ABB Gas Sampling Probe 2 User manual

Gas Sampling Probe 2
Operator’s Manual 42/2312 EN Rev. 8

3
Contents
Preamble 4
Specified Use 5
Safety Information 6
Guide for the Installation 8
Preparing for Installation 9
Structure and Function..................................................................................................................................9
Choosing the Sampling Point .....................................................................................................................10
Information on the Installation of the Wall Tube........................................................................................11
Assembly 12
Unpacking and Delivery Form ...................................................................................................................12
Assembling Probe 2....................................................................................................................................13
Electrical Installation 16
Requirements and Procedures for Electrical Connection............................................................................16
Electrical Connections for Probe 2 .............................................................................................................17
Inspection and Maintenance 19
Maintainance of the Filter Element of Probe 2 ...........................................................................................19
Technical Data 20
Probe 2........................................................................................................................................................20
Putting out of Service and Packing 21
Putting out of Service .................................................................................................................................21
Packing for Return......................................................................................................................................22
Index 23

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Contents of this Operator's Manual
This Operator's Manual contains all information required to be able to install, put
into operation, operate and maintain probe 2 with a heated or partially heated
probe tube safely and as specified.
Symbols and Typefaces in the Operator's Manual
WARNING denotes safety instructions which must be followed when
handling the device, in order to prevent danger to user.
NOTE denotes information about particular features with regard to the handling
of the device and the use of this Operator's Manual.
1, 2, 3, ... denotes the reference numbers in the figures.
Spare Parts
You can order spare parts via our service "Parts OnLine". You will find Parts
OnLine on the Internet at "http://www.abb.com/partsonline".
Further Details on the Internet
You will find further details about the products and services of ABB Analyzer
Technology on the Internet at "http://www.abb.com/analytical".
Further Information
If the information in this Operator's Manual does not cover a particular situation,
ABB after sales service will be pleased to provide further information.
Please contact your local service representative. For emergencies, please contact
ABB Service, Telephone: [phone], Telefax: +49-(0)621-
38193129031,
E-mail: automatio[email protected] mailto:[email protected]m
Preamble

5
Specified Use
Gas sampling probe 2 is used for the continuous sampling of gases in processes.
Any other application is not compliant with the specified use.
Observation of this Operator’s Manual is also part of the specified use.
Gas sampling probe 2 is particularly suitable for sampling gases with large gas
flows, increased gas pressure, high gas humidity and high dust content.
Specified Use

6
Requirements for Safe Operation
In order to operate in a safe and efficient manner the device should be properly
handled and stored, correctly installed and set-up, properly operated and
correctly maintained.
Personnel Qualifications
Only persons familiar with the installation, set-up, operation and maintenance of
comparable devices and certified as being capable of such work should work on
the device.
Special Information and Precautions
These include
The content of this operator's manual,
The safety information affixed to the device,
The applicable safety precautions for installing and operating electrical
devices,
Safety precautions for working with gases, acids, condensates, etc.
National Regulations
The regulations, standards and guidelines cited in this operator's manual are
applicable in the Federal Republic of Germany. The applicable national
regulations should be followed when the device is used in other countries.
Safety Information

7
Device Safety and Safe Operation
The device is designed and tested in accordance with EN 61010 Part 1, "Safety
Provisions for Electrical Measuring, Control, Regulation and Laboratory
Instruments" and has been shipped ready for safe operation. To maintain this
condition and to assure safe operation, read and follow the safety information in
this manual. Failure to do so can put persons at risk and can lead to device
damage as well as damage to other systems and devices.
Protective Lead Connection
The protective lead (ground) should be attached to the protective lead connector
before any other connection is made.
Risks of a Disconnected Protective Lead
The device can be hazardous if the protective lead is interrupted inside or outside
the device or if the protective lead is disconnected.
Risks Involved in Opening the Covers
Current-bearing components can be exposed when the covers or parts are
removed, even if this can be done without tools. Current can be present at some
connection points.
Risks Involved in Working with an Open Device
All work on a device that is open and connected to power should only be
performed by trained personnel who are familiar with the risks involved.
When Safe Operation can no Longer be Assured
If it is apparent that safe operation is no longer possible, the device should be
taken out of operation and secured against unauthorized use.
The possibility of safe operation is excluded:
If the device is visibly damaged,
If the device no longer operates,
After prolonged storage under adverse conditions,
After severe transport stresses.

8
Basic Steps
NOTE
Please refer to the planning documents for the installation.
Please also refer to the technical data (see chapter "Technical Data" on page 20).
The wall tube must be installed at the sampling point before the probe is installed
(see chapter "Preparing for Installation" on page 9).
Step Action
1 Unpack the supplied parts (see section "Unpacking and Delivery
Form" on page 12).
2 Install the gas sampling probe (see section "Assembling Probe 2" on
page 13).
3 Carry out the electrical connection (see sections
"Requirements and Procedures for Electrical Connection" on page 16
and "Electrical Connections for Probe 2" on page 17).
After you have carried out these steps, probe 2 is operative.
Guide for the Installation

9
Structure and Function
Interaction of the Components
The process gas is cleaned of dust particles by means of a ceramic inlet filter in
probe 2. The sample gas is subsequently transferred to the analyzer system via a
sample gas pipe.
Main Components of the Probe 2
1Mounting for the inlet filter
2Ceramic inlet filter (inner filter)
3Sample gas outlet or test gas or purge gas inlet
4Outlet of the heating cable
Electrically heated gas sampling tube
Integrated heating rod for heating from the ceramic inlet filter up to the end
of the sample gas outlet
Additional connection for compressed air, can be used as a test gas/purge
gas connection
Ceramic inlet filter
High retention rate for dust
Good cleaning action with compressed air purging
CHAPTER 1
Preparing for Installation

10
Choosing the Sampling Point
Choosing the Sampling Point
Select a sampling point as per the planning documents which is suitable for
extracting a representative sample flow.
Install the wall tube with assembly flange (DN 65, PN 6, Form B to DIN
2573) at the sampling point in such a way that the probe tube can be easily
installed and removed (see the section "Information on the Installation of the
Wall Tube" on page 11).
The probe tube must be easily accessible to allow maintenance work to be
performed.

11
Information on the Installation of
the Wall Tube
Installation of the Wall Tube
Please refer to the planning documents and the information in the chapter
"Assembly" on page 12 for installation of the wall tube.
Install the wall tube dependent on the installation conditions as per the following
sketches.
Installation of the wall tube
in brickwork
(dimensions in mm):
12534
Installation of the wall tube
in brickwork with metal sheeting
(dimensions in mm):
1
253
Installation of the wall tube
in an insulated sheet-metal channel
(dimensions in mm):
1
253
1Wall tube
2Assembly flange DN 65, PN 6, Form B to DIN 2558
3Gasket
4Welded-on rectangular block
5Sampling probe flange
The figure shows a view of the flange looking from the process
to the filter. The arrow indicates the flow direction of the
process gas.
Select the installation position of the wall tube, so that the holes
are located in the position shown here.

12
Unpacking and Delivery Form
Unpacking
WARNING
Danger of breakage!
The ceramic inlet filter of probe 2 is fragile.
Step Action
1 Unpack the component parts of probe 2 (see below).
2 Make sure that any accompanying accessories do not get lost.
3 Check the contents of the delivery to ensure that it is complete by
comparing the actual goods with the dispatch note.
NOTE
Keep the packing material for possible future transport.
If damage has occurred during transport due to improper handling, please submit
a damage report to the transport institution (railway company, post office,
forwarding agency) within seven days.
Delivery Form
Probe 2 is supplied in various partially pre-assembled component parts:
Gas sampling probe with flange and internal heating rod
Ceramic inlet filter (inner filter)
Installation set for mounting the ceramic inlet filter
(4 bolts M12 x 70 with nuts, spring washers and washers)
Harting connector, degree of protection IP55 (only for probe version
"heated, 650 W", catalog no. 23022-4-0768301)
Protective box (option), degree of protection IP54
Carry out the final assembly at the service location as described in the section
"Assembling Probe 2" on page 13.
CHAPTER 2
Assembly

13
Assembling Probe 2
Assembly of the Ceramic Inlet Filter
WARNING
Danger of breakage!
The ceramic inlet filter of probe 2 is fragile.
First of all, assemble the ceramic inlet filter as shown in the following drawing.
Please note that the compression spring 4has to be compressed by approx.
15 mm.
1Filter element
2Sealing gasket
3Bush
4Compression spring
5Pressure disk
6Bush
7Screw

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Assembly of Probe 2
180
650
1
2
α
1Mounting for the inlet filter
2Inlet filter (inner filter) with internal heating rod
3Gas sampling tube
4Wall tube with inlet flange
5Sample gas outlet and test gas/purge gas inlet G 1/4
L1 Fitting length
Lx Length of the gas sampling tube (approx. 400 mm)
xMinimum distance of the flange of probe 2 from the wall
The following table shows the recommended mounting angle and the minimum
distance xmin of the assembly flange from the wall depending on the mounting
angle of the probe 2:
Mounting angle α10° 15° 20° 25° 30° 35°
xmin/mm 133 138 143 147 151 153
Step Action
1 Align the gas sampling probe, so that the opening of the inlet filter
(inner filter) is not directly in the process gas flow.
2 Attach probe 2 to the flange of the wall tube with the enclosed
screws M12 x 70.
3 Connect the gas lines to the sample gas outlet and the test gas/purge
gas inlet.

15
Connect the Sample Gas Line
Connect the sample gas line to one of the two gas ports 5at the sample gas outlet
of the filter unit by means of a clamp ring screw fitting.
WARNING
Possible leakage!
When tightening the screw connection, relieve the pressure on the gas port,
e.g. by holding back with a suitable spanner. Otherwise there is a danger that
the gas port is twisted and becomes untight or breaks off.
Connect the Compressed Air Lines
If probe back-purging is available, connect the compressed air lines to one of the
two gas ports 5. Please note the maximum permissible pressure of 6 bar.

16
Requirements and Procedures for
Electrical Connection
WARNING!
Please observe the relevant national safety regulations for the construction
and operation of electrical installations as well as the following safety
instructions.
Before connecting the power supply, check that the operating voltage on the
rating plate is the same as the mains voltage.
The protective-conductor terminal must be connected to a protective
conductor before any other connections are set up.
The device can be dangerous if the protective conductor is interrupted inside
or outside the device or the protective-conductor terminal is disconnected.
WARNING!
You must be able to disconnect the device from the power supply! For this
purpose, install a 2-pin mains isolator in the power supply line, since the
device does not have its own power switch.
What material is required?
Select the required line material as per the planning documents.
The Harting connector required for the connection of the probe version "heated,
650 W", catalog no. 23022-4-0768301, is a constituent part of the scope of
supply and delivery.
CHAPTER 3
Electrical Installation

17
Electrical Connections for Probe 2
WARNING
Corrosion risk!
The probe tube heater of probe 2 must be switched on immediately after
assembly has been completed, since otherwise there is a risk of corrosion.
Design of the Electrical Connections
Probe Version Catalog No. Electrical Connection
heated, 650 W 23022-4-0768301 Harting connector, degree of
protection IP55 (see below)
partially heated, 255 W 23022-4-0768305 Silicone cable, 3 ×1.5 mm2,
length 1000 mm
Electrical Connection with Harting Connector
The Harting connector for connection to a power supply has the following pin
assignment:
PE
1N
2L1
3Not assigned
4Not assigned
5Not assigned
6Not assigned

18
The following figure shows the power cable led through the wall tube with the
Harting connector mounted on the mounting plate:
260
2
1
1Mounting plate for Harting connector
2Harting connector, degree of protection IP55
Step Action
1 Connect the cables of the current lead to the Harting connector as
shown in the above connector pin assignment .
2 Connect the Harting connector to the power supply.

19
Maintainance of the Filter Element
of Probe 2
WARNING
Danger of burns!
The gas sampling probe becomes hot during operation. Touching this
component can cause burns.
Interval for Cleaning the Filter Element
WARNING
Health hazard!
Dependent on the substances which it comes into contact with during
operation, the filter element could be contaminated with toxic or corrosive
substances. Always wear suitable protective clothing for cleaning work.
The service life of the filter depends on the operating conditions. Remove it as
required, so that you can visibly eliminate the dirt accumulation mechanically or
exchange it.
If the filter stone is obviously damaged, replace it with a new one. The interval
also depends on the operating conditions. You can determine this during
operation.
CHAPTER 4
Inspection and Maintenance

20
Probe 2
Permissible Operating Parameters
Process gas pressure pabs max. 400 kPa (4 bar)
Temperature max. 450 °C (Probe tube partially heated), max. 130 °C (Probe tube heated)
Flow rate max. 2000 l/h, relative to 100 kPa (1 bar) and 0 °C
Dust content max. 20 g/m3(application recommendation), max. 100 g/m3with back-purging
Back-purging pressure max. 600 kPa (6 bar)
Heating temperature of the
inlet filter
≥200 °C (at process gas temperature = 20 °C)
90% time (T90)< 2 s at 250 l/h
Filter fineness 0.3 µm
Ambient temperature +5...+50 °C
Voltage 230 VAC, 50...60 Hz (115 VAC on inquiry)
Pneumatic Connections
Sample gas Gas ports with G 1/4 female thread (DIN ISO 228/1) for threaded connections
for pipe with 6 mm outer ∅
for hose with 6 mm inner ∅
Compressed air (purging
air) or test gas
Gas ports with G 1/4 female thread (DIN ISO 228/1, provided with screw-type
blank cap)
Ceramic Inlet Filter
Dimensions Length: approx. 670 mm, area: approx. 975 cm2, Catalog No.: 23005-4-0730705
Retention rate for particles > 5 µm 99.99 by weight %
for particles 3.0...5.0 µm 99.99 by weight %
for particles 1.4...3.0 µm 99.98 by weight %
for particles 0.5...1.4 µm 99.5 by weight %
for particles 0.3...0.5 µm 99.5 by weight %
CHAPTER 5
Technical Data