Buhler GAS 222.21 Ex2 User manual

Gas Analysis
Installation and Operation Instructions
Original instructions
Sample gas probes
GAS 222.21 Ex2
BE460048
08/2019
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 2020
Document information
Document No.........................................................BE460048
Version.........................................................................08/2019

GAS 222.21 Ex2
Table of Contents
1 Introduction..................................................................................................................................................................................................................... 3
1.1 Intended Use......................................................................................................................................................................................................... 3
1.2 Type Plate............................................................................................................................................................................................................... 3
1.3 Contents................................................................................................................................................................................................................. 3
1.4 Ordering instructions ........................................................................................................................................................................................4
1.5 Product Description............................................................................................................................................................................................ 5
2 Safety instructions.........................................................................................................................................................................................................6
2.1 Important Information......................................................................................................................................................................................6
2.2 General Hazard Warnings ................................................................................................................................................................................ 7
2.3 Special conditions for safe use ........................................................................................................................................................................8
2.4 Ambient Temperature range of the equipment........................................................................................................................................8
3 Transport and storage ..................................................................................................................................................................................................9
4 Installation and connection ...................................................................................................................................................................................... 10
4.1 Installation site requirements....................................................................................................................................................................... 10
4.2 Installation ..........................................................................................................................................................................................................10
4.3 Installing the sampling tube (optional)...................................................................................................................................................... 10
4.4 Installing the outlet filter................................................................................................................................................................................. 11
4.5 Installing the Inlet Filter (Optional) .............................................................................................................................................................. 11
4.6 Insulation.............................................................................................................................................................................................................. 11
4.7 Connecting the Gas Line...................................................................................................................................................................................11
4.7.1 Blowback Connection........................................................................................................................................................................ 12
4.7.2 Connecting the calibrating gas line (optional).......................................................................................................................... 12
4.8 Connecting the Backwashing System and the Compressed Air Cylinder (Optional) .................................................................... 12
4.9 Electrical Connections.......................................................................................................................................................................................13
4.9.1 Version Without Terminal Box....................................................................................................................................................... 13
4.9.2 Version With Terminal Box.............................................................................................................................................................. 13
4.9.3 Connecting the Temperature Switch ...........................................................................................................................................14
4.9.4 Connecting the Earth Conductor/Earthing ................................................................................................................................14
4.9.5 Solenoid Valves (Optional)...............................................................................................................................................................14
4.9.6 Limit Switch (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 outlet filter................................................................................................................................................................ 17
6.1.2 Replacing the Inlet Filter .................................................................................................................................................................. 17
6.2 Backwashing the Intake Filter (within the process stream) ................................................................................................................. 18
6.2.1 Manual Blowback (Without Blowback Control) ........................................................................................................................18
6.2.2 Automatic Blowback (External Blowback Control)...................................................................................................................19
6.3 Maintenance Schedule .................................................................................................................................................................................... 19
7 Service and repair.........................................................................................................................................................................................................20
7.1 Troubleshooting ............................................................................................................................................................................................... 20
7.2 Spare Parts and Accessories.......................................................................................................................................................................... 20
8 Disposal............................................................................................................................................................................................................................21
9 Appendices.....................................................................................................................................................................................................................22
9.1 Technical Data....................................................................................................................................................................................................22
9.2 Connection Diagram ........................................................................................................................................................................................23
9.3 Terminal Diagram Probe Terminal Box......................................................................................................................................................23
9.4 Terminal Diagram Terminal Box Limit Switch .........................................................................................................................................24
9.5 Flow chart ............................................................................................................................................................................................................24
9.6 Dimensions .........................................................................................................................................................................................................25
9.7 List of chemical resistance .............................................................................................................................................................................. 27
9.8 User book (Please make copies) ....................................................................................................................................................................28
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GAS 222.21 Ex2
10 Attached Documents...................................................................................................................................................................................................29
ii Bühler Technologies GmbH BE460048 ◦ 08/2019

GAS 222.21 Ex2
1 Introduction
1.1 Intended Use
The sample gas probe is intended for installation into gas analysis systems in commercial applications.
It may be operated in a Zone 2, explosion class IIC, explosive gas atmosphere which is rarely and only temporarily explosive. Zone
2 explosive gas atmospheres may be extracted with or transported with these probes. The probe has a temperature switch
which may only be operated as simple electrical equipment on an intrinsically-safe circuit supplied by a type-tested switch amp-
lifier.
The explosion protection markings on the probes are:
ATEX: II 3G Ex ec ic mb1 IIC T3/T4 Gc
IECEx: Ex ec ic mb1 IIC T3/T4 Gc
1 Only for versions with solenoid valve.
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 may only be blown back with inert gases. Flammable gases from 25% LEL and up to the UEG
may be blown back provided the operator ensures the blown back gas is not and cannot be explosive. For safety reasons we re-
commend only using inert gases in these cases as well.
Blowing back explosive atmospheres (range from UEG to OEG) 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.
1.2 Type Plate
Example:
GAS 222.21 Ex2
000053273 462222110192331111111 001
Manufacturer and address
Model designation
Order no., item no.
Blast protection marking
Electrical supply
IECEx certificate number
Year of manufacture
II 3G Ex ec ic IIC T4 Gc
115/230V 50/60Hz;Valves:24V UC
IECEx IBE 17.0002X
Read manual! Year: 2017
Bühler Technologies GmbH
Harkortstr. 29 D-40880 Ratingen
1.3 Contents
– 1 x Sample gas probe
– 1 x Flange gasket and screws
– Product documentation
– Connection and mounting accessories (only optional)
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GAS 222.21 Ex2
1.4 Ordering instructions
The item number is a code for the configuration of your unit. Please use the following model key:
4622221 X 0 X X X X 3 X X X X X X X Product Characteristics
Terminal box
0 No
1 Yes
Flange
0 1 Flange DN65 PN6
0 2 Flange DN3"-150
Hazardous area Outside and Inside
2 9 Ex-Zone 2 outside
2 2 Ex-Zone 2 outside and inside
Temperature class
3 T3
4 T4
Power supply sample probe
3 115/230 V
Low temperature alarm
1 NC contact (open at operating temperature) (marked "ic")
2 NO contact (closed at operating temperature) (marked "ic")
Calibrating gas port
0 No
1 6 mm
2 6 mm with check valve
3 1/4"
4 1/4" with check valve
Capacitive vessel
0 No
1 Yes (not for Zone 2 inside)
Valve for pressurized air
0 Ball valve
1 Solenoid valve 115 V (marked "mb")
2 Solenoid valve 230 V (marked "mb")
3 Solenoid valve 24 V (marked "mb")
9 none
Pneumatic actuator internal ball valve
0 No
1 Mono stable depressurized open
2 Mono stable depressurized closed
Limit switch for pneumatic actuator
0 No
1 Yes
Solenoid valve for pneumatic actuator
0 No
1 Yes (marked "mb")
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GAS 222.21 Ex2
1.5 Product Description
The probe is equipped with self-regulating PTC heating cartridges and a temperature contact.
Probe Description
GAS 222.21 Ex2 Probe with inlet and/or outlet filter, shut-off valve and blowback connection
GAS 222.21-JB Ex2 Probe with inlet and/or outlet filter, shut-off valve, blowback connection and terminal box
Accessories Please refer to the data sheet at the end of this manual for accessories for this probe
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GAS 222.21 Ex2
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 temperature switch is being operated on an intrinsically-safe circuit,
– the controller itself is installed outside the explosive area,
– 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 observed.
These operating instructions are a part of the equipment. The manufacturer reserves the right to change performance-, specific-
ation- 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 222.21 Ex2
2.2 General Hazard Warnings
The maximum surface temperature of the probes solely varies by operating conditions (steam temperature, sample gas inlet
temperature, ambient temperature, fluid flow rate). For use in explosive areas please particularly note the related hazard warn-
ings.
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.
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.
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.
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GAS 222.21 Ex2
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 gasses could ignite or explode. Avoid the following hazard sources:
Application area!
Never operate the gas probe outside the specifications. Extracting 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 gas temperatures during blowback. Never blow-
back if gases are explosive. Only use nitrogen (inert gas) to blowback flammable gas.
2.3 Special conditions for safe use
The temperature switch must be operated intrinsically safe. See parameters in chapter “Connecting the Temperature Switch”.
2.4 Ambient Temperature range of the equipment
The ambient temperature range may be limited based on the version. Please note the Ambient temperature ranges under
"Technical Data".
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