System Components for Sample Gas Sampling Data Sheet 10/23-5.10 EN November 2004 A gas analysis system usually consists of two groups of devices: The gas analyzer measures the concentrations of the sample gas components and converts them into an electrical signal. Supplementary devices sample the sample gas from the process, condition it and feed it in the gas analysis system. In most cases, the sample gas sampled from the process cannot be processed by the gas analyzer without further conditioning. Too high a dust content, temperature and dew point as well as too high or too low pressure, and not least interference components in the sample gas can impair the operational capability of the gas analyzer and falsify the measuring result. Supplementary devices such as the sampling probe, the sample gas line, the sample gas cooler and pumps and filters ensure that the sample gas inlet conditions of the connected gas analyzers are satisfied and faultless measuring results are obtained independently of the process sequence and the local conditions. Contents Page Modular Sample Gas Probe System 3 FE2 Filter Unit 4 Annular Heating Element 5 Heating Sleeve 6 PFE2 Filter Unit 7 PFE3 Filter Unit 14 Selection Table for Probe Tube Types and Probes 16 Type 40 Probe Tube 17 Type 42 Probe Tube (heated) 18 Type 60 Probe Tube (Cement Flue Gas Probe) 19 Probe 2 20 Probe 1, Probe 11 21 Ceramic Filter 22 Process Pressure Reducers 23 Heated Sample Gas Lines 25 CGWB 13 Heated Sample Gas Line 26 TBL 01, TBL 01-E Heated Sample Gas Lines 28 Electronic Temperature Controller and Switching Relay 30
Modular Sample Gas Probe System Easily adaptable to different sampling conditions thanks to modular construction Components: FE2, PFE2, PFE3 filter units Probe tube types K, 40, 42, 60 Annular heating element Heating sleeve Probe tubes and filter unit heatable Connections for test gas and purging Filter with high retention rate and long service life Easy filter replacement Usable in emission measuring systems conforming to 13th BImSchV and 17th BImSchV (Federal Immission Protection Law) 10/23-5.10 EN November 2004 System Components for Sample Gas Sampling 3
FE2 Filter Unit Use The FE2 filter unit is a component of the modular gas sampling probe system. It is used for filtering gases containing dust. Process Gas Sampling Conditions Pressure p abs = 50 to 600 kpa Temperature max. 200 C (coated max. 180 C) Flow Rate 30 to 500 l/h, relative to 100 kpa and 0 C Pressure Drop approx. 0.6 hpa at 100 l/h Dust Content max. 3 g/m 3 (application recommendation); max. 40 g/m 3 with probe tube type 40 with blow-back device; max. 2000 g/m 3 with probe tube type 60 Filter Characteristics Filter Element Surface filter Filter Fineness 0.5 µm Retention Rate 99.98 % Seal Integrity 10 4 hpa l/s Dead Volume 280 ml Materials of the Gas-carrying Parts Casing and Connections Special steel Mat. No. 1.4571 Flange Special steel Mat. No. 1.0718 (optionally special steel Mat. No. 1.4571) Filter Aluminum oxide surface filter Coating Thermoset plastic, resistant up to 180 C Connection Ports Sample Gas/Test Gas G 1/4 internal thread to DIN ISO 228/1 Compressed Air (2 Ports) G 1/2 internal thread to DIN ISO 228/1 Probe Tube G 3/4 internal thread to DIN ISO 228/1 Compressed Air Supply for Blowback (See PFE2 Filter Unit, page 7) Instrument Air Free of dust, water and oil Pressure max. 600 kpa Ordering Information Catalog No. Housing and flange SS 23042-5-8018414 Housing and flange SS, coated 23042-5-8018417 Housing and flange SS, filt. fineness 0.3 µm 23042-4-0730709 Installation Flange DN 65, PN 6, Form B to DIN 2573, flange gasket A; positioning of holes: 0, 45, 90, 135, 180, 225, 270, 315, 360 Mounting Flange connect or bolt to the probe tube Weight approx. 8.0 kg 4 System Components for Sample Gas Sampling 10/23-5.10 EN November 2004
Annular Heating Element Use For heating the FE2 filter unit, which is a component of the modular gas sampling probe system. Heating is necessary if condensation is likely from moist gases and there is consequently risk of the filter becoming clogged and corroded. Data Power Supply 115 V AC or 230 V AC, 50 to 60 Hz Heater Output 200 W, 100 W or 50 W depending on setting The heating resistors are factory-set for heat output of 100 W Temperature of Heater (unregulated) approx. 120 C to 180 C (measured at ambient temperature of 20 C, still air) Ambient Temperature 0 to 55 C (still air) Degree of Protection of Housing IP 50 Materials Housing: aluminum alloy, heating surface: brass Weight approx. 1.7 kg Electrical Connections Terminals via cable gland PG 13.5 The electrical supply conductor must be heat resistant ( 200 C). Dimensional Drawing (dimensions in mm) Installation Two half shells are placed round the FE2 filter unit to be heated and closed with a wing screw. Option Regulated Heating with 1 x Pt 100 Ordering Information Catalog No. Ring heater 230 V, 50/60 Hz 23029-5-7865312 Ring heater 115 V, 50/60 Hz 23029-5-8008813 Ring heater with Pt 100, 230 V, 50/60 Hz 23029-5-7865316 Ring heater with Pt 100, 115 V, 50/60 Hz 23029-5-7865317 Heating Circuit 230 / 115 V AC 230 / 115 V AC 230 / 115 V AC 200 W 100 W 50 W 10/23-5.10 EN November 2004 System Components for Sample Gas Sampling 5
Heating Sleeve Regulated Heating Sleeve for FE2 Filter Unit Heater Micanite Holding Temperature max. 350 C Temperature Control max. 200 C (Pt 100) Power Supply 230 V AC, optionally 115 V AC Power Consumption 250 VA Connection Terminal box with PG 9 bolted connection, protection level IP 54 Supply Cable 3 x 1 mm 2 with silicone sheath, length 1 m Ambient Temperature 20 to +45 C Relative Humidity 75 % yearly mean; infrequent slight condensation permissible Weight approx. 1 kg Essential Accessories Insulating Mat Temperature Controller (see page 30) Ordering Information Catalog No. Heated sleeve, 230 V, 50/60 Hz, 300 VA 23043-5-8018410 Heated sleeve, 115 V, 50/60 Hz, 300 VA 23043-5-8018411 Isolation for heated sleeve 23043-5-8018412 6 System Components for Sample Gas Sampling 10/23-5.10 EN November 2004
PFE2 Filter Unit Use The PFE2 filter unit consists of the FE2 filter unit with a regulated heating sleeve, installed in a special-steel protective case. It is used to filter dust-containing gases and is a component of the modular gas sampling probe system. When used for gases with high dust content, the PFE2 can optionally be fitted with valves for automatic cleaning of the filter element in the FE2 filter unit. Protective Case Dimensions 450 x 450 x 400 mm (H x W x D) Material Special steel, Mat. No. 1.4301 Degree of Protection of Housing IP 54 Ambient Temperature 20 to +45 C Weight approx. 18 kg Options Heating sleeve, regulated (Pt 100), with insulating mat Annular heating element, unregulated Filter fineness 0.3 µm Pneumatic Valve Diaphragm Valve 2/2-way straight-way valve Operating Pressure/Control Pressure 600 kpa (6 bar) Nominal Diameter DN 12 Connections G 1/2 internal thread DIN ISO 228/1 Control air: G 1/8 internal thread DIN ISO 228/1 Material Brass Mode of Operation Closed in the normal position Ambient Temperature 0 to +100 C Control Valve Solenoid Valve 3/2-way solenoid valve Nominal Diameter DN 2.0 Pressure Range 600 kpa (6 bar) Connections G 1/8 internal thread DIN ISO 228/1 Material Brass Electrical Connections Standard connector Power Supply 115 V AC or 230 V AC, 50 to 60 Hz Power Consumption 8 VA Mode of Operation Closed in normal position Ambient Temperature 0 to +100 C 10/23-5.10 EN November 2004 System Components for Sample Gas Sampling 7
PFE2 Filter Unit Ordering Information Catalog No. 23028-0- 0 0 0 0 0 0 Design without protection box 1 with protection box IP 54 (450 x 450 x 400 mm) 2 with protection box, IP 54, anti-freeze heating 3 with protection box, IP 54, ambient temp. max. 65 C 4 with protection box IP 54 (330 x 203 x 270 mm) 5 Filter housing (equal FE 2) Housing and flange SS 3 Housing and flange SS, coated 4 Housing and flange SS, with filter element <0.3 µm (filtration fineness) 7 Housing and flange SS, coated, with filter element <0.3 µm (filtration fineness) 8 Heating Without 1 with heating unit and insulation (max. 200 C) 2 with ring heater, unregulated 3 Control / Monitoring Without 1 with 1x Pt 100 2 with 2x Pt 100 3 Back purging unit (without compressed air unit) without reverse purging 0 with pneumatic valve 1 with 3x pneumatic-, 1x air-bleed-valve(s) 2 with check valve for AC-FNT 3 Power supply 230 V, 50... 60 Hz 1 115 V, 50... 60 Hz 2 Catalog No. 23028-0- 0 0 0 0 0 0 8 System Components for Sample Gas Sampling 10/23-5.10 EN November 2004
PFE2 Filter Unit Probe Protective Case Dimensional Diagram (dimensions in mm) Sample gas connection Electrical connections Compressed air Purging Bulkhead fitting 10/12x1 mm Test gas connection Bulkhead fitting 4/6x1 mm Control air Bulkhead fitting 4/6x1 mm Cover swivels upwards Elongated holes for M8 safety collar bolts Flange plate with pipe clamp 2 1/2" RST 37-2 hot galvanized DIN 3568 for mounting at probe mounting adapter Take holes for cable glands on the left into account Terminal box with cable glands Use as required 2x Pg21 3x Pg16 1x Pg13,5 1x Pg11 10/23-5.10 EN November 2004 System Components for Sample Gas Sampling 9
PFE2 Filter Unit Dimensional Drawing: Mounting of Probe Protective Case with PFE2 Filter Unit (dimensions in mm) X α Minimum distance x min of the mounting flange from the wall depending on mounting angle α: α 10 15 20 25 30 35 x min /mm 229 248 268 287 307 324 PFE2 Filter Unit: Pneumatics Connections for 2-Stage Back-Purging 1 Terminal box 2 Probe protective case 3 B Bulkhead fitting compressed air 4 to 6 bar 4 E Plug (test gas connection) 5 Pilot valve, filter cleaning -Y2.1 6 Diaphragm valve, filter cleaning -Y2.2 7 C Sample gas connection 8 Pilot valve, pulsed compressed air -Y1.1 9 Diaphragm valve, pulsed compressed air -Y1.2 10 Bulkhead fitting 6 mm control air 2 6 bar 11 Bulkhead fitting 12 mm compressed air 4 6 bar 12 Heated sample gas line 13 Power supply for heated sample gas line 14 FE2 filter unit 15 Solenoid valve, venting -Y4 16 Diaphragm valve, tube and filter surface cleaning -Y3.2 17 Pilot valve, tube and filter surface cleaning -Y3.1 10 System Components for Sample Gas Sampling 10/23-5.10 EN November 2004
PFE2 Filter Unit Probe Protective Case, PFE2 Filter Unit Terminal Diagram, Terminal Block -X1 (Standard) Probe protective case Terminal box, strip -X1 1 1st Pt 100 FE2 filter unit 2 3 Pt 100 three wire connection IEC 751 Cl. B 4 1st Pt 100 Type 42 probe tube 5 6 Pt 100 three wire connection IEC 751 Cl. B 7 8 2nd Pt 100 FE2 filter unit (fail safe circuit) 9 10 Pt 100 three wire connection IEC 751 Cl. B 11 2nd Pt 100 Type 42 probe tube (fail safe circuit) 12 13 Pt 100 three wire connection IEC 751 Cl. B 14 Heater FE2 filter unit L N PE 15 16 17 230 V 50-60 Hz or 115 V 50-60 Hz Heater Type 42 probe tube L N 19 21 L N 19 21 Heater Type 42 probe tube PE N 18 20 22 PE 18 230 V 115 V 50-60 Hz 20 50-60 Hz N 22 PE 23 PE 23 10/23-5.10 EN November 2004 System Components for Sample Gas Sampling 11
PFE2 Filter Unit Probe Protective Case, PFE2 Filter Unit Terminal Diagram, Terminal Block -X2 (Standard) Probe protective case Terminal box, strip -X2 1st Pt 100 sample gas line 1 2 3 Pt 100 three wire connection IEC 751 Cl. B 2nd Pt 100 sample gas line (fail-safe circuit) 4 5 6 Pt 100 Three wire connection IEC 751 Cl. B 7 Heater sample gas line wattage acc. to length max. 3600 W L N PE 8 9 10 230 V 50-60 Hz or 115 V 50-60 Hz Anti-frost heater for system shut down approx. 5 C at ambient temperature -20 C 30 W Internal temperature approx. 100 C Use heat-resistant cables! L N PE 11 12 13 230 V 50-60 Hz or 115 V 50-60 Hz The heater operates unregulated. Switch on from outside only when system shut down 12 System Components for Sample Gas Sampling 10/23-5.10 EN November 2004
PFE2 Filter Unit Probe Protective Case, PFE2 Filter Unit Terminal Diagram, Terminal Block -X3 (for Cleaning) Probe protective case Terminal box, strip -X3 Pilot valve -Y2.1 filter cleaning Extended cleaning Pilot valve -Y3.1 cleaning of filter surface and tube A A R P R P L PE N L PE N 1 10 2 3 11 4 230 V 50-60 Hz or 115 V 50-60 Hz L PE N 1 10 2 Pilot valve -Y1.1 Pulsed compr. air A R P L PE N 5 12 6 Pilot valve -Y4 Venting R P B L PE N 7 13 8 Probe / flange PE PE 9 9 Internal temp. approx. 100 C Use heat-resistant cable Remove with equipotential bonding 10/23-5.10 EN November 2004 System Components for Sample Gas Sampling 13
PFE3 Filter Unit Design The PFE3 filter unit consists of a modified FE2 filter unit with a self-regulating heater. It is installed in a stainless steel protective case. Process Gas Sampling Conditions Pressure p abs = 50 to 600 kpa Temperature max. 200 C Flow Rate 30 to 500 l/h, relative to 100 kpa and 0 C Pressure Drop approx. 0.6 hpa at 100 l/h Dust Content max. 3 g/m 3 (application recommendation) Filter Characteristics Filter Element Surface filter Filter Fineness 0.5 µm (optional 0.3 µm) Seal Integrity 10 4 hpa l/s Dead Volume 280 ml Dimensions 50/20 x 135 mm Heater Type Self-regulating heater (400 W) Temperature 180 C (ambient temperature 20 C) Temperature Alarm approx. 150 C Power Supply 110 to 240 V AC Option Annular heating element (see page 5) Materials of the Gas-carrying Parts Casing, Flange and Connections Special steel Mat. No. 1.4571 Seals Viton Installation Flange DN 65, PN 6, Form B to DIN 2527; positioning of holes: 45, 135, 225, 315 Mounting Flange connect or bolt to the probe tube Connection Ports Sample Gas Pipe fitting 6 mm Test Gas Bulkhead fitting 6 mm (option) Probe Tube G 3/4 internal thread to DIN ISO 228/1 Protective Case Dimensions 270 x 203 x 330 mm (H x W x D) Material Special steel Mat. No. 1.4301 Degree of Protection of Case IP 54 Weight approx. 17 kg Ambient Temperature 20 to +45 C 14 System Components for Sample Gas Sampling 10/23-5.10 EN November 2004
PFE3 Filter Unit Dimensional Drawing, Gas Connections (dim. in mm) Electrical Connections 204 3 1 1 2 PE 3 270 2 4 PE 5 2x M16 50 2 1 3 4 5 6 7 8 9 10 11 12 13 3x M20 2x M16 1 Test gas connection (optional) 6 mm bulkhead fitting 2 Sample gas connection 6 mm pipe fitting 3 Check valve for ACF-NT (optional) 1 Heater for filter 2 Heater for sample gas line 3 Pt 100 (optional) 4 Pt 100 sample gas line 5 Temperature monitor Ordering Information Catalog No. 23046-0- 0 0 0 0 0 0 0 0 Design with protection box IP 54 (330 x 203 x 270 mm) 1 with protection box IP 54 (330 x 203 x 270 mm) and check valve for ACF-NT 2 Filter housing (without connections for back purging) Housing and flange stainless steel (filtration fineness 0.5 µm) 2 Housing and flange stainless steel, with filter element <0.3 µm (filtration fineness) 4 Heating With self-regulating heating and temperature alarm (110/220 V, AC) 1 with ring heater unregulated 2 Power supply 230 V AC 1 115 V AC 2 Catalog No. 23046-0- 0 0 0 0 0 0 0 0 10/23-5.10 EN November 2004 System Components for Sample Gas Sampling 15
Selection Table for Probe Tube Types and Probes Probe tube type 40 SS 1.4571 Probe tube type 40 SS 1.4571 coated Probe tube type 40 SS 1.4893 Probe tube type 40 silicone carbide Probe tube type 42 SS heated Probe tube type 60 water cooled Probe 2 unheated Probe 2 heated Probe 2 partially heated Probe 60 S water cooled Probe H water cooled Max. temperature Dust content < 130 C 2) < 180 C 2) 180 450 C 180 900 C 1300 C 1400 C < 50 mg/m 3 < 1000 mg/m 3 < 3 g/m 3 Water vapor < 65 C dew point > 65 C Acidic aerosols (acid dew pt. 130 C) > 3 g/m 3 1) 1) 1) 1) 40 100 g/m 3 1) 1) 1) 1) 1) 1) 2000 g/m 3 1) 1) 1) Flow velocity < 10 m/s > 10 m/s Technical data see... p. 17 p. 17 p. 17 p. 17 p. 18 p. 19 p. 20 p. 20 p. 20 3) 3) 1) Back purging required 2) with regulated heating sleeve 3) ACK Cement Analysis System data sheet (Document No. 10/23-8.40 EN) Lead-Through Tube Installation Brickwork with metal sheeting Isolated sheet-metal channel Brickwork 1 2 5 3 1 2 5 3 1 4 2 5 3 α Flow direction of process gas 1 Lead-through tube 2 Mounting flange DN 65, PN 6, Form B to DIN 2573 3 Gasket 4 Welded-on rectangular block 5 Sampling probe flange Minimum distance x min of the mounting flange from the wall depending on mounting angle α: α 10 15 20 25 30 35 x min /mm 133 138 143 147 151 153 Dimensions in mm 16 System Components for Sample Gas Sampling 10/23-5.10 EN November 2004
Type 40 Probe Tube Use For sampling hot dust-containing gases in conjunction with the FE2/PFE2 filter unit Dimensional Drawing (dimensions in mm) Special Steel Material No. 1.4571 (max. 450 C) Process Gas Sampling Conditions Pressure p abs = 50 to 500 kpa (0.5 to 5 bar) 12,6 ø 17,2 ø G3/4 Temperature SS Mat. No. 1.4571 max. 450 C SS Mat. No. 1.4571 (coated) max. 180 C SS Mat. No. 1.4893 max. 900 C Silicone carbide (max. length 1.000 mm) max. 1.300 C L1 16 Special Steel Material No. 1.4893 (max. 900 C) Flow Rate Pressure Drop max. 300 l/h approx. 10 hpa at 30 to 90 l/h 16,8 ø 21,4 ø G3/4 Dust Content max. 3 g/m 3 (application recommendation); max. 40 g/m 3 with blow-back device in conjunction with FE2/PFE2 filter unit Installation L1 Silicon-Carbide (max. 1300 C) SiC Protective Tube 16 G 3/4 external thread DIN ISO 228/1 Mounting Angle any; 8 to 90 downwards from the horizontal is recommended. It is imperative to install the silicon carbide probe tube vertically. 15 ø 23 ø 105 34 ø L1 16 G3/4 Ordering Information Catalog No. 23036-0- 0 0 0 0 0 0 0 0 0 0 Version Stainless steel (1.4571), up to 500 C 1 Stainless steel (1.4571), coated, up to 180 C 2 Silicon carbide up to 1300 C, max. 1000 mm 4 Stainless steel (1.4893), up to 900 C 5 Stainless steel (1.4571), up to 300 C, heated (for cement) 6 Nominal length 500 mm 1 1000 mm 2 1500 mm 3 2000 mm 4 2500 mm 5 3500 mm (only for heated version) 6 4000 mm (only for heated version) 7 4500 mm (only for heated version) 8 Catalog No. 23046-0- 0 0 0 0 0 0 0 0 0 0 10/23-5.10 EN November 2004 System Components for Sample Gas Sampling 17
Type 42 Probe Tube (heated) Use Low gas temperature High moisture content in gas Corrosive components in the process gas Typical places of use are: Sampling points in wet desulphurization plants (crude gas, clean gas, part-cleaned clean gas) Waste incineration plants Auxiliary boilers and stack emission measurements Process Gas Sampling Conditions Pressure p abs = 200 kpa (2 bar) Temperature < 200 C Flow Rate max. 250 l/h Flow Velocity max. 12 m/s (> 1000 mm max. 7 m/s) Dust Content max. 3 g/m 3 (application recommendation); max. 40 g/m 3 with blow-back device in conjunction with FE2/PFE2 filter unit T 90 Time approx. 0.4 s at 250 l/h Probe Tube Heater Heat Output nominal length 1.000 mm: 2 x 200 W nominal length 1.500 mm: 2 x 300 W nominal length 2.000 mm: 2 x 400 W Nominal Voltage 230 V/115 V AC, 50 to 60 Hz Control Control temperature max. 200 C Temperature Sensor Pt 100 Continuous Operation at 200 C flue gas temperature 450 C Ordering Information Catalog No. Length 1000 mm 23041-4-8018392 Length 1500 mm 23041-4-8018393 Length 2000 mm 23041-4-8018394 Dimensional Drawing (dimensions in mm) and Terminal Diagram 40 160 1000/1500/2000 mm 25 x 1,5 40 x 2 Heater Pt100 12345 Temperature Controller Connectionr 18 System Components for Sample Gas Sampling 10/23-5.10 EN November 2004
Type 60 Probe Tube (Cement Flue Gas Probe) Use For sampling hot cement flue gas with high dust content for CO, CO 2, NO and SO 2 analysis in dry cement production process (e.g. recuperator furnaces, furnaces with grate coolers), at rotary kiln inlet and/or after precalcination. Process Gas Sampling Conditions Pressure p abs = max. 200 kpa (2 bar) Temperature max. 1200 C for length = 3500 mm max. 1250 C for length = 3000 mm max. 1300 C for length = 2500 mm max. 1350 C for length = 2000 mm max. 1400 C for length = 1500 mm Flow Rate max. 250 l/h Dust Content max. 2000 g/m 3 with periodical compressed air cleaning in conjunction with FE2 filter unit Dead Time (T t ) for Length = 3500 mm approx. 40 s at 60 l/h, approx. 9 s at 250 l/h 90% Time (T 90 ) for Length = 3500 mm approx. 82 s at 60 l/h, approx. 17 s at 250 l/h Pressure Drop approx. 10 hpa Materials of the Gas-carrying Parts Special steel, Material No. 1.4541 Mounting A flanged probe connector (internal diameter 200 mm) should be installed by the customer. The mounting flange is essential for installing the probe tube. Cooling Water Supply Quality Drinking water quality with approx. 30 % anti-freeze if required Outlet Temperature min. 50 C (or > dew point of the cement flue gas), max. 85 C Pressure p abs = max. 400 kpa (4 bar) Quantity Circulated approx. 3 m 3 /h (closed system) Type 60 S Probe Tube Model with reinforced protection tube and flange DN 150, PN 16 Ordering Information Catalog No. Length 1500 mm 23038-4-0856831 Length 2000 mm 23038-4-0856832 Length 2500 mm 23038-4-0856833 Length 3000 mm 23038-4-0856834 Length 3500 mm 23038-4-0856835 Length 1500 mm, reinforced protection tube 23038-4-8018478 Length 2000 mm, reinforced protection tube 23038-4-8018479 Length 2500 mm, reinforced protection tube 23038-4-8018480 Length 3000 mm, reinforced protection tube 23038-4-8018481 Length 3500 mm, reinforced protection tube 23038-4-8018482 Type 60 S, length 1500 mm 23038-4-0730642 Type 60 S, length 2000 mm 23038-4-0730643 Type 60 S, length 2500 mm 23038-4-0730644 Type 60 S, length 3000 mm 23038-4-0730645 Type 60 S, length 3500 mm 23038-4-0730646 Dimensional Drawing (dimensions in mm) ø60,3 ø89 1 2 L3 L2 L1 ~70 35 3 ~60 3 90 A A 1 Sample gas inlet ports 2 Thickened shank of probe tube 3 Cooling water connections L1 Probe tube length L2 Length of thickened shank: 800 mm for L1 2000 mm 1300 mm for L1 2500 mm L3 200 mm with reinforced protection tube 10/23-5.10 EN November 2004 System Components for Sample Gas Sampling 19
Probe 2 Use Wherever large volumes of gas are sampled, gas pressure is raised and there is a high moisture or dust content in the gas. Process Gas Sampling Conditions Pressure p abs = max. 400 kpa (4 bar) Temperature max. 450 C (probe tube unheated) max. 450 C (probe tube partially heated) max. 130 C (probe tube heated Flow Rate max. 2000 l/h Dust Content max. 20 g/m 3 (application recommendation), max. 100 g/m 3 with purging Purging Pressure max. 600 kpa (6 bar) Heating Temperature of Inlet Filter 200 C (at process gas temperature of 20 C) 90% Time (T 90 ) < 2 s at 250 l/h Filter Fineness 0.3 µm Sample Gas Outlet G 1/4 internal thread DIN ISO 228/1 Test Gas/Purge Air Inlet G 3/8 internal thread DIN ISO 228/1 Electrical Connections Harting connector, IP 55 Probe Tube Heating Heat Output (unregulated) Nominal length 1200 mm: 650 W partially heated (for heating of the wall bushing): 255 W Nominal Voltage 230 V/115 V AC, 50 to 60 Hz Ordering Information Catalog No. 1200 mm, 220 V, 650 W 23022-4-0768301 1200 mm, 220 V, 255 W, partially heated 23022-4-0768305 Dimensional Drawing and Connection Diagram Z Material of the Gas-carrying Parts Support Tube, Heating Rod, Connecting Pipe Special steel, Material No. 1.4571 Inlet Filter Aluminum oxide Seals Ceramic fiber Flange Special steel, Material No. 1.4581 Mounting Flange DN 65, PN 6, Form B, to DIN 2573 position of holes: 45, 135, 225, 315 Mounting Angle any; 10 to 35 downwards from the horizontal recommended (take direction of flow into account), see dimensional diagram α 1 650 1 = N 2 = L1 1 Filter mounting 2 Gas sampling probe tube 3 Sample gas outlet or test gas/purge air inlet 4 Harting connector Z 260 180 4 20 System Components for Sample Gas Sampling 10/23-5.10 EN November 2004
Probe 1, Probe 11 Probe 1 Use in interior air, garage and tunnel monitoring for the gases carbon monoxide (CO) and oxygen (SO 2 ) Probe 11 Use in interior air, garage and tunnel monitoring, including corrosive atmospheres. The materials used ensure that with the gases normally occurring no adsorption occurs. Technical Data Sampling Pressure Atmospheric pressure Gas Temperature 25 to +50 C Sample Gas Flow Rate max. 120 l/h Pressure Drop with New Filter 10 hpa at 120 l/h Dust Content in the Air approx. 100 mg/m 3 Sample Gas Connection Port G 1/8 internal thread DIN ISO 228/1 or nozzle for flexible tube of internal diameter 4 mm Materials Silicone carbide (filter), aluminum (end seals), PVC (nozzle) Transport and Storage Temperature 25 to +70 C Mounting On wall or suspended from ceiling Technical Data Sampling Pressure Atmospheric pressure Gas Temperature 25 to +50 C Sample Gas Flow Rate max. 70 l/h Pressure Drop with New Filter 10 hpa (mbar) at 70 l/h Service Life of Filter (estimated) filter constant (2500) d (days) = flow rate (l/h) x dust concentration (mg/m3 ) Sample Gas Connection Port Bolted connection for flexible pipe with internal diameter 4 mm and external diameter 7 mm Materials Polycarbonate (probe head), aluminum oxide (filter) Transport and Storage Temperature 25 to +70 C Mounting On wall or suspended from ceiling Ordering Information Catalog No. Room air probe 1 23011-5-5862922 Ordering Information Catalog No. Room air probe 11 23021-4-0859585 Dimensional Drawing (dimensions in mm) Dimensional Drawing (dimensions in mm) ~ 140 ~ 83 ~ 104 85 mm wide 8,4 ~ 57 10/23-5.10 EN November 2004 System Components for Sample Gas Sampling 21
Ceramic Filter Use For filtering dust from gases in the gas conditioning systems of analyzer systems when the gas sampling probe does not have a filter. The ceramic filter is positioned upstream the other devices in the sample gas conditioning chain. The ceramic filter can be heated with the annular heating element if condensation from the sample gas is likely. Technical Data Flow Rate (Air) max. 300 l/h Gas Pressure p abs = 20 kpa to 1.7 MPa (0.2 to 17 bar) at 20 C filter temperature, max. 200 kpa (2 bar) at 180 C Pressure Drop 0.1 to 0.85 hpa at 30 to 250 l/h (air) Dynamic Characteristics at Flow rate (air) 30 l/h 60 l/h 90 l/h Dead time T t 3.7 s 2.3 s 1.7 s 90% time T 90 11.5 s 5.5 s 3.9 s Filter Fineness 0.5 µm Dimensional Drawing (dimensions in mm) Construction, Mounting Materials of the Gas-carrying Parts Housing: steel, St 37 K or special steel, Material No. 1.4571; Filter: aluminum oxide; Seals: FPM, Cu, Al 2 O 3 fiber Gas Connection Ports G 1/4 internal thread DIN ISO 228/1 or pipe connectors for pipe of internal diameter 4 mm Filter Surface approx. 212 cm 2 Weight approx. 2.1 kg Filter Heating Annular heating element, see page 5 Mounting On wall with angle bracket Ordering Information Catalog No. Ceramic filter, steel version 23031-5-8018177 Ceramic filter, stainless steel version 23031-5-8018178 22 System Components for Sample Gas Sampling 10/23-5.10 EN November 2004
Process Pressure Reducers Use If the pressure of the process gas is too high for the analyzer, a pressure reducer is required to lower the pressure. The type of pressure reducer used is determined by the properties of the process gas and the required sample gas pressure. Technical Data Construction Casing: Brass Casing: Brass Casing: Special steel Casing: Special steel Single-stage with one manometer (outlet) Single-stage with two Single-stage without manometers (inlet/ outlet) manometer Single-stage with two manometers (inlet/ outlet) Inlet pressure max. 1.5 MPa (15 bar) max. 3.5 MPa (35 bar) max. 3.5 MPa (35 bar) max. 3.5 MPa (35 bar) Outlet pressure (adjustable) Safety valve set to Manometer display Inlet pressure Manometer display Outlet pressure 0.8 to 10 kpa (8 to 100 mbar) 0 to 250 hpa (0 to 250 mbar) 10 to 40 kpa (0.1 to 0.4 bar) 50 kpa (0.5 bar) 0 to 4 MPa (0 to 40 bar) 0 to 60 kpa (0 to 0.6 bar) 10 to 70 kpa (0.1 to 0.7 bar) 80 kpa (0.8 bar) 10 to 70 kpa (0.1 to 0.7 bar) 80 kpa (0.8 bar) 0 to 4 MPa (0 to 40 bar) 0 to 150 kpa (0 to 1.5 bar) Flow rate 25 to 250 l/h 25 to 250 l/h 25 to 250 l/h 25 to 250 l/h Material Diaphragm Buna rubber Buna rubber Special steel Special steel Material Gasket Buna rubber Buna rubber EPDM EPDM Material Housing Brass Special steel; gascarrying parts: brass Special steel Special steel Weight approx. 1.25 kg approx. 2.65 kg approx. 2.35 kg approx. 2.35 kg Gas temperature and max. 50 C max. 50 C max. 50 C max. 50 C ambient temperature Catalog No. 23035-5-5864958 23035-5-5864951 23422-4-0730699 23422-4-0730700 Supplied: Pressure reducer with angle bracket 10/23-5.10 EN November 2004 System Components for Sample Gas Sampling 23
Process Pressure Reducers Dimensional Drawings (dimensions in mm) Pressure reducer single-stage with one manometer (outlet) (Catalog No. 23035-5-5864958) Pressure reducer single-stage without manometer (Catalog No. 23422-4-0730699) 79 approx. 30 (variable) Ø 4 GasTech 105 approx. 94 (depending on handwheel position) Pressure reducer single-stage with two manometers (inlet/outlet) (Catalog No. 23035-5-5864951) Pressure reducer single-stage with two manometers (inlet/outlet) (Catalog No. 23422-4-0730700) 118 Ø4 approx. 30 (variable) 148 GasTech approx. 94 (depending on handwheel position) 24 System Components for Sample Gas Sampling 10/23-5.10 EN November 2004
Heated Sample Gas Lines Heated Sample Gas Line CGWB 13 Parallel strip heater (holding temperature max. 200 C) Pt 100 resistance thermometer for control system Flexible sample gas pipe, replaceable (option) Self-regulating anti-frost heater (option) Self-regulating heater (option, holding temperature max. 100 C) Heated sample gas line TBL 01 Fixed resistor heating conductor (holding temperature max. 200 C) Pt 100 resistance thermometer for control system Self-regulating heater (option, holding temperature max. 100 C) Heated sample gas line TBL 01-E Competitive version Pipe ends with polyamide hard caps Selection Table for Heated Sample Gas Lines CGWB 13 TBL 01 TBL 01-E Heater Self-regulating strip heater (30 C) x Self-regulating strip heater (100 C) x x Fixed resistor heating conductor (200 C) x x Parallel strip heater x Outer covering Polyvinyl chloride Polyamide Polyamide Options Line can be shortened x Gas-carrying line can be replaced x Small bending radius x x Gas connections Various options Various options Stainless steel Electrical connections (heater and Pt 100) Power fixed, Pt 100 plug Power and Pt 100 plug Power and Pt 100 fixed Maximum line length 130 m (60 m) 100 m (40 m) 40 m Applications CO, O 2, CO 2 Anti-frost heater CO, O 2, CO 2 Holding temp. 100 C Holding temp. 100 C SO 2, NO x, C n H m Holding temp. 200 C Holding temp. 200 C Holding temp. 200 C 10/23-5.10 EN November 2004 System Components for Sample Gas Sampling 25
CGWB 13 Heated Sample Gas Line Technical Data Frost protected line Self-regulating strip heater Regulated parallel strip heater Outer covering PVC PVC PVC Medium-carrying pipe PTFE PTFE PTFE Integral pipe-end connectors 1) POM cap POM cap Metal cap and metal cap with flange Heater self-regulating strip heater self-regulating strip heater CPD heating element, regulated Power supply 230 V or 115 V, 50 to 60 Hz 230 V or 115 V, 50 to 60 Hz 230 V or 115 V, 50 to 60 Hz Heat output 16 W/m 38 W/m 60 W/m Current consumption Making /holding current = 65/25 ma 0.15 A/m 0.3 A/m Holding temperature see diagram see diagram 200 C Ambient temperature T amb 30 to +60 C 30 to +60 C 30 to +60 C External diameter 30 mm 43 mm 40 mm; with replaceable flexible pipe: 45 mm Flexible sample gas pipe 6 x 4 x 1 mm or 8 x 6 x 1 mm 6 x 4 x 1 mm or 8 x 6 x 1 mm 6 x 4 x 1 mm or 8 x 6 x 1 mm Maximum line length 130 m 90 m 60 m with replaceable flexible pipe: 25 m, 60 m if laid straight Line duct PG 42 PG 42 PG 42 Minimum bending radius 300 mm 300 mm 300 mm Weight approx. 1 kg/m approx. 1 kg/m approx. 1 kg/m Connection lead for heater (fixed) 3 x 2.5 mm 2 ; length 2.5 m 3 x 2.5 mm 2 ; length 2.5 m 3 x 2.5 mm 2 ; length 2.5 m Connection lead for Pt 100 (with plug) 1) For line lengths > 10 m, only the analyzer side is assembled, an assembly set for the probe side is supplied. LIYCI 2 x 0.14 mm 2 ; length 5 m Holding Temperature Diagrams Frost protected line, 6 x 4 x 1 mm PTFE, 16 W/m, self-regulating Self-regulating strip heater, 6 x 4 x 1 mm PTFE Medium pipe temperature C 50 40 30 20 Medium pipe temperature C 100 90 80 70-30 - 20-10 0 + 10 + 20 + 30 + 40 Ambient temperature C - 30-20 - 10 0 + 10 + 20 + 30 + 40 Ambient temperature C Dimensional Drawing (dimensions in mm) L = m Probe Side Analyzer Side 300 6 30 49 50 60 24 11 6 42 56 26 System Components for Sample Gas Sampling 10/23-5.10 EN November 2004
CGWB 13 Heated Sample Gas Line Ordering Information Catalog No. 23281-0- 0 0 0 0 0 0 0 Version controlled (Pt 100) 2 self-regulated 16 W/m, 30 C (antifreeze) 3 self-regulated 38 W/m, 100 C 7 Connection probe side with metal cap for PFE 2 2 probe: metal cap / analyzer: flange 3 end of line: plastics 4 Gas conducting line PTFE-tube 6x4x1 mm 1 PTFE-tube 8x6x1 mm 2 Power supply 230 V, 50/60 Hz 1 115 V, 50/60 Hz 2 Controlling and monitoring without Pt 100 0 with 1 x Pt 100 1 Catalog No. 23281-0- 0 0 0 0 0 0 0 10/23-5.10 EN November 2004 System Components for Sample Gas Sampling 27
TBL 01, TBL 01-E Heated Sample Gas Lines Technical Data TBL 01 Self-regulating strip heater 30 W/m TBL 01 Fixed resistor heating conductor 90 W/m TBL 01-E Fixed resistor heating conductor 90 W/m Outer covering Polyamide corrugated tubing Polyamide corrugated tubing Polyamide corrugated tubing Medium-carrying pipe PTFE PTFE PTFE Integral pipe end connectors Hard caps, metal caps Hard caps, metal caps and metal cap with flange Polyamide hard caps Power supply 230 V or 115 V, 50 to 60 Hz 230 V or 115 V, 50 to 60 Hz 230 V or 115 V, 50 to 60 Hz Heat output 30 W/m 90 W/m 90 W/m Current consumption I = 0.15 A/m (starting current), I = f(length) I = f(length) I = 65 ma (holding current) Holding temperature see diagram on page 26 200 C 200 C Ambient temperature 30 to +60 C 30 to +60 C 30 to +60 C External diameter 43 mm 43 mm 43 mm Flexible sample gas pipe 6 x 4 x 1 mm or 8 x 6 x 1 mm 6 x 4 x 1 mm or 8 x 6 x 1 mm 6 x 4 x 1 mm or 8 x 6 x 1 mm Flexible test gas pipe 6 x 4 x 1 mm Maximum line length 100 m 40 m 40 m Line duct PG 48 PG 48 Minimum bending radius 200 mm 200 mm 200 mm Weight approx. 1 kg/m approx. 1 kg/m approx. 1 kg/m Electrical connection for heater and Pt 100 Screw fitting (fixed for hard cap) Plugs (see dimensional drawing; fixed for hard cap) fixed TBL 01 Dimensional Drawing (dimensions in mm) Analyzer side Probe side A,B A PG11 B 6 6 49 50 60 6 42 56 24 11 PG7 80 250 300 11 24 L = m TBL 01-E Dimensional Drawing (dimensions in mm) End Cap PA SS SS 53 6 6 1000 1000 120 120 Sensor Location Length max. 40 m 28 System Components for Sample Gas Sampling 10/23-5.10 EN November 2004
TBL 01, TBL 01-E Heated Sample Gas Lines TBL 01 Ordering Information Catalog No. 23283-0- 0 0 0 0 0 0 Design Resistor heating line 90 W/m 1 self regulating heating line 30 W/m 2 Gas conducting line with PTFE-tube 6x4x1 mm 1 with PTFE-tube 8x6x1 mm 3 Material of sheathing with plastic hose of PA (outside and indoors installation) 1 Connections End of line with flange connection 1 End of line: probe: metal cap / analyzer: flange 5 End of line with flanges 6 End of line with plastic tops 7 End of line with 2 metal tops 8 Control / Monitoring without Pt 100 0 with 1 x Pt 100 1 Power supply 230 V, 50... 60 Hz 1 115 V, 50... 60 Hz 2 Catalog No. 23283-0- 0 0 0 0 0 0 TBL 01-E Ordering Information Catalog No. Resistor heating line 90 W/m, PTFE 6x4x1, PA caps, 230V 23284-4-0730695 Resistor heating line 90 W/m, PTFE 8x6x1, PA caps, 230V 23284-4-0730696 Resistor heating line 90 W/m, PTFE 6x4x1, PA caps, 115V 23284-4-0730697 Resistor heating line 90 W/m, PTFE 8x6x1, PA caps, 115V 23284-4-0730698 10/23-5.10 EN November 2004 System Components for Sample Gas Sampling 29
Electronic Temperature Controller and Switching Relay Temperature Controller Control Range 200 to +850 C Measurement Input Pt 100 Outputs 2 x Relay 3 A, 250 V AC Power Supply 110 to 240 V AC +10/ 15 %, 48 to 63 Hz Dimensions 48 x 48 mm, C-rail housing Weight 140 g Catalog No. 23345-5-8328859 Connection Diagram Switching Relay Load Voltage U rms = 24 to 265 V Max. Load Current I rms = 30 A (Ambient temperature = 25 C) Weight 200 g Catalog No. 23345-5-8328731 30 System Components for Sample Gas Sampling 10/23-5.10 EN November 2004
The Industrial IT word mark and all mentioned product names in the form XXXXX IT are registered or pending trademarks of ABB. ABB has Sales & Customer Support expertise in over 100 countries worldwide. www.abb.com The Company s policy is one of continuous product improvement and the right is reserved to modify the information contained herein without notice. Printed in the Fed. Rep. of Germany (10.04) ABB 2004 10/23-5.10 EN Rev. 4 ABB Automation Products GmbH Analytical Division Stierstaedter Strasse 5 60488 Frankfurt am Main Germany Phone: +49 69 7930-40 Fax: +49 69 7930-4566 E-Mail: analytical-mkt.deapr@de.abb.com