Buhler APO User manual

Gas Analysis
Installation and Operation Instructions
Original instructions
Sample gas probes
APO
BE460014
01/2020
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..........................................................BE460014
Version.........................................................................01/2020

APO
Table of Contents
1 Introduction..................................................................................................................................................................................................................... 2
1.1 Intended Use.........................................................................................................................................................................................................2
1.2 Scope of Delivery.................................................................................................................................................................................................. 2
1.3 Ordering Instructions......................................................................................................................................................................................... 2
2 Safety instructions......................................................................................................................................................................................................... 3
2.1 Important advice................................................................................................................................................................................................. 3
2.2 General hazard warnings .................................................................................................................................................................................4
3 Transport and storage .................................................................................................................................................................................................. 5
4 Installation and connection ........................................................................................................................................................................................6
4.1 Installation site requirements.........................................................................................................................................................................6
4.2 Installation ............................................................................................................................................................................................................6
5 Operation and controls ................................................................................................................................................................................................ 7
5.1 Before Start-Up .................................................................................................................................................................................................... 7
6 Maintenance....................................................................................................................................................................................................................8
7 Service and repair...........................................................................................................................................................................................................9
7.1 Troubleshooting ..................................................................................................................................................................................................9
7.2 Spare parts and accessories .............................................................................................................................................................................9
8 Disposal........................................................................................................................................................................................................................... 10
9 Appendices...................................................................................................................................................................................................................... 11
9.1 Modular standard APO-G.................................................................................................................................................................................11
10 Attached Documents....................................................................................................................................................................................................12
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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 Scope of Delivery
– 1 x Sample gas probe
– 1 x Flange gasket and screws
– Product documentation
– Connection and mounting accessories (only optional)
1.3 Ordering Instructions
Description Material Gas temperature Length Item no.
Base flange APO-G 1.4571 Up to 600 °C -- 46 006 000
Base flange APO-G ANSI 3" 150 lbs 1.4571 Up to 600 °C 46 006 000C
Sampling tube
Sampling tube 01 1.4571 Up to 600 °C max. 1000 mm 46 222 001 1000
Sampling tube 02 Ceramic/1.4571 Up to 1600 °C max. 1000 mm 46 222 002 10
Sampling filter 03 / inlet filter dust load
<10 g/m³
Sintered stainless steel
1.4404/1.4571
Up to 600 °C 222 mm 46 222 303
Sampling filter 031 / inlet filter dust load
<10 g/m³ with built-in displacement
Sintered stainless steel
1.4404/1.4571
Up to 600 °C 222 mm 46 222 3031
Sampling filter 04 / inlet filter dust load
>10 g/m³
Sintered stainless steel
1.4404/1.4571
Up to 600 °C 523 mm 46 222 304
Sampling filter 041 / Inlet filter dust load
>10 g/m³ with built-in displacement
Sintered stainless steel
1.4404/1.4571
Up to 600 °C 523 mm 46 222 3041
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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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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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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 Installation
The probe consists of the APO-G base body the sampling tube you selected screws onto. If the probe is transported to the install-
ation site in pieces, it will first need to be assembled. This is limited to screwing in the sampling tube and, if necessary, the cor-
responding extensions. The probe is then attached to the mating flange using the corresponding seals and screws.
The sample gas line must be carefully and properly connected using a suitable fitting (G 3/8").
WARNING Hazardous electrical voltage
The device must be installed by trained staff only.
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5 Operation and controls
NOTICE
The device must not be operated beyond its specifications.
5.1 Before Start-Up
Before starting the device, verify
– the hose connections are not damaged and correctly installed.
– no parts of the gas probe have been removed.
– the gas inlet and outlet of the gas probe are open.
– ambient parameters are met.
– type plate information and technical specifications were observed!
– whether cable glands are sealed properly.
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6 Maintenance
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 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
Housing temperatures may be high during operation.
Allow the unit to cool down before performing maintenance.
The sampling tubes and removed, changed and installed as described in chapter Installation and connection [> page6].
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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 – Intake filter plugged – Clean or replace intake filter
– Wet condensate trap / filter element – Replace filter element, if possible install con-
densate trap upright, check condensate trap
during operation, and empty, if necessary
– Gas circuit clogged – Clean sampling tube
Tab.1: Troubleshooting
7.2 Spare parts and accessories
Please also specify the model and serial number when ordering parts.
You will find upgrade and expansion parts in the attached data sheet and our catalogue.
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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 Modular standard APO-G
The modular standard series APO-G consists of a base flange APO-G and a sampling tube of your choice. Choose from a variety of
sampling tubes in different lengths and materials.
Sampling tube 01 mm (in)
Sampling tube 02 mm (in)
Sampling tube 03 / 031 / 04 / 041 mm (in)
Base flange APO G
D
C
B A
A B C D
Ø185
(7.3)
Ø145
(5.7)
Ø18
(0.7)
Ø18
(0.7)
Base flange APO G
ANSI 3" 150
Ø190.5
(7.5)
Ø152.4
(6.0)
Ø23.9
(0.9)
Ø19.1
(0.75)
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10 Attached Documents
– RMA - Decontamination Statement
12 Bühler Technologies GmbH BE460014 ◦ 01/2020

RMA-Nr./ RMA-No.
Die RMA-Nummer bekommen Sie von Ihrem Ansprechpartner im Vertrieb oder Service./ You may obtain the RMA
number from your sales or service representative.
Firma/ Company
Firma/ Company
Straße/ Street
PLZ, Ort/ Zip, City
Land/ Country
Zu diesem Rücksendeschein gehört eine Dekontaminierungserklärung. Die gesetzlichen Vorschriften schreiben vor,
dass Sie uns diese Dekontaminierungserklärung ausgefüllt und unterschrieben zurücksenden müssen. Bitte füllen Sie
auch diese im Sinne der Gesundheit unserer Mitarbeiter vollständig aus./ This return form includes a decontamination
statement. The law requires you to submit this completed and signed decontamination statement to us. Please com-
plete the entire form, also in the interest of our employee health.
Ansprechpartner/ Person in charge
Name/ Name
Abt./ Dept.
Tel./ Phone
E-Mail
Gerät/ Device
Anzahl/ Quantity
Auftragsnr./ Order No.
Serien-Nr./ Serial No.
Artikel-Nr./ Item No.
Grund der Rücksendung/ Reason for return
Kalibrierung/ Calibration Modifikation/ Modification
Reklamation/ Claim Reparatur/ Repair
andere/ other
bitte spezifizieren/ please specify
Ist das Gerät möglicherweise kontaminiert?/ Could the equipment be contaminated?
Nein, da das Gerät nicht mit gesundheitsgefährdenden Stoffen betrieben wurde./ No, because the device was not operated with
hazardous substances.
Nein, da das Gerät ordnungsgemäß gereinigt und dekontaminiert wurde./ No, because the device has been properly cleaned and
decontaminated.
Ja, kontaminiert mit:/ Yes, contaminated with:
explosiv/
explosive
entzündlich/
flammable
brandfördernd/
oxidizing
komprimierte
Gase/
compressed
gases
ätzend/
caustic
giftig,
Lebensgefahr/
poisonous, risk
of death
gesundheitsge-
fährdend/
harmful to
health
gesund-
heitsschädlich/
health hazard
umweltge-
fährdend/
environmental
hazard
Bitte Sicherheitsdatenblatt beilegen!/ Please enclose safety data sheet!
Das Gerät wurde gespült mit:/ The equipment was purged with:
Diese Erklärung wurde korrekt und vollständig ausgefüllt und von einer
dazu befugten Person unterschrieben. Der Versand der (dekontaminier-
ten) Geräte und Komponenten erfolgt gemäß den gesetzlichen Bestim-
mungen.
This declaration has been filled out correctly and completely, and signed by
an authorized person. The dispatch of the (decontaminated) devices and
components takes place according to the legal regulations.
Datum/ Date
rechtsverbindliche Unterschrift/ Legally binding signature
Falls die Ware nicht gereinigt, also kontaminiert bei uns eintrifft, muss die
Firma Bühler sich vorbehalten, diese durch einen externen Dienstleister
reinigen zu lassen und Ihnen dies in Rechnung zu stellen.
Should the goods not arrive clean, but contaminated, Bühler reserves the
right, to comission an external service provider to clean the goods and in-
voice it to your account.
Firmenstempel/ Company Sign
DE000011
01/2019
RMA-Formular und Erklärung über Dekontaminierung
RMA-Form and explanation for decontamination
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

Dekontaminierungserklärung
Die Analyse defekter Baugruppen ist ein wesentlicher Bestandteil der Qualitätssicherung der Firma
Bühler Technologies.
Um eine aussagekräftige Analyse zu gewährleisten muss die Ware möglichst unverändert untersucht
werden. Es dürfen keine Veränderungen oder weitere Beschädigungen auftreten, die Ursachen ver-
decken oder eine Analyse unmöglich machen.
Bei elektronischen Baugruppen kann es sich um elektrostatisch sensible Baugruppen handeln. Es ist
darauf zu achten, diese Baugruppen ESD-gerecht zu behandeln. Nach Möglichkeit sollten die Baugrup-
pen an einem ESD-gerechten Arbeitsplatz getauscht werden. Ist dies nicht möglich sollten ESD-
gerechte Maßnahmen beim Austausch getroffen werden. Der Transport darf nur in ESD-gerechten Be-
hältnissen durchgeführt werden. Die Verpackung der Baugruppen muss ESD-konform sein. Verwenden
Sie nach Möglichkeit die Verpackung des Ersatzteils oder wählen Sie selber eine ESD-gerechte Ver-
packung.
Beachten Sie beim Einbau des Ersatzteils die gleichen Vorgaben wie oben beschrieben. Achten Sie auf
die ordnungsgemäße Montage des Bauteils und aller Komponenten. Versetzen Sie vor der Inbetrieb-
nahme die Verkabelung wieder in den ursprünglichen Zustand. Fragen Sie im Zweifel beim Hersteller
nach weiteren Informationen.
Analysing defective assemblies is an essential part of quality assurance at Bühler Technologies.
To ensure conclusive analysis the goods must be inspected unaltered, if possible. Modifications or
other damages which may hide the cause or render it impossible to analyse are prohibited.
Electronic assemblies may be sensitive to static electricity. Be sure to handle these assemblies in an
ESD-safe manner. Where possible, the assembles should be replaced in an ESD-safe location. If un-
able to do so, take ESD-safe precautions when replacing these. Must be transported in ESD-safe con-
tainers. The packaging of the assemblies must be ESD-safe. If possible, use the packaging of the spare
part or use ESD-safe packaging.
Observe the above specifications when installing the spare part. Ensure the part and all components
are properly installed. Return the cables to the original state before putting into service. When in doubt,
contact the manufacturer for additional information.
DE000011
01/2019
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