Bühler technologies GAS 222.35 Ex1 Owner's manual

Gas Analysis
Installation and Operation Instructions
Original instructions
Sample gas probes
GAS 222.35 Ex1
BE460055
04/2023
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
E-Mail: [email protected]
Internet: www.buehler-technologies.com

Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
Internet: www.buehler-technologies.com
E-Mail: [email protected]
Read this instruction carefully prior to installation and/or use. Pay at-
tention particularly to all advises and safety instructions to prevent in-
juries. Bühler Technologies can not be held responsible for misusing
the product or unreliable function due to unauthorised modifications.
All rights reserved. Bühler Technologies GmbH 2023
Document information
Document No..........................................................BE460055
Version.........................................................................04/2023

GAS 222.35 Ex1
Table of Contents
1 Introduction.....................................................................................................................................................................................................................2
1.1 Intended Use.........................................................................................................................................................................................................2
1.2 Dust Atmosphere Requirements ....................................................................................................................................................................4
1.3 Type Plate...............................................................................................................................................................................................................4
1.4 Scope of delivery ..................................................................................................................................................................................................4
1.5 Ordering instructions......................................................................................................................................................................................... 5
1.6 Product Description............................................................................................................................................................................................ 5
2 Safety instructions .........................................................................................................................................................................................................6
2.1 Important Information......................................................................................................................................................................................6
2.2 General Hazard Warnings ................................................................................................................................................................................ 7
2.3 Ambient Temperature range of the equipment........................................................................................................................................9
2.4 Permissible gas inlet temperature.................................................................................................................................................................9
3 Transport and storage ................................................................................................................................................................................................10
4 Installation and connection .......................................................................................................................................................................................11
4.1 Installation site requirements........................................................................................................................................................................11
4.2 Installation ...........................................................................................................................................................................................................11
4.3 Installing the upstream filter .........................................................................................................................................................................11
4.4 Insulation.............................................................................................................................................................................................................. 11
4.5 Connecting the Gas Line.................................................................................................................................................................................. 12
4.5.1 Blowback Connection........................................................................................................................................................................ 12
4.5.2 Connecting the calibrating gas line (optional).......................................................................................................................... 12
4.6 Connecting the Blowback and Pressure Vessel (Optional).................................................................................................................... 13
4.7 Electrical Connections...................................................................................................................................................................................... 13
4.7.1 Connecting the Earth Conductor/Earthing ................................................................................................................................ 13
4.7.2 Connecting the Heating Tape......................................................................................................................................................... 14
4.7.3 Solenoid Valves (Optional) .............................................................................................................................................................. 14
5 Operation and Control.................................................................................................................................................................................................15
5.1 Before Startup .....................................................................................................................................................................................................15
6 Maintenance.................................................................................................................................................................................................................. 16
6.1 Maintaining the filter element ......................................................................................................................................................................17
6.1.1 Replacing the upstream filter .........................................................................................................................................................17
6.2 Blowback of the in-situ filter (within the process stream).................................................................................................................... 18
6.2.1 Manual Blowback (Without Blowback Control)........................................................................................................................ 18
6.2.2 Automatic Blowback (External Blowback Control)................................................................................................................... 18
6.3 Maintenance Schedule .................................................................................................................................................................................... 19
7 Service and repair........................................................................................................................................................................................................ 20
7.1 Troubleshooting ............................................................................................................................................................................................... 20
7.2 Spare Parts and Accessories ........................................................................................................................................................................... 21
8 Disposal ...........................................................................................................................................................................................................................22
9 Appendices .....................................................................................................................................................................................................................23
9.1 Technical Data....................................................................................................................................................................................................23
9.2 Probe Terminal Diagram.................................................................................................................................................................................24
9.3 Flow chart ............................................................................................................................................................................................................24
9.4 Dimensions .........................................................................................................................................................................................................25
9.5 List of chemical resistance ..............................................................................................................................................................................26
9.6 User book (Please make copies).....................................................................................................................................................................27
10 Attached Documents...................................................................................................................................................................................................28
iBühler Technologies GmbHBE460055 ◦ 04/2023

GAS 222.35 Ex1
1 Introduction
1.1 Intended Use
The sample gas probe is intended for installation into gas analysis systems in commercial applications.
ATEX
Used in zone 1 (explosion group IIC) and 21 (dust group IIIC) and sampling from zone 0 (explosion group IIC) and 20 (dust group
IIIC).
IECEx:
Used in zone 1 (explosion group IIC) and sampling from zone 0 (explosion group IIC).
DANGER Explosion hazard
Gas and dust atmosphere must not be present at the same time. These so-called hybrid
mixtures can have different ignition points than the individual components and are
therefore not included in the explosion protection markings for gas and dust.
Blowing an internal explosive atmosphere back from the gas probe is prohibited due to the potential risk of explosion. Process
gases or process gas mixtures must not contain solids which produce ignitable impact sparks when combined with the probe
materials including filter and sampling tubes.
Probe marking, depending on the selected options and temperature class:
for zone 0/1: for zone 1:
ATEX: II 1G/2G Ex db1 eb mb2 IIC T5/T6...T1/T2 Ga/Gb ATEX: II 2G Ex db1 eb mb2 IIC T6...T2 Gb
IECEx: Ex db1 eb mb2 IIC T5/T6...T1/T2 Ga/Gb IECEx: Ex db1 eb mb2 IIC T6…T2 Gb
for zone 0/21: for zone 20/1:
ATEX: II 1G/2D
Ex db1 eb mb2 llC T5 ... T1 Ga
Ex tb mb2 lllC T80 °C ... T226 °C Db
ATEX: II 1D/2G
Ex ta lllC T120 °C ... T300 °C Da
Ex db1 eb mb2 llC T6 ... T2 Gb
IECEx: - IECEx: -
for zone 20/21: for zone 21:
ATEX: II 1D/2D Ex ta/tb mb2 IIIC T120°C/T80°C...T300°C/T226°C Da/Db ATEX: II 2D Ex tb mb2 IIIC T80°C...T226°C Db
IECEx: - IECEx: -
1 "db" only for GAS 222.21/31 versions with limit switch.
2 "mb" only for version with solenoid valve.
Please refer to the type plate for the exact probe marking.
For devices designed for sampling from zone 0 or zone 20 the areas of application are indicated in the marking with "/":
II 1G/2G Ex db eb mb IIC T5/T6 Ga/Gb
Parameters for sampling from Zone 0
Parameters for use in Zone 1
The opposite is an example of the gas marking with separate areas of applic-
ation. The same procedure applies to dust approvals.
Please note, unlike the operating zone, the temperature class for sampling zone 0 is lower. This is also indicated by the ignition
protection marking in the type plate.
Always note the explosion protection marking in the name plate of your equipment (and all add-on parts).
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GAS 222.35 Ex1
Sample gas probes are among the main components in a gas conditioning system.
– Therefore also note the related drawing in the data sheet in the appendix.
– Before installing the device, verify the listed technical data meet the application parameters.
– Further verify all contents are complete.
Please refer to the type plate to identify your model. In addition to the job number it also contains the item number and model
designation.
Please note the specific values of the device when connecting, and the correct versions when ordering spare parts.
Passing through gases
Flammable gases above the UEL (upper explosion limit) may only be blown back with inert gases. Flammable gases from 25% LEL
(lower explosion limit) and up to the LEL may be blown back provided the operator ensures the blown back gas is not and cannot
be explosive. For safety reasons we recommend only using inert gases in these cases as well.
Blowing back explosive atmospheres (range from LEL to UEL) with the probes is prohibited due to possible adiabatic compres-
sion (high blowback pressure against contaminated filter). The operator is responsible for compliance with these conditions tak-
ing into account his risk assessment.
Limitations categories/zones due to accessories
Please note, the accessories used may limit the approved applications of the probes.
Please note the following table:
ATEX + IECEX Only ATEX
GAS 222 types with accessories: Gas Dust Gas and dust
(separate zones)
Sampling zone/operating zone
11 Ex1, 21 Ex1, 30 Ex1,
31 Ex1, 35 Ex1, 35-U Ex1
Pressure vessel PAV 01
(item no. 46222PAV and accessories)
Zone1***/Zone 1 Zone 20/Zone 21 Zone 20/Zone 1
11 Ex1, 21 Ex1, 30 Ex1,
31 Ex1
Ceramic inlet filter*
(item no.:46222307 + 46222307F)
Zone 2/Zone 1 Zone 20/Zone 21 Zone 20/Zone 1
or
Zone 2 / Zone 21
11 Ex1, 20 Ex1, 21 Ex1 Ceramic outlet filter*
(item no. 46222026 + 46222026P)
Zone 2/Zone 1 Zone 20/Zone 21 Zone 20/Zone 1
or
Zone 2 / Zone 21
11 Ex1, 20 Ex1, 21 Ex1 Sampling tubes
(item no.: 46222001, 462220011, 46222006,
46222004, 46222016, 46222017, 46222018
Zone 0/Zone 1 No zone/Zone 21 Zone 0/Zone 21
11 Ex1, 20 Ex1, 21 Ex1 Ceramic sampling tubes**
(item no.: 4622200205, 4622200210,
4622200215)
Zone 2/Zone 1 No zone/Zone 21 Zone 2/Zone 21
* Accessories not suitable for sampling highly ignitable dusts with a minimum ignition energy (MIE) of <3mJ.
** When sampling gas from Zone 2, ceramic sampling tubes may only be used if application- and process-related intensive elec-
trostatic charges are ruled out.
*** Blowback of explosive atmosphere/gases is prohibited.
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GAS 222.35 Ex1
1.2 Dust Atmosphere Requirements
The sample gas probe may only be used in areas with explosive dust atmosphere if the smouldering temperatures of the dust
layers and the ignition temperatures of the dust atmosphere is higher than the following temperatures.
Probe temperature class
T80 °C T120 °C T130 °C T175 °C T226 °C T300 °C
Smouldering tem-
perature for max.
5 mm dust layer
≥ 155 °C ≥ 195 °C ≥ 205 °C ≥ 250 °C ≥ 301 °C ≥ 375 °C
Dust atmosphere ig-
nition temperature
≥ 120 °C ≥ 180 °C ≥ 195 °C ≥ 263 °C ≥ 339 °C ≥ 450 °C
The basis for safety factors is EN 1127-1.
1.3 Type Plate
Example:
0158
GAS 222.35 Ex1
000092697 462223510149420013111 001
Manufacturer and address
Model designation
Order no., item no.
Electrical supply
Type examination certificate no.
230V; valve/клапан 24V UC
Bühler Technologies GmbH
Harkortstr. 29 D-40880 Ratingen
IBExU17ATEX1088X
IECEx IBE 17.0024X
Ex eb mb IIC T4 Gb
Explosion protection marking II 2G
IECEx certificate number:
Ex eb mb IIC T4 Gb
ATEX certificate number:
Explosion protection marking
1.4 Scope of delivery
– 1 x Sample gas probe
– 1 x Flange gasket and screws
– Product documentation
– Connection and mounting accessories (only optional)
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GAS 222.35 Ex1
1.5 Ordering instructions
The item number is a code for the configuration of your unit. Please use the following model key:
46222351 X X X X 4 X 0 X X X 0 0 0 Product Characteristics
Flange
0 1 Flange DN65 PN6
0 2 Flange DN3"-150
x x Other
Hazardous area
Outside
4 Zone 1 (Atex/IECEx)
7 Zone 21 (Atex)
9 none
Inside
3 Zone 0 (Atex/IECEx)
4 Zone 1 (Atex/IECEx)
6 Zone 20 (Atex)
7 Zone 21 (Atex)
9 none
Temperature class inside/outside (dust only ATEX)
Ga/Gb Ga/Db Da/Gb Da/Db
4 T3/T4 T3/T130°C T175°C/T4 T175°C/T130°C
Temperature class inside/outside (dust only ATEX)
Gb/Gb Gb/Db Db/Gb Db/Db
4 T4/T4 T4/T130°C T130°C/T4 T130°C/T130°C
Power supply sample probe
1 115 V
2 230 V
Calibration gas port
0 No
1 6 mm
2 6 mm with check valve
3 1/4"
4 1/4" with check valve
Pressure vessel *
0 No
1 Yes
Purge valve *
0 Ball valve
1 Solenoid valve 110 V (marked with "mb")
2 Solenoid valve 230 V (marked with "mb")
3 Solenoid valve 24 V (marked with "mb")
9 none
* Blowback of explosive atmosphere prohibited.
1.6 Product Description
The probe has a self-regulating heating tape.
Probe Description
GAS 222.35 Ex1 Probe with retractable upstream filter and blowback connection
Accessories Please refer to the data sheet at the end of this manual for accessories for this probe
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GAS 222.35 Ex1
2 Safety instructions
2.1 Important Information
This unit may only be used if:
– the product is being used under the conditions described in the operating- and installation instructions, used according to
the nameplate and for applications for which it is intended. any unauthorized modifications to the device will void the war-
ranty provided by Bühler Technologies GmbH,
– the limits in the data sheet and the instructions must be observed,
– the handle including O-ring are installed at a suitable ambient temperature range and filter (where applicable),
– monitoring equipment / protection devices must be connected correctly,
– service and repairs not described in these instructions is performed by Bühler Technologies GmbH,
– using genuine replacement parts.
– Regulation IEC/EN60079-14 must be observed when erecting electrical systems in explosive areas.
– Additional national regulations pertaining to initial operation, operation, maintenance, repairs and disposal must be ob-
served.
– These operating instructions are a part of the equipment. The manufacturer reserves the right to change performance-, spe-
cification- or technical data without prior notice. Please keep these instructions for future reference.
Signal words for warnings
DANGER
Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.
WARNING
Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not
avoided.
CAUTION
Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property or
minor or medium injuries if not avoided.
NOTICE
Signal word for important information to the product.
Warning signs
These instructions use the following warning signs:
Warns of a general hazard General notice
Warns of voltage Unplug from mains
Warns not to inhale toxic gasses Wear respiratory equipment
Warns of corrosive liquids Wear a safety mask
Warns of explosive areas Wear gloves
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GAS 222.35 Ex1
2.2 General Hazard Warnings
The maximum surface temperatures of the probes also vary based on operating conditions (steam temperature, sample gas in-
let temperature, ambient temperature, fluid flow rate). When used in explosive areas, also particularly note the related hazard
warnings.
The equipment must be installed by a professional familiar with the safety requirements and risks.
Be sure to observe the safety regulations and generally applicable rules of technology relevant for the installation site. Prevent
malfunctions and avoid personal injuries and property damage.
The operator of the system must ensure:
– Safety notices and operating instructions are available and observed,
– The respective national accident prevention regulations are observed,
– The permissible data and operational conditions are maintained,
– Safety guards are used and mandatory maintenance is performed,
– Legal regulations are observed during disposal,
– compliance with national installation regulations.
Maintenance, Repair
Please note during maintenance and repairs:
– Repairs to the unit must be performed by Bühler authorised personnel.
– Only perform conversion-, maintenance or installation work described in these operating and installation instructions.
– Always use genuine spare parts.
– Do not install damaged or defective spare part. If necessary, visually inspect prior to installation to determine any obvious
damage to the spare parts.
Always observe the applicable safety and operating regulations in the respective country of use when performing any type of
maintenance.
NOTICE Accessories may limit critical operating parameters of the base unit
Adding accessories may limit critical operating parameters. Ambient temperatures, zone
classifications, explosion groups, temperature classes or chemical resistances of ac-
cessories may vary from the base unit.
Always include all technical data in the operating instructions and data sheets of all
components in the safety assessment.
NOTICE When used in explosive areas
Regulation IEC/EN60079-14 must be observed when erecting electrical systems in ex-
plosive areas.
Additional national regulations pertaining to initial operation, operation, maintenance,
repairs and disposal must be observed.
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
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GAS 222.35 Ex1
DANGER Toxic, corrosive gas/condensate
Sample gas/condensate may be hazardous to health.
a) If necessary, ensure a safe gas/condensate discharge.
b) Always disconnect the gas supply when performing maintenance or repairs.
c) Protect yourself from toxic/corrosive gasses/condensate when performing mainten-
ance. Wear appropriate protective equipment.
DANGER Explosion hazard
Life and explosion risk may result from gas leakage due to improper use.
a) Use the devices only as described in this manual.
b) Regard the process conditions.
c) Check tubes and hoses for leakage.
DANGER Danger to life and explosion during installation and maintenance
The unit must not be worked on (assembly, installation, maintenance) in explosive at-
mospheres.
DANGER
Use in explosive areas
Flammable gas or dust atmospheres could ignite or explode. Avoid the following hazard
sources:
Application area!
Never operate the gas probe outside the specifications. Sampling gases or gas mixtures
which are also explosive in the absence of air is prohibited.
Electrostatic charge (sparking)!
The equipment may only be used where normal operating conditions do not frequently
produce flammable, electrostatic discharge.
Always clean plastic housing parts and decals with a damp cloth.
Sparking!
Protect the M3 connectors from external blows.
Flame propagation!
If the process holds a risk of flame propagation, install a flame arrestor.
Adiabatic compression (explosion hazard)
Adiabatic compression may cause high temperatures during blowback. Never blowback
if explosive gas or dust atmospheres are present. Only use nitrogen (inert gas) to blow-
back flammable gas.
Dust
If possible, take the electrical components which must be opened for repair to a dust-
free room. If unable to do so, prevent dust from entering the housing.
Zonal carryover when sampling from zone 20, 21, 22
If the particle size of the dusts being filter is smaller than the fineness of the filter ele-
ments used, zonal carryover from the process to the probe must be expected.
The fineness of the filter elements used must be clearly smaller than the average particle
size of dusts in the process gas.
Dust ignition
Regularly clean dust from all components. Dust layers >5mm may have lower smoulder-
ing temperatures and the dust layer could potentially ignite at a temperature below its
smouldering temperature.
Also remove dust under the thermal insulation and from the gas probe heating tape.
The ignition temperature and smouldering temperature of flammable dusts or dust lay-
ers which are present must be above the marked surface temperature plus a safety
factor (also see section "Dust atmosphere requirements").
8 Bühler Technologies GmbH BE460055 ◦ 04/2023