M&C TechGroup SP3200 Operator's manual

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.: [phone]
E-Mail: [e-mail]
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

mm

Length

„L max“

mm

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

CC

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

VA

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

Meßgasausgang
Sa m p le o u t

Option

Option

C/I

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

Option

RS

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

2X

3VA

Meßgasausgang
Sa m p l e o ut

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