be examined must be classified as potentially explosive because it contains combustible gases, only downstream devices (flowmeters, analysers) with corresponding identification according to directive 94/9/EC must be used. Suitable explosion isolation with a flame arrestor must be established. Any downstream units are not covered by this operating manual.

For sampling with probe SP3200(V) from explosion zone 2 sample tubes or pre-filters and extension tubes can be choosen from tables 1 – 3 below.

For sampling with probe SP3200(V) from explosion zone 22 a pre-filter has to be choosen from table 2 below. Additional extension tubes from table 3 can be choosen.

Sample tube Type

SP2000/SS

SP2000/SS-Vm

SP2000/HC SP2000/KA

SP2000/IC

Part

No.

20S9065 20S9067 20S9090 20S9080 20S9072

max. temper-

ature

°C

600 Stainl. steel 1.4571 1000 2500 G 3/4“a 25/22 37 600 Stainl. steel 1.4571 1000 2500 G 3/4“a 25/06 37

900 Hastelloy C4 1000 2500 G 3/4“a 25/22 37 1300 Kanthal / 1.4571 1000 1500 G 3/4“a 27/20 37 1200 Incoloy 956 1000 2000 G 3/4“a 25/22 37

Material

Tube / Connection

part

Length

„L max“

Connec-

tion

thread

„G“

Tube ø

o/i

[mm]

Connection

ø o

[mm]

Table 1 Sample tube for use with probe SP3200(V)

6 Gas sampling and gas conditioning technology 2-1.3.9-ME

Type Part-Nr. Material

Filter in the probe:

S-3 SS150 S-2K150 Option spun glass cartridge FW

Filter FW (spun glass) 93S2083

Preliminary filters to be selected:

SP2000ST/V20-T

SP2000ST/V12-1A-1 SP2000ST/V20-0 SP2000ST/V20-0/HC SP2000ST/V20-1 SP2000ST/V20-1/HC SP2000ST/V20-1/HC 0,5μm SP2000ST/V20-3

Table 2 Possible filters and preliminary filters for use inside the probe

90F0126 90S0020

20S9315

20S9559 20S9105 20S9115 20S9145 20S9155 20S9156 20S9300

1.4404 150 x 30 2 Ceramic Aerolith 150 x 30 2

Spun glass, high temperature resistant

PTFE needled felt (antistatic) Al2O3/SIC 500x40 1

1.4404 200x50 3 Hastelloy x 200x50 3

1.4404 500x60 3 Hastelloy x 500x60 3 Hastelloy x 500x60 0,5

1.4404 1000/300x31 3

Dimension [mm]

450x40 3

The preliminary filters can be extended with the following extension tubes.

Extension [mm]

with volume displacer 500 20S9165 1000 20S9170 Not suitable for pre-filter SP2000/V12-1A-1 1500 20S9175 Not suitable for pre-filter SP2000/V12-1A-1

Art. no.

Filter porosity[m]

Table 3 Extension tubes

8 OPTIONS

The following options are suitable for use in hazardous areas. Please read the identification for the respective zone in table 4.

When selecting options, attention must be paid to the operating parameters.

2-1.3.9-ME Gas sampling and gas conditioning technology 7

Scheme test gas feeding or backflushing

Entn a h m e so nd e Sa m p le Pr o b e

R / BB

Option Option

CCF

Entn a h m e so nd e Sa m p le Pr o b e

BBF

Option Option

Entn a hm e so nd e Sa m p l e Pro b e

Meßgasausgang Sa m p le o u t

Prüf g a s/ Rüc ksp ülung Cal. gas/ pure gas

Meßgasausgang Sa m p l e o ut

Prüf g a s/ Rüc ksp ülung Cal. gas/ pure gas

i-L uft I-Air

Meßgasausgang Sa m p l e o ut

Entn a h m e so nd e Sample Probe

Entn a hm e so nd e Sa m p l e Pro b e

Option

Entn a hm e so nd e Sa m p l e Pro b e

Meßgasausgang Sa m p l e o ut

Meßgasausgang Sa m p le o u t

Option

C/I

Entn a h m e so nd e Sa m p le Pr o b e

Option

Prü fg a s Cal. gas

Meßgasausgang Sa m p l e o ut

Rückspülung Pure g a s

Prüfgas oder Rückspülung Cal. gas or pure gas

Entn a h m e so nd e Sa m p le Pr o b e

Option

Figure 2 Schematic view of the options for backflush and test gas feeding

3VA

Meßgasausgang Sa m p l e o ut

8 Gas sampling and gas conditioning technology 2-1.3.9-ME

General safety instructions for back flushing and feeding of calibration gas

A backflushing gas suitable for the sampling point must be selected for backflushing.

The backflushing pressure / calibration gas pressure must always be higher than the process pressure. This minimum pressure must be monitored with a press switch at the inlet side of the accumulator or the check valve. If the flush gas pressure drops below the process pressure, the backflushing solenoid valve must not be operated.

The maximum permissible pressures of 6 bar abs. must not be exceeded (see technical data).

Do not choose back flush intervals longer than 3 seconds because in case of strong pollution of the pre-filter pressure inside the probe would be rising and than discharging to the analyser via the patented pressure control valve in the outlet of the probe due to a defined leak rate of this valve.

At sampling points with inerting, backflushing must be performed with corresponding inert gas. It must be ensured that the inert gas does not introduce oxygen or combustible gases into the system.

8.1 BACKFLUSH UNIT TYPE /RS

The backflush unit type /RS consists of a pressure relief valve, solenoid valve, accumulator and patented pressure control valve in the probe outlet.

The cyclical operation of the solenoid valve and monitoring of the backflushing pressure must be effected externally. The electrical connection of the solenoid valve must be made in an EEx e connection box. An additional solenoid valve in the sample gas outlet of the probe is not necessary because the patented pressure control valve shuts the probe outlet during back purging in order to protect the downstream analysis against the pressure push of the back purge.

8.2 OPTION /R, /BB AND /BBF FOR TEST GAS FEEDING OR BACKFLUSHING VIA CHECK VALVE R 1/4“,

BB 3/8“ OR BBF 3/8“

For back purging of the probe tube or the preliminary filter, flush gas is fed via the check valve. Hereby, it is recommended to separate the downstream analysing system from the probe in order to avoid pressure pushes to the system (Option /I). The opening pressure of the check valve is 0,7 bar. The flush gas or calibration gas pressure should be higher than 0,7 bar.

Options /R and /BB are for backflush of the inside space of the probe and the preliminary filter, the option

BBF is for backflush of the probe filter and the preliminary filter.

NOTE!

In order to avoid the cooling down of the inside probe, it is recommended to effect the backflush in short intervals of <1s.

During the feeding of test gas, the analyse system remains connected. The quantity of test gas should be at least 25% higher than the quantity of sample gas which is taken in by the analysing system, thus avoiding a mixture with the test gas. For processes with overpressure, this kind of feeding the test gas is not recommended. In this case, you should use an integrated ball valve in the inlet of the probe as stop valve.

2-1.3.9-ME Gas sampling and gas conditioning technology 9

In principle, you need only a small quantity of test gas for probes with an integrated ball valve, because the probe is separated from the process when the ball valve is activated so that there is no danger of a mixture with the process gas.

In case of manual operation, please turn the turning handle to the right side until the limit stop in order to shut off the probe.

NOTE!

In case of low pressure operation, please take into consideration that as from 300 mbar secondary air will be taken in via the non-closed check valve.

8.3 OPTION /CC, /CCF TEST GAS FEEDING BEFORE OR BEHIND THE PROBE FILTER TO BE SELECTED BY

THE USER

The normal execution ex our works provides the feeding of test gas before the probe filter (Function /CC). By changing the insert in the fitting for the check valve against the insert additionally attached, this function can be changed so that test gas can be fed behind the probe filter (Function /CCF).

8.4 OPTION /C/I TEST GAS FEEDING VIA CHECK VALVE BEHING THE PROBE FILTER WITH PNEUMATIC

STOP VALVE OF THE PROBE OUTLET TO THE PROCESS

By activating the pneumatic stop valve with compressed air, the measuring gas way behind the probe filter is shut off. Now, you can feed test gas via the check valve to the sample gas outlet of the probe without any loss.

8.5 OPTION 2-WAY BALL VALVE

For any service work, eg. changing of the filter element or cleaning works, the stop valve in the probe inlet is actuated from outside with the turning handle. This becomes necessary eg. in case of overpressure in the process or in case of toxic gas components.

In case of toxic gas components, please backflush the probe after shut off and before opening!

8.6 OPTION SPUN GLASS CARTRIDGE FW

For option FW the filter element is dropped and a spun glass cartridge is mounted at the filter housing lid. This spun glass cartridge is filled with a high temperature resistant spun glass. The option FW is used at sample points with risk of quickly blocking filter surfaces due to taar or sticky substances. The use of standard filter elements S-3SS150 oder S-2K150 is not possible with option FW.

8.7 OPTION /3VA TEST GAS FEEDING AND BACKFLUSHING VIA 3/2-WAY BALL VALVE

With the 3/2-way ball valve, you can execute both functions „backflushing“ and „test gas feeding“ one after the other. Only one operation each may be automated via the pneumatic actuation.

10 Gas sampling and gas conditioning technology 2-1.3.9-ME

This kind of gas feeding provides the advantage that during backflushing the downstream analyse system is automatically separated from the probe respectively, the probe is automatically separated from the process during test gas feeding. For that reason, you need a lower quantity of test gas as no mixture with the process gas may occur.

For the measuring operation, the ball valve must be put into the central position. For backflushing, the ball valve must be put into the corresponding position. This means in case of manual operation to turn the handle from the central position to the left side as far as it will go.

For the test gas feeding, the ball valve must be turned to the right side as far as it will go. For the measuring operation, return the ball valve into the neutral position.

Ball valve position

Fi- gure 3 Function scheme of the option 3/2-way ball valve /3VA

Measuring Ball valve position

Blow back Ball valve position

Test gas

8.8 BALL VALVE DRIVE MS1

The following drives are available:

Pneumatic drive with spring return type MS/ NC or NO Hereby 2 operating conditions can be realised:

a. Using a shut off ball valve VA the conditions:

"Open=measuring" and "shut".

b. Using a 3/2-way ball valve 3VA either the conditions:

"Open=measuring" and "blow back" or "Open=measuring" and "test gas feeding" Type MS-C for test gas feeding and type MS-B for blow back.

When placing the order specify, if the ball valve is

NC, (shut without control air), or NO, (open without control air). Standard = NC

8.9 OPTION /2X SECOND SAMPLE GAS OUTLET ON THE PROBE

With this option, the probe has got two sample gas outlets ¼“ NPTi.

8.10 OPTION /PT100 ADDITIONAL PT100 WITH TERMINAL BOX FOR EXTERNAL TEMPERATURE CON-

TROL

Additional PT100 (2-conductors) with separate terminal box mounted on the probe. The screwed cable gland has got a terminal range of 7-12 mm.

2-1.3.9-ME Gas sampling and gas conditioning technology 11

8.11 PROBE HEATING

The probe heating type HEX5-x.08 is suitable for temperature ranges of 85°C -185°C. It consists of a heating plate with heating cartridges and a control electronic.

For the heater type HEX5.1.08, the control electronic is mounted onto the probe. This means a range of the ambient temperature for the probe of 0 – 50°C.

The probe heating type HEX5.2.08 is designed for an external mounting of the control unit (in Ex zone 2). For the electrical connection, a terminal box is mounted on the probe which means an ambient temperature range of 0 – 70°C. The externally mounted control unit can be used within an ambient temperature range of 0 – 50°C.

Technical data may be taken from the separate operating manual HEX5-x.08.

9 TECHNICAL DATA

Gas sample probe type SP3200V (up to 185 °C) SP3200 (more than 185 °C)

Part No. 20S5705 20S5700

Weather protection shield yes

Filter housing material Stainless steel 316 / 316Ti

Sealing materials Graphite, FPM Graphite

Probe flange sealing material Graphite

Pre-filter / sample tubes optional, see data sheet 2-1.1.0.6 and 2-1.1.0.8

Sample pressure max. 0,5-6 bar

Ambient temperature -20 °C to max. 200 °C depending on the temperature class

Permissible process gas temperature depending on the temperature class, however max. 200°C at the probe entry

Filter chamber volume 120 cm3

Filter element, porosity F-3SS150= stainless steel*, 3 micron S-2K150= ceramic**, 2 micron

Sample gas outlet connection 1x 1/4“ NPTi for max. 8mm-tube connectors

Connection gas outlet at option RS 6 mm Swagelok connector

Mounting flange DN65 PN6, FormB, SS316Ti* >DN or ANSI possible**

Weight 7 kg

Option heating type HEX5 HEX5-1.08 HEX5-2.08

Part No. 20S9650 (a) 20S9655 (a)

Temperature controller integrated (on the probe) externally

Mounting controller in the Ex-zone 2 and 22

Control electronic

Power supply 240V 50/60Hz max. 800W, alternatively 120V,50/60Hz max. 830W

Electrical connection cable gland, terminal range 6-12mm, terminals max. 4mm2

Marking

12 Gas sampling and gas conditioning technology 2-1.3.9-ME

II 3 G Ex nA nC nL IIC T5 to T2,

II 3 D Ex tD A22 IP65 T75°C to T235°C

Class I, Division 2, Groups A/B/C/D, T5 - T2B



Temperature controller

II3G Ex nA nC nL IIC T5 to T2 II3D Ex tD A22 IP65 T75°C to T235°C

Class I, Div. 2, Groups A/B/C/D T5 – T2B

Admissible medium temperature on the probe inlet

Power max. 800 W (240V), max. 830 W (120V)

Case protection IP65; EN60529

Operating temperature 0°C to max. 230°C according to T-class, pls. indicate with order.

Ambient temperature 0 °C to +50 °C controller: 0 °C bis +50 °C, heating termi-

The admissible medium temperature is limited by the materials used (< 200°C) and by the maximum admissible surface temperatures as shown in table 4.

nal box: -20 °C bis +70 °C

Low temperature alarm contact

Excess temperature limiter +5°C to Tsoll, manual reset

Option back purge unit type RS RS

Part No. 20S5560 (a)

Power supply 230V 50/60Hz 9W or 115V 50/60Hz 9W (a)

Electrical connection cable 3x1mm2

Marking

Connection G 1/2”i at the buffer vessel

Max. back purge pressure 6 bar abs.

Volume buffer vessel 2 liters

Ambient temperature -20°C to 60°C

Option 2-way-ball valve in the probe entrance /VA

Part No. 20S9050

Operating temperature -20°C up to 185°C

Option 2/3-way-ball valve in the probe entrance

Part No. 20S9325

5°C to Tset, capacity 250V 3A AC, 0,25A DC.

1 contact NO, potentialfree.

II 3GD T4

/3VA

Backflush / Test gas connection 6mm tube

Operating temperature -20°C up to +185°C

Option pneum. drive for ball valve /VA o. /3VA MS1

Part No. 20S9055

Connection control air G1/4” i

Pressure control air 5-10 bar

Option valve for blowback or calibration gas 1/4”

Part No. 20S9045

Opening pressure >0,7 bar

Connection 6mm tube

Maximum blow back pressure 6 bar abs.

Maximum operating temperature +185 °C

Option variable calibration gas feeding /R + /CC and /CCF

2-1.3.9-ME Gas sampling and gas conditioning technology 13

Part No. 20S9045 + 20S9012

Way of test gas /R/CC = via sample gas outlet or /R/CCF = via probe filter element

Check valve /R check valve 1/4”

Opening pressure >0,7 bar

Connection 6mm tube

Maximum blow back pressure 6 bar abs.

Maximum operating temperature +185 °C

Option high performance blow back valve /BB /BBF

Part No. 20S9008 20S9006

Way of blow back gas via filter chamber via probe filter element

Check valve high performance check valve 3/8”

Opening pressure >0,7 bar

Connection 8mm tube

Maximum blow back pressure 6 bar abs.

Maximum operating temperature 185 °C

Option test gas valve / shut-off valve /C + /I

Part No. 20S9011 + 20S9009

Way of test gas via sample gas outlet with shut-off to the process

Check valve check valve 1/4”

Opening pessure >0,7 bar

Connection 6mm tube

Shut-off valve bellow-type valve with pneumatic drive

Pressure control air 3-10 bar

Connection control air 1/8” NPT i

Option second sample gas outlet /2X

Part No. 20S9015

Connection 1/4” NPT i

Option spun glass cartridge /FW

Part No. 20S9047 20S9046

Material SS316Ti, Novapress SS316Ti, Graphite

Maximum surface temperature of the gas sample probe:

The maximum surface temperature of the gas sample probe depends on the temperature of the process medium and the options used (heating HEX5-x.08 and backflush /RS). Under no circumstances, the sample probes SP3200(V)… must exceed the maximum surface temperature fixed by the temperature class. The maximum surface temperatures and inferable temperature classes of the gases are shown in the following table.

14 Gas sampling and gas conditioning technology 2-1.3.9-ME

The intended use of the probe restricts the process medium temperature at the probe inlet and the choice of options to the extent that the maximum surface temperature must lie below the temperature limit given in table 5 for the combustible gases used or must correspond to the temperature class of the combustible gases used.

Gas sample probe SP3200(V) for gas sampling out o f processes with combustible gases

Variants

Identification

Max. medium tempera-

ture at the probe inlet [°C]

Max. surface temperature

[°C]

Temperature class

SP3200(V)/HEX5-x.08

and all options

II 3 G

T2 – T5

Corresponding to the operating temperature of the selected temperature

class for

the heating,

see table 4.1

limiter temperature of the

T2 – T5

Corresponding to the

selected temperature

class for the heating,

see table 4.1

Table 4 Maximum surface temperatures for the use of heating HEX5-x.08

Temperature classes

T-Class ATEX Cenelec/IEC/Nec 505 T2 T2 230 235 T2A 215 220 T3 T3 185 190 T3A 165 170 T3B 150 155 T3C 145 150 T4 T4 120 125 T4A 105 110 T5 T5 85 90

T-Class NEC 500

Operating temperature °C

Limiter °C

Table 5 Temperature classes for use of heating HEX5-x.08

T2 – T5 Corresponding to the selected temperature

class for the heating,

see table 4.1

10 RECEIPT OF GOODS AND STORAGE

 The probe and any special accessories should be unpacked carefully immediately upon delivery and

checked against the delivery note for completeness.

 The delivery should be checked for transport damage and the transport insurer notified immediately

of any damage.

 The gas sample probe is usually delivered in two packages:

- gas sample probe with the necessary fastening bolts, nuts and flange gasket;

- sample tube or preliminary filter – possibly with extension tube.

The probe should be stored in a room protected from frost!

11 PREPARATIONS FOR INSTALLATION

2-1.3.9-ME Gas sampling and gas conditioning technology 15

 First make sure that conditions at the intended place of use correspond to the data on

the rating plate.

 The temperature of the process must be taken into account when selecting the sam-

pling point.

 Heating of the probe above the temperature limit given in table 5 must be prevented.  It must be ensured that the temperature class of the probe corresponds to the ig-

nition temperatures of the combustible gases/vapours.

 Select the optimum sampling point in accordance with general guidelines or agree on a

sampling point with the responsible authorities.

 Place the sampling point in such a way that there is sufficient space for installation and

removal of the probe. Do not forget to include the insertion length of the sample tube in your considerations.

 Easy access to the probe must be ensured to facilitate later maintenance work.  The customer-side sample nozzle should be dimensioned so that the temperature of the

nozzle is always above the process dew point to prevent corrosion and blockages.

 If the ambient temperature in the area of the nozzle is higher than 60°C due to radiant

heat, a radiant heat reflective plate must be installed locally to protect the probe.

 The mounting flange connection for the nozzle should be DN65 PN6. If another connec-

tion size is desired, an optional intermediate flange adapter /SO10 is available.

 The necessary minimum flange size or minimum nozzle diameter depends on the diam-

eter of the sample tube or preliminary filter used.

The prevailing operating parameters must be checked against the following table prior to installation:

Operating parameters for the combustible gas (SP3200(V))

Gas composition corrosive toxic explosive Zone classification process side Zone classification environment Ignition temperature of the gases/vapours °C

(>max. surface temper-

ature from table 4)

Explosion group IIA IIB IIC

Corresponds to tem-

perature class

Process conditions

Low pressure/ excess pressure situation mbar mbar Process temperature °C, min. °C max.

What parameters should be measured, eg. 02, CO, SO2, NOX,..,

Required gas flow rate l/h, min. l/h, max. Necessary T90 time sec.

Table 6 Operating parameters

Vol.% mg/Nm³ ppm

12 MOUNTAGE

The M&C probes SP3200 und SP3200V have been developed for stationary use. With correct selection and installation, they will guarantee many years of trouble-free service with a minimum of maintenance.

We recommend a horizontal mounting position with the sample gas outlet showing downwards (this is not absolutely essential for proper functioning of the probe). The probe should be installed with an inclination of approximately 10° with respect to the process.

16 Gas sampling and gas conditioning technology 2-1.3.9-ME

The following procedure is recommended:

 Remove the probe cover after opening the two toggle-type fasteners.

Work on the gas sample probe may only be carried out when the process and environment have been declared to non-hazardous areas, i.e. they are free of explosive atmospheres.

Figure 4 Schematic drawing of the filter housing cover

 Turn handle A about one full turn anticlockwise so that the cover is lifted.  Place handle C in position E.  Swing out clamp B to the left (in the direction of G).  Pull out the filter housing cover with handle A.

The following figures illustrate the steps described above.

2-1.3.9-ME Gas sampling and gas conditioning technology 17

Figure 5 Removal of the filter housing cover

 Check that the filter element is screwed on firmly.  Insert the filter holder part again.

The filter holder part is closed in reverse order.

 Push the ¾" flat gasket on to the thread of the preliminary filter or extension tube, screw the filter or

tube into the ¾” internal thread in the flange and tighten.

If the sample nozzle does not match with the size of the standard flange connection DN65 PN6, mount the optional flange adapter attached to the consignment on to the probe in the same way.

 Place the flange gasket on to the sample nozzle.  Insert the complete probe unit into the process-side sample nozzle and screw tight with the nuts and

bolts delivered.

12.1 CONNECTION OF THE SAMPLE LINE

 A ¼” NPT internal thread is provided on the probe side for connection of the sample line. Suitable con-

necting unions for explosion-protected lines in the sizes Ø 6 mm (standard), 8 mm or 10 mm can be screwed into this thread using PTFE sealing tape.

The fittings must be tightened carefully to avoid damaging the internal components. The fittings must not be overtightened.

In case of leaks, do not tighten the fittings further. Instead, the relevant fitting should be re-

18 Gas sampling and gas conditioning technology 2-1.3.9-ME

moved completely and then refitted.

Then check the connection for leaks.

The sample line is connected as follows:

 Loosen the toggle-type fasteners on the isolating cover and remove the cover.  Loosen the thumb screw of the heat conducting plates and remove the plates.  Screw a suitable union into the probe head using sealing tape.  Remove the top part of the sample line mounting clamp and insert the sample line through the sili-

con cap in the bottom part of the bracket plate and into the union.

 Screw off the top part of the mounting clamp. In the case of larger sample line diameters it might be

necessary for centric mounting of the sample line to move a little the small mounting bracket of the mounting clamp after having loosened the two screws and then tighten again.

 Connect the line to the union. For Swagelok

fittings:

- Insert the line with supporting sleeve fully into the union.

- Tighten the union nut finger-tight.

- Before tightening, mark the union nut in 6 o’clock position.

- Grip the body with a spanner and tighten the union nut by 1¼ turns; after a full turn, the marking must be turned further to 9 o’clock position.

 Then place the heat conducting plates in the guide slots on the side of the sample gas connection

and tighten with the thumb screw.

A supporting sleeve must always be used when connecting hose assemblies to stainless steel unions. The connection must be checked for leaks.

When using the option backflushing unit /RS the corresponding line must be connected to the accumulator.

A backflushing gas suitable for the sampling point must be selected for backflushing.

The backflushing pressure must always be higher than the process pressure. This minimum pressure must be monitored at the inlet side of the accumulator with a pressure monitoring switch. If the flush gas pressure drops below the process pressure, the backflushing solenoid valve must not be operated.

2-1.3.9-ME Gas sampling and gas conditioning technology 19

At sampling points with inerting, backflushing must be performed with corresponding inert gas. It must be ensured that the inert gas does not introduce oxygen or combustible gases into the system.

The backflushing pressure must not exceed 6 bar abs..

Do not choose back flush intervals longer than 3 seconds because in case of strong pollution of the pre-filter pressure inside the probe would be rising and than discharging to the analyser via the pressure control valve in the outlet of the probe due to a defined leak rate of this valve.

 Now, refit the cover and fasten it with the toggle-type fasteners.

The probe and all options must be earthed. The bleeder resistor must be < 10

 everywhere.

The function of the probe must be monitored by a flow controller at the downstream analyser. A steady decline in the sample gas flow can be an indication of the need for maintenance work on the probe. The probe must be serviced when the flow rate drops below 50%.

We also recommend the installation of an additional submicron filter in front of the analyser system.

- Further information can be found in the Internet at www.mc-techgroup.com.

13 ELECTRICAL CONNECTION

A wrong supply voltage can damage the device. Make sure that the supply voltage corresponds to the voltage shown on the rating plate before connecting the device.

he requirements of VDE 0100 and its associated standards and regulations must be observed when erecting high-voltage power installations with rated voltages of up to 1000 V! In any case, we recommend the use of heat-resistant cables.

An external main switch must be provided.

For option /RS, the cable of the solenoid valve must be connected in a suitable EEx e connection box.

A fuse suitable for the rated current of the solenoid valve (max. 3xIB per DIN 41571 or IEC 127) or protective motor switch with short-circuit and thermal rapid release (set on the rated current) must be installed in front of the solenoid valve as short circuit protection. The rated voltage of the fuse must be equal to or higher than the specified rated voltage of the solenoid valve. The breaking capacity of the fuse link must be equal to or higher than the maximum conceivable short circuit current at the place of installation (usually 1500 A). The fuse value is specified on the magnet coil – Fuse 0.1 A for 230V/50Hz or 0.2A for 115V/60Hz.

20 Gas sampling and gas conditioning technology 2-1.3.9-ME

The solenoid valve should be operated cyclically every 60 minutes (carry out min. 1 pulse/s).

Please read the electrical connection of the heating in the separate operating instructions of the heating

HEX5-x.08.

14 STARTING-UP

The requirements of VDE 0100 and its associated standards and regulations must be observed when erecting high-voltage power installations with rated voltages of up to 1000 V.

An external main switch must be provided.

For option /RS, the control circuit of the solenoid valve must be protected with a 0.1A

fuse.

Make sure that the supply voltage corresponds to the voltage shown on the rating plate before starting the device.

Switch on the power supply.

Caution: In ambient temperatures higher than 40°C, the temperature at the protective or isolating cover is higher than 60°C.

15 MAINTENANCE

When working during operation:

High surface temperatures! Touching the surfaces can result in burns. Wear protective gloves.

Aggressive condensate possible! Wear safety goggles and suitable protective clothing.

The requirements of VDE 0100 and its associated standards and regulations must be observed when erecting and servicing high-voltage power installations with rated voltages of up to 1000 V!

Work on the gas sample probe must only be carried out when the environment has been declared as non-hazardous area, i.e. it is free of explosive atmospheres.

The process side must also be declared as non-hazardous area – free of explosive atmospheres – before the filter chamber is opened.

The backflushing unit must be switched off before the filter chamber is opened.

2-1.3.9-ME Gas sampling and gas conditioning technology 21

The gas sample probe with preliminary filter and internal filter must be checked for temperature and dust deposits in suitable intervals of time depending on the process conditions. Dust layers of more than 5 mm must be removed immediately. The filters must be checked for damage and replaced if necessary. Also remove the dust deposits under the cover.

The probe must be shut down when the respective maximum surface temperature is exceeded.

The system and process-specific safety measures must be observed for all maintenance work.

Maintenance intervals cannot be recommended. They must be determined on site depending on the specific application and process conditions. An indication of the need for maintenance work on the probe can be a steady decline in the sample gas flow to the analyser system.

15.1 REPLACEMENT OF THE FILTER ELEMENT

Maintenance of the probe is mainly limited to replacement of the filter elements and inspection of the seals and gaskets. For this:

 Remove the protective cover after opening the toggle-type fasteners.  Dismount the filter holder part (see figure 3).  Unscrew the filter thumb screw and replace the filter element.  Inspect the filter element seals and replace them if necessary.  Inspect the flat graphite gasket or Viton gasket in the cover and replace if necessary.  Clean the filter chamber.  Insert the filter holder part again and tighten hand-tight.  Fit the protective cover.

Possibly necessary spare gaskets must be out of graphite or Viton.

15.2 REPLACEMENT OF THE PRELIMINARY FILTER

The complete probe unit must be removed from the process before replacing the preliminary filter. The preliminary filter can, depending on the type and degree of contamination, be cleaned mechanically or in an ultrasonic bath and is then reusable.

15.3 CLEANING OF THE PROBE

The gas sample probe must be inspected at suitable intervals in time. Dust layers of more than 5 mm must be removed immediately. The dust deposits under the cover must also be removed.

To prevent static charging, the probe should always be cleaned with a moist cloth.

22 Gas sampling and gas conditioning technology 2-1.3.9-ME

16 SHUTDOWN

Before shutdown, i.e. switching off the heater, the probe should be flushed with a suitable inert gas to prevent condensation of aggressive components of the process gas.

17 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 SP3200 and SP3200V

(R) Recommended spare parts

(S) Spare parts

Part No. Indication

90 F 0126

90 S 0020

93 S 0055

93 S 0020

93 S 0025

93 S 0030

90 S 2072

90 S 2084

Recommended quantity being in operation [years]

C/R/S

Filter element F-3SS150, 1.4404, 3 μm, 150 mm

Filter element S-2K150, ceramic, 2 μm, 150 mm Gasket (30) for filter element, material graphite R 4 8 12 O-ring (39) for lid SP3200V, material FPM R 2 4 8 O-ring (55) for lid SP3200V, material FPM R 2 4 8 Gasket (69) for lid SP3200, material graphite R 2 4 8 Gasket for sample tube, 3/4", material graphite R 1 2 3 Flange seal DN65PN6 (67mm i.), material graphite R 1 1 1

C 6 12 18

1 2 3

18 ANNEX

 Drawing SP3200 RS, HEX5-1.08  Drawing SP3200 RS, HEX5-1.08  EC – Declaration of conformity

Further product documentation can be found in the internet under: www.mc-techgroup.com

2-1.3.9-ME Gas sampling and gas conditioning technology 23