Bühler technologies GAS 222.15 User manual

Gas Analysis
Installation and Operation Instructions
Original instructions
Sample gas probes
GAS 222.15
BE460038
10/2019
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 2021
Document information
Document No......................................................... BE460038
Version..........................................................................10/2019

GAS 222.15
Table of Contents
1 Introduction..................................................................................................................................................................................................................... 2
1.1 Intended Use.........................................................................................................................................................................................................2
1.2 Type Plate............................................................................................................................................................................................................... 2
1.3 Scope of Delivery..................................................................................................................................................................................................2
1.4 Ordering instructions ........................................................................................................................................................................................ 2
1.5 Product Description............................................................................................................................................................................................ 3
2 Safety instructions.........................................................................................................................................................................................................4
2.1 Important advice .................................................................................................................................................................................................4
2.2 General hazard warnings ................................................................................................................................................................................. 5
3 Transport and storage ..................................................................................................................................................................................................6
4 Installation and connection ........................................................................................................................................................................................ 7
4.1 Installation site requirements......................................................................................................................................................................... 7
4.2 Installing the sampling tube (optional)........................................................................................................................................................ 7
4.3 Installing the downstream filter (optional)................................................................................................................................................. 7
4.4 Insulation............................................................................................................................................................................................................... 7
4.5 Connecting the Gas Line....................................................................................................................................................................................8
4.5.1 Connecting the Gas Line.................................................................................................................................................................... 8
4.5.2 Connecting the calibrating gas line (optional)........................................................................................................................... 8
4.6 Electrical connections ........................................................................................................................................................................................9
4.6.1 Plug Connection................................................................................................................................................................................... 9
5 Operation and Control................................................................................................................................................................................................ 10
6 Service............................................................................................................................................................................................................................... 11
6.1 Maintaining the filter element ...................................................................................................................................................................... 11
6.1.1 Replacing the downstream filter................................................................................................................................................... 12
6.1.2 Replacing the Outlet Filter with Micro-Fibreglass Filter Element........................................................................................ 12
7 Service and repair..........................................................................................................................................................................................................13
7.1 Troubleshooting .................................................................................................................................................................................................13
7.2 Spare Parts and Accessories ............................................................................................................................................................................13
8 Disposal........................................................................................................................................................................................................................... 14
9 Appendices......................................................................................................................................................................................................................15
9.1 Technical Data.....................................................................................................................................................................................................15
9.2 Flow chart .............................................................................................................................................................................................................15
9.3 Dimensions ......................................................................................................................................................................................................... 16
9.4 Connection Diagram .........................................................................................................................................................................................17
9.5 User book (Please make copies) .................................................................................................................................................................... 18
10 Attached Documents................................................................................................................................................................................................... 19
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GAS 222.15
1 Introduction
1.1 Intended Use
The sample gas probe is intended for installation into gas analysis systems in commercial applications.
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/ID number, this also contains the article
number and model designation.
Please note the specific values of the device when connecting, and the correct versions when ordering spare parts.
1.2 Type Plate
Example:
GAS 222.15
100107323 462215009902000112213 001
230V 50/60Hz 440W
Material: 1.4571/1.4408/PTFE
Read manual!
Manufacturer and address
Model designation
Order no., Item no.
Material
Electrical supply
1.3 Scope of Delivery
– 1 x Sample gas probe
– 1 x Flange gasket and screws
– Product documentation
– Connection and mounting accessories (only optional)
1.4 Ordering instructions
The item number is a code for the configuration of your unit. Please use the following model key:
4622215 0 9 9 0 3 X 0 0 9 9 9 9 9 9 Product Characteristics
Flange type
DIN DN65 PN6
Power supply sample probe
3 115/230 V
Calibrating gas connection
0 No calibrating gas connection
1 6 mm
2 6 mm + check valve
3 1/4"
4 1/4" + check valve
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1.5 Product Description
Probe Description
GAS 222.15 Probe with outlet filter, self-regulating
Accessories Please refer to the data sheet at the end of this manual for accessories for this probe
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2 Safety instructions
2.1 Important advice
Operation of the device is only valid if:
– the product is used under the conditions described in the installation- and operation instruction, the intended application
according to the type plate and the intended use. In case of unauthorized modifications done by the user Bühler Technolo-
gies GmbH can not be held responsible for any damage,
– when complying with the specifications and markings on the nameplates.
– the performance limits given in the datasheets and in the installation- and operation instruction are obeyed,
– monitoring devices and safety devices are installed properly,
– service and repair is carried out by Bühler Technologies GmbH,
– only original spare parts are used.
This manual is part of the equipment. The manufacturer keeps the right to modify specifications without advanced notice. Keep
this manual for later use.
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
In this manual, the following warning signs are used:
Warning against hazardous situations General notice
Warning against electrical voltage Disconnect from mains
Warning against respiration of toxic gases Wear respirator
Warning against acid and corrosive substances Wear eye/face protection
Warning against potentially explosive atmospheres Wear protection gloves
Warning against hot surface
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GAS 222.15
2.2 General 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.
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.
DANGER Toxic, corrosive gases
The measuring gas led through the equipment can be hazardous when breathing or
touching it.
a) Check tightness of the measuring system before putting it into operation.
b) Take care that harmful gases are exhausted to a save place.
c) Before maintenance turn off the gas supply and make sure that it cannot be turned
on unintentionally.
d) Protect yourself during maintenance against toxic / corrosive gases. Use suitable pro-
tective equipment.
DANGER Potentially explosive atmosphere
Explosion hazard if used in hazardous areas.
The device is not suitable for operation in hazardous areas with potentially explosive at-
mospheres.
Do not expose the device to combustible or explosive gas mixtures.
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GAS 222.15
3 Transport and storage
Only transport the product inside the original packaging or a suitable alternative.
The equipment must be protected from moisture and heat when not in use. They must be stored in a covered, dry and dust-free
room at a temperature between -20°C to 50°C (-4°F to 122°F).
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4 Installation and connection
4.1 Installation site requirements
Sample gas probes are intended for flange mounting.
– Installation site and installation position are determined based on requirements specific to the application.
– If necessary, the connection piece should be slightly tilted toward the centre of the channel.
– The installation site should be protected from the weather.
– In addition, adequate and safe access for installation and future maintenance work should be provided. Particularly follow
the uninstalled size of the probe tube!
If the probe is transported to the installation site in pieces, it will first need to be assembled.
4.2 Installing the sampling tube (optional)
The sampling tube, if necessary with the fitting extension, must be screwed in. The probe is then attached to the mating flange
using the included seal and nuts.
4.3 Installing the downstream filter (optional)
NOTICE
The downstream filter and the O-ring for the handle must be inserted prior to first star-
tup.
Operating without downstream filter prohibited!
O-ring handle
Attach an O-ring suitable for the expected ambient temperature to the handle.
Attach the downstream filter to the handle. Then carefully insert the handle with
filter in the gas probe and turn 90° to secure.
Verify the handle is seated correctly. When seated correctly it locks onto the filter
housing.
4.4 Insulation
On heated probes completely insulate any exposed flange areas and, if applicable, the connection piece to absolutely prevent
thermal bridges. The insulating material must meet the application requirements and be weatherproof.
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4.5 Connecting the Gas Line
The sample gas line must be carefully and properly connected using a suitable fitting.
This table provides an overview of the sample gas probe connections:
Probe
GAS 222
Reservoir
PAV01
Ball valve
pneumatic drive
Control valve
3/2-way solenoid
valve
Connecting flange 1) DN65/PN6/
DN3“-150 2)
Sample gas inlet G3/4
Sample gas outlet NPT 1/4
Blowback connection G3/8
Test gas connection 1) Tube Ø6 mm
Tube Ø1/4 2)
Filling port NPT 1/4
Condensate G1/2
Bypass NPT 1/4
Control air G1/8 G1/4
NPT 1/4
Tab.1: Gas Probe Connections (Varies by Model)
1) Varies by version.
2) Only GAS 222.xx ANSI and GAS 222.xx AMEX
WARNING Gas emanation
Sample gas can be harmful to the health!
Check the lines for leaks.
4.5.1 Connecting the Gas Line
Please note the following items when connecting the sample gas line (NPT 1/4") on heated probes to prevent thermal bridges:
– Choose the shortest possible screw connection.
– Shorten the connection pipe for the sample gas line as much as possible. To do so, remove the insulation around the sample
gas line. This is done by loosening the fixing bolts.
CAUTION Fragile
The insulation is fragile. Handle with care, do not drop.
After connecting the sample gas line it must be braced and secured with the clamp.
Long sample gas lines may require additional support clamps along the way to the analysis system! Once all lines have been
connected and checked for leaks, carefully reinstall and secure the insulation.
WARNING Gas emanation
Sample gas can be harmful to the health!
Check the lines for leaks.
4.5.2 Connecting the calibrating gas line (optional)
Connecting the calibrating gas line requires a Ø6 mm or Ø1/4” pipe fitting.
If the calibrating gas connection was ordered with check valve, a Ø6 mm or Ø1/4” pipe can be connected directly to the check
valve.
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4.6 Electrical connections
WARNING Hazardous electrical voltage
The device must be installed by trained staff only.
CAUTION Wrong mains voltage
Wrong mains voltage may damage the device.
Regard the correct mains voltage as given on the type plate.
Electric strength test
The necessary tests of all assemblies required to be tested were carried out at the factory (test voltage 1 kV or 1.5 kV depending
on component).
To check the electric strength again yourself, only do so on the respective individual components.
– Now perform the electric strength test against earth.
4.6.1 Plug Connection
The probe includes two cubic plugs per EN 175301-803. The plug is configured so it cannot be connected reversed. For safety reas-
ons this configuration must not be modified.
One plug is for the power supply, the other is the alarm output. Please see the enclosed terminal diagram for the connection.
The probe itself has self-regulating heating elements and can therefore be connected to a 100V-230VAC power supply.
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5 Operation and Control
NOTICE
The device must not be operated beyond its specifications.
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6 Service
During maintenance, remember:
– The equipment must be maintained by a professional familiar with the safety requirements and risks.
– Only perform maintenance work described in these operating and installation instructions.
– When performing maintenance of any type, observe the respective safety and operation regulations.
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.
DANGER The gas inside the filter, condensate and used filter elements may be caustic or corros-
ive.
Sample gas can be harmful.
a) Before maintenance turn off the gas supply and surge with air if necessary.
b) Exhaust sample gas to a safe place.
c) Protect yourself against toxic / corrosive gas during maintenance. Wear appropriate
personal protection equipment.
CAUTION Hot surface
Risk of burns
Depending on the operating parameters, the housing temperature may reach over 100
°C during operation.
Allow the unit to cool down before performing maintenance.
CAUTION Excess pressure
The unit mustn’t be pressurised or energised when opened.
If necessary, close the gas supply and ensure a safe pressure on the process end before
opening.
6.1 Maintaining the filter element
The probes feature a particle filter which needs to be changed as it becomes dirty.
To do so, disconnect the voltage supply and if applicable close the shut-off valve to the process or switch off the process.
CAUTION!Do not damage the rear filter seat.
NOTICE
Ceramic filter elements are very brittle by nature. Handle them with care, don’t let them
fall.
Filter elements made out of sintered stainless steel can be cleaned in an ultrasonic bath
and be used several times as long as both seals are still in proper conditions.
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6.1.1 Replacing the downstream filter
– Turn the handle at the back end of the probe by 90° (handle must then be horizontal), pushing in slightly, and remove.
– Remove the dirty filter element and check the sealing surfaces.
– Before installing the new filter element, replace the seal on the handle plug (seal included with the filter element).
– Then carefully insert the handle with new filter, push in slightly and turn 90° (handle must then be vertical). Pull on the
handle to verify the filter element is firmly seated.
– With the filter removed, if necessary also need clean the inside of the sampling tube by blowing it out or using a cleaning
wand.
6.1.2 Replacing the Outlet Filter with Micro-Fibreglass Filter Element
– Turn the handle at the rear end of the probe by 90° (handle must be horizontal), pushing in slightly, and remove.
– Unscrew the dirty filter element counter-clockwise from the thread of the handle.
– Pull both stainless steel filter seats off the filter element.
– Before installing the new filter element, replace the seal on the handle and inside the stainless steel filter seats (seals are in-
cluded with the filter element).
– Then turn the handle with the new filter by 90° (handle must be vertical), pushing in slightly.
CAUTION!Do not damage the rear filter seat.
Filter element
Stainless steel filter seat
(with two interior O-rings)
Thread Handle
With the filter removed, you may also clean the inside of the sampling tube if necessary by blowing it out or using a cleaning
wand.
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7 Service and repair
This chapter contains information on troubleshooting and correction should an error occur during operation.
Repairs to the unit must be performed by Bühler authorised personnel.
Please contact our Service Department with any questions:
Tel.: [phone] or your agent
If the equipment is not functioning properly after correcting any malfunctions and switching on the power, it must be inspected
by the manufacturer. Please send the equipment inside suitable packaging to:
Bühler Technologies GmbH
- Reparatur/Service -
Harkortstraße 29
40880 Ratingen
Germany
Please also attach the completed and signed RMA decontamination statement to the packaging. We will otherwise be unable to
process your repair order.
You will find the form in the appendix of these instructions, or simply request it by e-mail:
[email protected].
7.1 Troubleshooting
CAUTION Risk due to defective device
Personal injury or damage to property
a) Switch off the device and disconnect it from the mains.
b) Repair the fault immediately. The device should not be turned on again before elim-
ination of the failure.
Problem / Malfunction Possible cause Action
No or reduced gas flow – Filter element plugged – Clean or replace filter element, clean
sampling tube
Temperature alarm – Heat-up not yet completed – Wait for heat-up to complete
– Heater – Send in probe for repair
No heat output – No / incorrect voltage – Power supply
Condensation forming – Heater defective – Send in probe for repair
– Thermal bridges at the sampling point – Insulate to eliminate thermal bridges
Tab.2: Troubleshooting
7.2 Spare Parts and Accessories
Please also specify the model and serial number when ordering parts.
Upgrade and expansion parts can be found in our catalog.
Available spare parts:
Item no. Description
90 091 05 Measuring outlet seal
90 090 79 Flange seal DN65 PN6
90 090 68 Flange seal FD 40 WS
46 222 012 O-ring kit for filter element and probe, material: Viton
46 222 024 O-ring kit for filter element and probe, material: Perfluoroelastomer
Please see the accessories data sheet in the appendix for filter elements
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8 Disposal
Dispose of parts so as not to endanger the health or environment. Follow the laws in the country of use for disposing of elec-
tronic components and devices during disposal.
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9 Appendices
9.1 Technical Data
Gas Probe Technical Data
Probe operating temperature: max. 200 °C
Ambient temperature: -20 to +80 °C
Self-regulating heater: +180 °C
Low temperature alarm: Contact open at operating temperature, closes at < 140°C, Max. switching current 4A
Electrical data: 230 V, 2.0 A, 50/60 Hz
115 V, 3.8 A, 50/60 Hz
Max. operating pressure: 6 bar
Parts in contact with media: Flange: 1.4571
Seals: Graphite/1.4404 and see filter
9.2 Flow chart
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9.3 Dimensions
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9.4 Connection Diagram
Mains
Insufficient temperature alarm
Pin assignment
Mains 115-230 VAC 400 W
Heater
Low temperature alarm
max. Voltage 230 V
max. switching current 4 A
(contact opens
when the operating
temperature is reached)
(contact closes
when the operating
temperature is reached)
Optionally with NO contact
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9.5 User book (Please make copies)
Maintained on Unit no. Operating hours Remarks Signature
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