Bühler technologies GAS 222.35 User manual

Gas Analysis
Installation and Operation Instructions
Original instructions
Sample gas probes
GAS 222.35
BE460062
09/2021
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......................................................... BE460062
Version......................................................................... 09/2021

GAS 222.35
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 ........................................................................................................................................................................................ 3
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 upstream filter .......................................................................................................................................................................... 7
4.3 Insulation............................................................................................................................................................................................................... 7
4.4 Connecting the Gas Line.................................................................................................................................................................................... 7
4.4.1 Blowback Connection......................................................................................................................................................................... 8
4.4.2 Connecting the Gas Line.................................................................................................................................................................... 8
4.4.3 Connecting the calibrating gas line (optional)........................................................................................................................... 8
4.5 Connecting the Blowback and Pressure Vessel (Optional) .....................................................................................................................8
4.6 Electrical connections ........................................................................................................................................................................................9
4.6.1 Connection via Terminal Strip......................................................................................................................................................... 9
4.6.2 Heated Pressure Vessel (Optional) ................................................................................................................................................. 9
5 Operation and Control................................................................................................................................................................................................ 10
5.1 Basic function of the probe controller.........................................................................................................................................................10
5.1.1 Regulator Functions...........................................................................................................................................................................10
5.1.2 Advanced functions for built-in blowback control (optional)...............................................................................................10
5.2 Use of menu functions ....................................................................................................................................................................................10
5.2.1 Menu Navigation Overview .............................................................................................................................................................11
5.2.2 Detailed description of the operational principle .................................................................................................................... 12
5.3 Description of menu functions ..................................................................................................................................................................... 12
5.3.1 Main Menu ........................................................................................................................................................................................... 12
5.3.2 Probe Controller Submenu [Display: Prob]................................................................................................................................. 13
5.3.3 Regulator Submenu for Heated Extension [Display: Adon] (Optional).............................................................................. 13
5.3.4 Submenu Blowback control [Display: bbc] (optional) .............................................................................................................14
6 Service...............................................................................................................................................................................................................................15
6.1 Maintaining the Filter Element......................................................................................................................................................................15
6.1.1 Replacing the upstream filter.........................................................................................................................................................16
6.2 Inlet filter blowback (within the process stream).................................................................................................................................... 16
6.2.1 Manual Blowback (Without Blowback Control) ........................................................................................................................ 17
6.2.2 Automatic Blowback (External Blowback Control)................................................................................................................... 17
6.2.3 Built-In Blowback Control (Optional)............................................................................................................................................ 17
7 Service and repair......................................................................................................................................................................................................... 18
7.1 Troubleshooting ................................................................................................................................................................................................ 18
7.2 Spare Parts and Accessories ........................................................................................................................................................................... 19
8 Disposal...........................................................................................................................................................................................................................20
9 Appendices......................................................................................................................................................................................................................21
9.1 Technical Data.................................................................................................................................................................................................... 21
9.2 Flow chart ............................................................................................................................................................................................................ 21
9.3 Dimensions .........................................................................................................................................................................................................22
9.4 Connection Diagram ........................................................................................................................................................................................23
9.5 Connection diagram heated pressure vessel............................................................................................................................................24
9.6 User book (Please make copies) ....................................................................................................................................................................25
10 Attached Documents...................................................................................................................................................................................................26
iBühler Technologies GmbHBE460062 ◦ 09/2021

GAS 222.35
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 222.35
100107323 462235009902000112213 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)
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GAS 222.35
1.4 Ordering instructions
The item number is a code for the configuration of your unit. Please use the following model key:
4622235 0 9 9 0 X X 0 0 X X X 9 9 9 Product Characteristics
Flange / approval
0 DIN DN65 PN6
Power supply sample probe
1 115 V
2 230 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
Connection heated extension
0 No
Built-in temperature controller 1)
0 No
Blowback with air reservoir 2)
Air reservoir heating
1 Yes
9 No
Built-in blowback control 1)
1 Internal controller
9 No
Compressed air valve / valve voltage information
0 Manual
1 115 V
2 230 V
3 24 V
9 None (if no blowback requested)
Pneumatic drive for ball valve
9 N/A
Limit switch for pneumatic drive
9 No
Control valve for pneumatic drive
9 No control valve
1) The electronics can either be equipped with temperature controller for heated extension or blowback control
2) For flammable sample gas, always use inert gas for blowback. Probe blowback prohibited when using explosive gases!
1.5 Product Description
Probe Description
GAS 222.35 Probe with retractable inlet 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
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 222.35
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 222.35
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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GAS 222.35
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 upstream filter
The upstream filter, if necessary with matching extension, must be screwed in. The probe is then attached to the mating flange
using the included seals and screws.
4.3 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.
4.4 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.
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GAS 222.35
4.4.1 Blowback Connection
Without accessories installed for the blowback device, the blowback connection comes with a sealed G3/8 screw-in connection. If
you require blowback, you will need to undo this screw-in connection and ensure the blowback line is connected properly and
tight.
DANGER Toxic, corrosive gasses
Explosive or toxic gases can develop due to a leaking or open blowback connection.
4.4.2 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.
4.4.3 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.
4.5 Connecting the Blowback and Pressure Vessel (Optional)
The air lines must be connected carefully and properly, using suitable fittings.
If the probe is equipped with pressure vessel for efficient blowback (optional), a manual shut-off valve (ball valve) must be in-
stalled in the air supply, immediately upstream from the pressure vessel.
NOTICE
The operating pressure of the compressed air (inert gas) required for blowback must al-
ways be higher than the process pressure.
Required pressure differential min. 3 bar (44 psi).
DANGER Broken pressure vessel
Gas leak, danger due to flying parts.
Maximum operating pressure of the pressure vessel 10 bar (145 psi)!
The operating pressure reduces based on the operating voltage (see solenoid valve type
plate).
8 Bühler Technologies GmbH BE460062 ◦ 09/2021