Buhler GAS 222.35 AMEX Installation And Operation Instructions Manual

Brand: Buhler

Model: GAS 222.35 AMEX

Type: Installation And Operation Instructions Manual

This manual is also suitable for

GAS 222.21 AMEX

Gas Analysis

Installation and Operation Instructions

Original instructions

Sample gas probes

GAS 222.35 AMEX

BE460058

08/2019

Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen

Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20

E-Mail: [email protected]

Internet: www.buehler-technologies.com

Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen

Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 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.

Document information

Document No......................................................... BE460058

Version.........................................................................08/2019

GAS 222.35 AMEX

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 .................................................................................................................................................................................................. 7

4 Installation and connection ........................................................................................................................................................................................8

4.1 Installation site requirements.........................................................................................................................................................................8

4.2 Installation ............................................................................................................................................................................................................8

4.3 Installing the Inlet Filter ....................................................................................................................................................................................8

4.4 Insulation...............................................................................................................................................................................................................8

4.5 Connecting the Gas Line....................................................................................................................................................................................9

4.5.1 Blowback Connection......................................................................................................................................................................... 9

4.5.2 Connecting the Gas Line.................................................................................................................................................................... 9

4.5.3 Connecting the calibrating gas line (optional)..........................................................................................................................10

4.6 Connecting the Blowback and Pressure Vessel (Optional) ...................................................................................................................10

4.7 Electrical connections ......................................................................................................................................................................................10

4.7.1 Heated pressure vessel (optional) ..................................................................................................................................................11

5 Operation and Control.................................................................................................................................................................................................13

5.1 Before Start-Up ...................................................................................................................................................................................................13

6 Maintenance.................................................................................................................................................................................................................. 14

6.1 Maintaining the filter element ......................................................................................................................................................................15

6.1.1 Replacing the Inlet Filter .................................................................................................................................................................. 15

6.2 Blowback of the in-situ filter (within the process stream).................................................................................................................... 16

6.2.1 Manual Blowback (Without Blowback Control) ........................................................................................................................16

6.2.2 Automatic Blowback (External Blowback Control)...................................................................................................................16

6.3 Maintenance Schedule .....................................................................................................................................................................................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 Connection Diagram ........................................................................................................................................................................................ 21

9.3 Connection diagram heated pressure vessel............................................................................................................................................22

9.4 Flow diagram......................................................................................................................................................................................................22

9.5 Dimensions .........................................................................................................................................................................................................23

9.6 List of chemical resistance..............................................................................................................................................................................24

9.7 User book (Please make copies) .................................................................................................................................................................... 25

10 Attached Documents...................................................................................................................................................................................................26

iBühler Technologies GmbHBE460058 ◦ 08/2019

GAS 222.35 AMEX

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.

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 222.35 AMEX

100105177 462223516633000999999 001

Cl. 1, Div. 2, Gps. B, C, D, T3

CSA Certificate: 1728394

Install per drawing 46/115-Z01-06-4

115-230 V; max. 360W @ 230V

at -20 up to 80 °C; max. 6 bar

Manufacturer and address

Year: 2019

Type designation

Order no., Item no.

Blast protection marking

CSA certificate number

Drawing number

Item description

Year of manufacture

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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1.4 Ordering instructions

The item number is a code for the configuration of your unit. Please use the following model key:

4622235 1 6 6 X 3 X 0 0 X 9 X 9 9 9 Product Characteristics

Ex temperature classes

3 T3

4 T4

Sample probe power supply

3 115 / 230 V

Calibration gas connection

0 No calibration gas connection

1 6 mm

2 6 mm + check valve

3 1/4"

4 1/4" + check valve

Blowback with air reservoir

Air reservoir heating

1 Yes

9 No

Compressed air valve/valve voltage information

0 Manual

1 120 V 60 Hz

2 240 V 60 Hz

9 None (if no blowback requested)

Pneumatic drive for ball valve

9 N/A

Control valve for pneumatic drive

9 No control valve

Please note, using certain accessories may limit gas probe use in Ex areas! Observe the respective operating manuals, accessory

compatibility charts, and data sheets to ensure proper technical product design!

In the case of flammable gases, always use inert gas for blowback. Probe blowback prohibited when using explosive sample

gas!

1.5 Product Description

The probe is equipped with self-regulating PTC heating cartridges and a temperature contact.

Probe Description

GAS 222.35 AMEX 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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2 Safety instructions

2.1 Important advice

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,

– Monitoring equipment / protection devices must be connected correctly,

– service and repairs not described in these instructions is performed by Bühler Technologies GmbH,

– using genuine replacement parts.

– Regulation IEC/EN60079-14 must be observed when erecting electrical systems in explosive areas.

– Additional national regulations pertaining to initial operation, operation, maintenance, repairs and disposal must be ob-

served.

– These operating instructions are a part of the equipment. The manufacturer reserves the right to change performance-, spe-

cification- or technical data without prior notice. Please keep these instructions for future reference.

Signal words for warnings

DANGER

Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.

WARNING

Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not

avoided.

CAUTION

Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property or

minor or medium injuries if not avoided.

NOTICE

Signal word for important information to the product.

Warning signs

These instructions use the following warning signs:

Warns of a general hazard General notice

Warns of voltage Unplug from mains

Warns not to inhale toxic gasses Wear respiratory equipment

Warns of corrosive liquids Wear a safety mask

Warns of explosive areas Wear gloves

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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.

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.

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.

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DANGER

Use in explosive areas

Flammable gasses and dust 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 equipment 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

Dust:

If possible, take the electrical components which must be opened for repair to a dust-

free room. If unable to do so, prevent dust from entering the housing.

Ignition of dust layers!

When using the device in a dusty environment, routinely clean dust from all compon-

ents.

The ignition temperature resp. smouldering temperature of flammable dusts resp. dust

layers present must be considerably higher than the maximum surface temperature of

the probe (observe applicable standards and statutory regulations).

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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

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 Explosion hazard

When used in explosive areas

Flammable gasses and dust could ignite or explode.

Never operate the gas probe outside the specifications. Extracting gases or gas mixtures

which are also explosive in the absence of air is prohibited.

DANGER Explosion hazard due to ignition of dust

When using the device in a dusty environment, routinely clean dust from all compon-

ents.

The ignition temperature resp. smouldering temperature of flammable dusts resp. dust

layers present must be considerably higher than the maximum surface temperature of

the device (observe applicable standards and statutory regulations).

If possible, take the electrical components which must be opened for repair to a dust-

free room. If unable to do so, prevent dust from entering the housing.

DANGER Explosion hazard due to flame propagation

Severe injuries and damage to the system

If the process holds a risk of flame propagation, install a flame arrestor.

4.3 Installing the Inlet Filter

The inlet 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.

4.4 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

DN65/PN6/

DN3“-150

Sample gas inlet G3/4

Sample gas outlet NPT 1/4

Blowback connection G3/8

Test gas connection

Tube Ø6 mm

Tube Ø1/4

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)

Varies by version.

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 Blowback Connection

If the probe has a G3/8 blowback connection, without factory installed blowback device it will be open. The blowback connection

must be sealed gas-tight prior to start-up.

DANGER Toxic, corrosive gasses

Explosive or toxic gases can develop due to a leaking or open blowback connection.

4.5.2 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.

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WARNING Gas emanation

Sample gas can be harmful to the health!

Check the lines for leaks.

4.5.3 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.

4.6 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.

On probes used to sample flammable gas, nitrogen (inert gas) must be used for blowback. Blowback of explosive gases is prohib-

ited.

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).

DANGER Adiabatic compression during gas blowback (explosion hazard)!

Adiabatic compression may cause high gas temperatures and must be checked by the

user.

Gas blowback may result in high gas temperatures due to adiabatic compression. This

can cause flammable gases to ignite spontaneously.

a) Blowback of explosive atmosphere / gases is prohibited.

b) Flammable atmosphere / gases (non-explosive) may only be blown back with nitro-

gen (inert gas).

4.7 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.

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CAUTION Equipment damage

Cables damaged

Do not damage the cable during installation. Install a strain relief for the cable connec-

tion. Secure the cable against twisting and loosening. Please note the temperature res-

istance of the cables (> 100°C/212°F).

The probe includes two cubic plugs per EN 175301-803 (ex DIN43650) and a junction box. The plugs are prewired to the junction

box. For safety reasons this connection must not be modified. The electrical connections must only be run to the terminals of the

junction box.

The power supply for the two heating cartridges (mains supply 115/230V, 50/60 Hz) and the connection for the thermal alarm

contact are provided via the terminal strip in the junction box. Per EN 60079-14 and -15, connection for the alarm output must

be connected energy-limited (U

max

= 30 V, I

max

= 100 mA). Please see the enclosed terminal diagram for the connection.

– Only use cables with a temperature resistance of >100°C to connect to power.

– Make sure the connecting cable has sufficient strain relief (match cable diameter to the seal on the cubic plug).

– Please note, the heating system briefly has high starting currents (max. 6A). Use a suitable fuse (8A). When connecting,

please also observe the applicable Ex protection regulations.

NOTICE

The thermal alarm contact must be connected energy-limited!

max

= 30 V, I

max

= 100 mA)

WARNING High voltage

Damage to the device in case of insulation testing

Do not proceed insulation tests with high voltage

to the device as a whole!

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.

4.7.1 Heated pressure vessel (optional)

A heated blowback vessel may optionally be used for blowback. Heated via self-regulating PTC heating cartridge to protect

against frost.

The electrical (mains connection 115/230 V AC) connects via the junction box per the enclosed terminal diagram at the end.

– Only use cables with a temperature resistance of >100°C to connect to power.

– Make sure the connecting cable has sufficient strain relief (match cable diameter to the seal on the junction box).

– When connecting, also observe the applicable Ex protection regulations and general warnings in these operating instruc-

tions.

CAUTION Equipment damage

Cables damaged

Do not damage the cable during installation. Install a strain relief for the cable connec-

tion. Secure the cable against twisting and loosening. Please note the temperature res-

istance of the cables (> 100°C/212°F).

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DANGER Adiabatic compression during gas blowback (explosion hazard)!

Adiabatic compression may cause high gas temperatures and must be checked by the

user.

Gas blowback may result in high gas temperatures due to adiabatic compression. This

can cause flammable gases to ignite spontaneously.

a) Blowback of explosive atmosphere / gases is prohibited.

b) Flammable atmosphere / gases (non-explosive) may only be blown back with nitro-

gen (inert gas).

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5 Operation and Control

NOTICE

The device must not be operated beyond its specifications.

NOTICE

The weather hood must be closed during operation!

WARNING Housing or component damage

Never exceed the maximum working pressure and temperature range of the drive.

DANGER Explosion hazard due to electrostatic discharge

Equipment may only be used where normal operating conditions do not produce fre-

quent flammable, electrostatic discharge.

5.1 Before Start-Up

Before starting the device, verify:

– The hose and electrical connections and the heating tape are not damaged and installed correctly.

– No parts of the sample gas probe have been removed.

– The protection and monitoring devices are installed and functional (e.g. flame arrester).

– The gas inlet and outlet on the gas probe are open.

– Ambient parameters are met.

– Probe parts are resistant to media to be conveyed and in the surrounding area.

– The performance specifications in the type plate are met.

– The voltage and frequency of the heating tape match the mains values.

– The temperature has an energy-limited connection (U

max

= 30V, I

max

= 100 mA).

– The electrical connections are tight.

– The monitoring equipment is connected and set as specified.

– All connection cables are installed without strain.

– Precautions have been taken; earthing.

– The junction box cover is closed and the cable gland is properly sealed.

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6 Maintenance

– Damaged parts must be replaced immediately.

– Regularly check the function of the electrical protection.

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 Danger to life and explosion during installation and maintenance

The unit must not be worked on (assembly, installation, maintenance) in explosive at-

mospheres.

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.

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.

DANGER Dangerous electrostatic charge (explosion hazard)

Incendive electrostatic charges may occur when cleaning plastic housing parts and

decals (e.g. with a dry cloth or compressed air). The sparks this produces could ignite

flammable, explosive atmospheres.

Always clean plastic housing parts and decals

with a damp cloth

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DANGER Explosion hazard due to ignition of dust

When using the device in a dusty environment, routinely clean dust from all compon-

ents.

The ignition temperature resp. smouldering temperature of flammable dusts resp. dust

layers present must be considerably higher than the maximum surface temperature of

the device (observe applicable standards and statutory regulations).

If possible, take the electrical components which must be opened for repair to a dust-

free room. If unable to do so, prevent dust from entering the housing.

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.

6.1.1 Replacing the Inlet Filter

The probes are equipped with an inlet filter which is always inside the process stream. The filter is suitable for blowback with

compressed air (inert gas), i.e. blowing air (inert gas) through the filter from the inside to the outside to remove adhering

particles. When sampling flammable gases, nitrogen (inert gas) must be used for blowback. Blowback of explosive gases is pro-

hibited.

The effectiveness of cleaning a filter within a process is directly influenced by the available airflow (amount of gas). We there-

fore recommend using a pressure vessel directly on the probe.

With sufficient inlet filter blowback (within the process stream) the probes are maintenance-free. However, due to process con-

ditions the filter may clog over time. In this case the filter element will need to be replaced.

Proceed as follows:

– Slightly push in the handle at the back of the probe and turn 90° (handle must then be horizontal) and remove.

– Screw the dirty filter element out of the handle.

– Check the sealing faces on the handle, replace O-rings, then install the filter element and new seal. (The spare filter includes

O-rings and seals).

– Then insert the handle with the new or cleaned filter, push in slightly and turn 90° (handle must then be vertical). Pull on the

handle to verify the filter element is firmly seated.

NOTICE

The weather hood can only be closed again when the handle is completely vertical. In or-

der to do so, loosen the hood from the locking supports by lifting slightly and then fold

down. Ensure that the hood lock clicks into place correctly.

Condensate inside the pressure vessel

Depending on the installation site and application conditions a small amount of condensate may form inside the blowback air

pressure vessel. Open the drain screw at the bottom of the vessel and drain the condensate at least once a year.

If the probe needs to be serviced more frequently due to operating conditions, we recommend also draining the condensate at

these intervals.

CAUTION High pressure

Pressure vessel under pressure.

Before opening the condensate drain, close the air supply to the blowback control and

drain the vessel by manual blowback.

Pressing the main switch for the blowback control to interrupt the voltage supply.

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6.2 Blowback of the in-situ filter (within the process stream)

DANGER Adiabatic compression during gas blowback (explosion hazard)!

Adiabatic compression may cause high gas temperatures and must be checked by the

user.

Gas blowback may result in high gas temperatures due to adiabatic compression. This

can cause flammable gases to ignite spontaneously.

a) Blowback of explosive atmosphere / gases is prohibited.

b) Flammable atmosphere / gases (non-explosive) may only be blown back with nitro-

gen (inert gas).

Be sure to use filtered air with a minimum rating of PNEUROP / ISO Class 4 for blowback:

Class Particles / m

Particle size:

(1 to 5) µm

Pressure dew point

[°C]

Residual oil content

[mg / m

]

to 1000

(no particles ≥ 15 µm)

≤ 3 ≤ 5

6.2.1 Manual Blowback (Without Blowback Control)

The shut-off valve in the air supply (inert gas supply) to the pressure vessel must be open. The optional pressure gauge on the

pressure vessel shows the current operating pressure.

–

Abruptly

open the ball valve in the connecting line from the pressure vessel to the probe until the display on the pressure

gauge has dropped to the lowest reading.

6.2.2 Automatic Blowback (External Blowback Control)

Automatic blowback requires a shut-off valve downstream from the probe. The control unit for the system is designed for se-

quential valve control, i.e.:

1. Closing the shut-off valve downstream from the probe with a controller.

2. Open the solenoid valve between the pressure vessel and probe for approx. 10 seconds.

3. Open the shut-off valve downstream from the probe again.

Blowback can also be set as a closed process at intervals ranging from several minutes to hours or even days based on require-

ments.

16 Bühler Technologies GmbH BE460058 ◦ 08/2019

GAS 222.35 AMEX

6.3 Maintenance Schedule

NOTICE

When using the probe in explosive areas the maintenance schedule must be observed!

Maintenance schedule for normal ambient conditions:

Component Interval in operating

hours

Work to be performed To be performed by

Entire probe every 8000 h – Check gas connections

– Check safety devices and controllers

– Check electrical protective measures

– Proper function, dirt, visual inspection for dirt / dam-

age.

If damaged, replace or have repaired by Bühler.

Operator

Ball valves every 8000 h – Check ball valve function and check for leaks. Operator

Filter every 8,000 h – Check dirt level of filter. Operator

Seals every 8,000 h – Replace O-rings.

– Replace seals after every filter change.

Operator

Pressure vessel every 8,000 h – Drain condensate Operator

Entire probe

With respect to the

ball valve and solenoid

valves

after 20,000 h or

3years

– Inspection by Bühler Service technician /

Bühler

17Bühler Technologies GmbHBE460058 ◦ 08/2019

GAS 222.35 AMEX

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.: +49-(0)2102-498955

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 clogged – Clean or replace filter element

– Gas circuit clogged – Clean sampling tube

– Ball valve closed – Open ball valve

– Blowback (optional) not responding – Check compressed air supply

– Check solenoid valve, check pneumatic con-

trol

No heat output – No/incorrect power supply – Check power supply

Condensation forming – Heater defective – Send in probe for repair

– Thermal bridges at the sampling point – Insulate to eliminate thermal bridges

18 Bühler Technologies GmbH BE460058 ◦ 08/2019

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Buhler GAS 222.35 AMEX Installation And Operation Instructions Manual

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Model: GAS 222.35 AMEX

Type: Installation And Operation Instructions Manual

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