psg basic & psg plus gas sampling probes · 2020. 9. 3. · agt-psg gmbh & co.kg errors and...

PSG Basic & PSG Plus Gas Sampling Probes

Instruction Manual

Instruction Manual Gas Sampling Probes

AGT-PSG GmbH & Co.KG Errors and omissions expected

Original – Instruction Manual Gas Sampling Probes Rev. 3/2021

Important Instructions

Read this page before proceeding!

AGT-PSG GmbH & Co. KG designs, manufactures and tests its products to meet many national and international stand-ards. Because these products are sophisticated technical products, you MUST properly install, operate and maintain them to ensure they continue to operate within their normal specifications. The following instructions should be adhered to and integrated into your safety program when installing, using and maintaining AGT-PSG GmbH & Co. KG products.

Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life, personal injury, property damage, damage to the product - and warranty invalidation. Read all instructions prior to installing, operating, and servicing the product. If you do not understand any instructions, contact your AGT-PSG representative for clarification. Follow all warnings, cautions, and instructions marked on and supplied with the product.

Inform and educate your personnel in the proper installation, operation, and maintenance of the product. Install your equipment as specified in the Installation Instructions of the appropriate Instruction Manual and per applicable local and national codes. Connect all products to the proper electrical and pressure sources. To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product. When replacement parts are required, ensure that qualified people use replacement Parts specified by AGT-PSG. Unauthorized parts and procedures can affect the product’s performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.

Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being per-formed by qualified persons, to prevent electrical shock and personal injury. The information contained in this document is subject to change without notice. 1st Edition 07/2016 2nd Edition 12/2019 3rd Edition 05/2021 © 2021 by AGT-PSG GmbH & Co.KG




Introduction The instruction manual contains information about the component assembly, function, installation, operation, maintenance, return and disposal of the following PSG gas sampling probes: PSG Basic and PSG Plus incl. PSG Plus DSBP (Dual Stage Back Purge).

This manual covers these PSG gas sampling probes, information about configurations and options. But the manual does not cover installation / operation of probes in hazardous areas (explosive environments), with flammable gas components and mobile gas sampling probes (in such cases, please look at additional manuals to cover these options and applications).

Use

Gas sampling probes are used for Gas applications: continuous measurement acc. to the extractive measurement method – for Continuous Emission Monitoring (CEM) and for Process Analysis Technology (PAT). The gas sampling probes PSG Basic & PSG Plus / Plus DSBP are designed for continuous gas sampling to meet the requirements for these applications. To accomplish a constant, “clean” and unaltered sample gas PSG takes care for applicable filter material, high sample gas temperatures, elevated or low pressure, high dust concentrations / water & acid dew points, corrosive gas components, aerosols & mist and tough environmental conditions to avoid wrong gas sampling via probe. Subsequently follows a gas transfer to the different gas measuring units via (heated) sample gas lines. The probes are designed for representative sampling through rough filtering of (hot and wet) sample gases which contain different amounts of dust particles. Due to the diverse options they meet all the different requirements of varying applica-tions regarding filtering, corrosion resistance – especially taking care for high sample gas dew points (acid dew points) by heated external filters. For very high dust amounts additional an internal filter (pre-filter) or alternatively a sophis-ticated single or dual stage back purge system is offered.

Definitions

The following definitions explain the use of the terms WARNING, CAUTION and NOTE in this manual.

Indicates an imperative operational procedure or an important condition or instruction

Indicates an operational or maintenance procedure, a process, a condition, an instruction, etc. Failure to comply may result in injury, death or permanent health risk.

Indicates an operational or maintenance procedure, a process, a condition, an instruction, etc. Failure to comply may result in damage to or destruction of the instrument, or impaired performance.




Introduction

Symbols – some are used in this manual

This symbol indicates general information relevant to the safety or health of personnel if no specialized symbol is available.

Dangerous voltages may be exposed.

Possible danger of explosion

Warning of flammable substances

Toxic substances may be present

Substances harmful to health may be present

Warning of corrosive substances

Indicates notes relating to heavy instruments

This symbol indicates general noteworthy information or tips which have no influence on the safety or health of personnel.

The instrument must be connected to ground before use.

The instrument must be disconnected from the main power supply before being serviced or repaired.

Unplug the power cable.

Follow the instructions.




Introduction

Symbols – some are used on or inside the device

Dangerous voltages may be exposed. The instrument may only be opened and serviced by qualified per-sonnel after disconnecting the power supply.

Hot surfaces may be exposed.

Grounding connection point

Follow the instructions.

These symbols are - if used - on the device's user interface to indi-cate the unit's operational status.

EC Declaration of Conformity and CE Marking

CE Certification

The product described in this instruction manual complies with the following EU directives: EMV Instruction

The requirements of the EU directive 2014/30/EU “Electromagnetic compatibility“ are met. Low Voltage Directive

The requirement of the EU directive 2014/35/EU “Low Voltage Directive“ are met. The compliance with this EU directive has been examined according to DIN EN 61010. CE marking guideline

The guideline 93/68/EWG is followed as well as 2014/68/EU for pressure equipment. Declaration of conformity The CE Certification can be downloaded from the AGT-PSG homepage.

Scope of Delivery

Sample gas probe Flange gasket and screws - according to the order: see order acknowledgement Instruction manual Attached and enclosed accessories: see separate position in the order acknowledgement.




Introduction

Information on Name Plates

AGT-PSG provides 2 name plates: On filter housing On terminal box The filter housing name plate provides details on the configuration of the probe, installed sample gas options. It indicates the following details:

Part No. Job No. AGT-PSG Pmax Porosity SN Pt CW CE

Filter Housing Name Plates as Example (New & former version) This name plate is located outside the sample probe filter housing. The terminal box name plate provides the following details:

AGT-PSG Company address Order No. Article No. Year of construction Probe No.

This name plate is located outside the terminal box of the sample gas probe. Please refer to this serial number if you have any questions about your sample gas probe or if you need to order spare

parts or consumables.

AGT-PSG GmbH & Co. KG Weißkirchener Straße 3 D-61449 Steinbach/Ts.




Safety Instructions

Intended Use

The PSG gas sampling probes PSG Basic and PSG Plus or PSG Plus DSBP are intended for use as part of sample handling of a gas analyzer system using extractive measuring techniques.

This device must not be used in medical, diagnostic or life support applications or as safety device. The implementation as a safety device is prohibited in cases where SIL

certification is required.

This instrument may be operated and serviced only by trained personnel who are famil-

iar with the function of this device and aware of the risk on an open and energized unit.

This device is not designed and should not be used in hazardous areas without addi-

tional safety measures. Use of this equipment in explosive atmospheres could result in in-jury, explosion or death. Consult factory for hazardous area equipment!

This device is not designed and should not be used in the analysis of explosive or flam-mable gases. Use of this equipment in this way could result in flash burn, injury, explosion

or death. Consult factory for applications with flammable gases!

General Safety Notice / Residual Risk

A safe and proper operation requires a proper transport, storage, unpacking and a correct installation followed by a proper set-up finally. After start of operation a careful maintenance in the requested intervals is necessary - only by qualified personal. Read these SAFETY instructions carefully prior to installation and the operating information before start-up. Follow the information and warnings given in this instruction manual! The regulations, standards and guidelines in this operator's manual are applicable acc. to EU legislation. Take care that the relevant national regulations should be followed when the device is used in other countries. If this equipment is used in a manner not specified in these instructions, safety may be impaired.

Despite incoming goods inspections, production control, routine tests and application of state-of-the-art test methods, an element of risk remains when operating a process gas sampling probe.




Safety Instructions

Even when operated as intended and observing all applicable safety instructions some residual risks remain, including, but not limited to, the following:

• An interruption of the protective earth line, e.g. in an extension cable, may result in risk to the user.

• Live parts are accessible when operating the device with cover removed.

• The emission of gases hazardous to health may even be possible when all gas connections have been correctly made.

Avoid exposure to the dangers of these residual risks by taking particular care when in-stalling, operating, maintaining and servicing the analyzer.

Authorized Personnel

In-depth specialist knowledge is a necessity for working with a gas sampling probe.

Authorized personnel for installing, operating, servicing and maintaining the probe are instructed and trained qual-ified personnel of the operating company / the manufacturer.

It is the responsibility of the operating company to

• Train staff, observe safety regulations and follow the instruction manual.

Operators must - before starting work -

• Have been trained,

• Have read & understood all relevant sections of the instruction manual,

• and know the safety mechanisms and regulations.

To avoid personal injury and loss of property, do not install, operate, maintain or service this instrument before reading and understanding this instruction manual and receiving appropriate training.




Safety Instructions

Electrical Safety

General Considerations

The operation and maintenance of electrical apparatus always requires the observance of several safety rules. Please observe the following safety rules when making electrical connections, performing maintenance or repair work and espe-cially when replacing components. These safety rules are for your own personal safety as well as the safety of the appa-ratus.

Electrical components of this system may only be serviced by qualified technicians. Adher-

ence to relevant local safety specifications is mandatory.

Ensure that all contacts that can be touched while performing work are either voltage free or protected from such contact.

If the probe must be opened disconnect all power supplied to the device. If the probe must remain powered in order to perform the maintenance or repair work, then this work may only be performed by qualified personnel capable of judging potential dangers.

Never disconnect ground connections within or outside of the instrument. Disconnecting the ground could result in potential safety hazards.

When replacing electrical fuses use only fuses of the specified type.

If you feel that safe operation of the instrument is no longer possible, take it out of operation. Furthermore, take steps to ensure that it cannot be put back into operation by unauthorized personnel.

Fuses may only be replaced by fuses of an identical type and with identical ratings. It is forbidden to bypass fuses or use repaired fuses.

Power Supply and Grounding

Before switching the unit on, ensure that the local mains voltage corresponds to the unit's oper-ating voltage.

A fuse should be provided at the installation site which will completely disconnect the unit in case of failure. An emergency cut-off switch should also be provided within easy reach of the instrument.

The power cord used with the unit must provide a protective earth (PE) contact.

Connect the protective earth connection (PE) before all other connections.

Working on units equipped with screw-type terminals for electrical connections may require the exposure of energized components.

Cables for external data processing must be double-insulated against mains power. If this is not possible, cables must be laid in such a way as to guarantee a clearance of at least 5 mm from power cables. This clearance must be permanently secured (e.g. with cable ties).




Safety Instructions

Surface Temperature

This analytical sample handling device (sample gas probe) utilizes components which require high operating temperatures. These components which are accessible only after opening the cover may be designated in the diagram above.

Particular caution is required in handling the high temperature heater. Under operating condi-tions, the heater can have a temperature as high as 180 °C or even higher (up to 250 °C). These high temperatures are protected from direct contact by the thick insulation of the heat-ing device and normally present no danger. The metal components have temperatures ranging from 80° to 180°C (up to 250 °C). Servicing of the probe heater (or exchange the heater ) should only be performed by qualified personnel. Thermally insulated gloves must be worn when exchanging the heated parts.

Take care to wait long enough and let the parts cool down to avoid problems with the heating device.

Under operating conditions, the gas sampling probe temperature is controlled to approx. 180 °C (self-control) up to 250 °C (regulated). The heated components are accessible only after opening the cover.

Safe Operation not Possible

If it is apparent that safe operation is no longer possible, the device should be put out of operation and secured against

unauthorized use.

Safe operation is no longer possible:

o If the device is visibly damaged, o If the device no longer operates (indicated by alarm message), o After prolonged storage under adverse conditions, o After severe transport stresses, o If permissible temperature cannot be provided, o If PSG filter unit cannot be protected against direct heat radiation, rain, draughts & heavy soiling.

Remark: Protection of the filter unit with a protective box can be a good solution, c.f. (consult factory)!




Technical Description

Main Common Features – PSG Basic, PSG Plus and Plus DSBP

Very large active outer filter surface leads to extreme low maintenance

o Dust concentration and corresponding maintenance:

< 100 mg/m3 requires maintenance any 2 years

< 1 g/m3 requires maintenance twice a year

< 3 g/m3 requires maintenance any 3 months

Different sample gas temperatures and corresponding tubes

o < 600 °C with Tube SS 1.4571

o < 900 °C with Tube SS 1.4893 or Hastelloy C4 (high resistant)

o < 1300 °C with Tube Kanthal APM

Temperature controlled filter heating up to 250 °C

o Temperature alarm contact should be 20 °C below setting

Self-regulated filter heating – fixed to 160 °C

o Temperature alarm contact included at 140 °C

Corrosion resistant probe leads to long lifetime being realized with

o Housing: SS 1.4571, Fittings: SS 316, Filter: SiC, Gaskets: FPM/ FFKM

Filter and gaskets material – standard and options

o Silicon carbide (SiC) standard filter - resistant ceramic version

o Borosilicate glass fiber filter – option if no acidic components available

o Gaskets FPM as standard (< 200 °C) - high resistant FFKM (< 250 °C)

Calibration (test) gas & single back purge connection as standard included

Filter change without tools and sample line dismounting

Compact protective housing for outdoor installation

o Weather protection box enables operation under rough conditions





Performance/ Special Functions – Probe PSG Basic

Continuous gas sampling for low & medium dust loaded gases o Up to 3 g/m3

High dust load with options pre-filter PF or single stage back purge

o Up to 10 g/m3

Quick and easy installation and mounting

Extreme compact design allows installation with small space

Easy maintenance due to space-saving bracket design

Performance/ Special Functions – Probe PSG Plus

Single or dual stage back purge for high and very high dust concentrations

Dual stage back purge

o up to 40 g/m3

o Up to 280 g/m3 – under certain conditions, c.f.

Comfortable and quick filter changes without tools

8-hole flange for variable mounting

Upgradeable with diverse options

Special additional Function – Probe PSG Plus DSBP

Dual stage back purge via valve block & accumulator on board

Dual stage back purge

o up to 280 g/m3

2 Coax solenoid valves direct mounted at the probe

2 l pressure accumulator mounted direct at the probe

Additional insulation for ambient temperatures up to -30 °C





Technical Data – Probe PSG Basic, PSG Plus and PSG Plus DSBP

Probe PSG Basic and Common Part of PSG Plus & Plus DSBP

Process Gas Sampling Conditions Low & Medium Dust

Pressure pabs: 50…6000 hPa (mbar (abs))

Sample Gas Temperature: Up to 600 °C Tube: SS 1.4571

Sample Gas Temperature: Up to 900 °C Standard Tube: High resistant Tube:

SS 1.4893 Hastelloy C4

Sample Gas Temperature: Up to 1300 °C Tube: Kanthal APM

Ambient temperature 250 W heater: -30 to +50 °C 350 W heater: -50 to +50 °C

Flow 30…1500 l/h, referred to 1013 hPa and 0 °C

Pressure drop Approx. 0.6 hPa at 100 l/h

Standard Basic with standard fil-ter unit

Dust concentration: Maintenance:

< 100 mg/m³ Any 2 years

< 1 g/m³ Twice a year

< 3 g/m³ Any 3 months

High Dust Content 1-stage back purge Pre-Filter PF > 3 up to < 10 g/m³ Option

Connections Sample gas G1/4" f (DIN ISO 228/1)

Test gas (stand.) / tubing (option) G1/4" f (DIN ISO 228/1) / 6 mm Tube

Filter Heating

Type Content

Heating sleeve incl. PT100

230/ 115 VAC, 50 - 60 Hz 250 W

230/ 115 VAC, 50 - 60 Hz 350 W

Ring heater self-regulated 230/ 115 VAC, 48 - 62 Hz 2 x 100 W

Isolation

Removable insulation jacket, heating sleeve only

Additional insulation protective housing, heating sleeve only, for ambient temperature:

-30 to +60 °C

Temperature, self-regulating Standard: 160 °C Alarm: 140 °C

Temperature, regulated

Up to 250 °C; Acid dew point and salification to be evaluated

Alarm: 20 °C below setting

Temperature control

PID-controller ST49 incl. solid state relays for DIN-rail-mounting

Heating sleeve only

With controller in connection box, heating sleeve only

Temperature sensor PT100 (only heating sleeve)

Filter Properties

Filter with Surface of 212 cm2 Ceramic, silicon carbide (SiC) Standard

Glass fiber: if no acidic components to be measured Special

Porosity SiC ceramic: 0.3 µm Borosilicate glass fiber: 0.1 μm

Tightness 10-4 hPa l/s

Dead volume ca. 280 ml

Dimensions 50/20 x 135 mm

Protective Housing

Dimensions 250 x 205 x 270 mm (L x B x T)

Material Stainless steel SS 304

Ambient temperature -20 °C to +60 °C; Option: -30 °C to +60 °C Add. measures

Weight Approx.14 kg Complete probe

For heating with thermostat control With adapted connection box

Without protective housing With adapted connection box

Without protective housing, for heating with thermostat control

With adapted connection box

Protection class connection box IP67 EN 60529

Mounting Flange DN65, PN6, 4-hole, form B according to DIN 2527

Installation angle 10° to 35° inclination to horizontal position Recommended

Materials in Contact with Sample Gas

Housing, gas connections / flange Stainless steel SS 1.4571 // Fitting: stainless steel SS 316

Gaskets FPM as standard: Up to 200 °C

FFKM as corrosion resistant version: Up to 250 °C

Filter material Silicon Carbide (SiC) Standard

Borosilicate (glass fiber) Special Pressure reduction valve at probe outlet

to prevent pressure peaks during back purge, 6 mm O.D. tube connection

Option





Probe PSG Plus & PSG Plus DSBP

Process Gas Sampling Conditions

Pressure pabs // Sample Gas Temperature // Ambient temperature // Flow // Pressure drop

See: PSG Basic

Low & Medium Dust Content

PSG Plus: with standard unit filter

Dust concentration: Maintenance:

< 100 mg/m³ Any 2 years

< 1 g/m³ Twice a year

< 3 g/m³ Any 3 months

High Dust Content with single stage back purging

> 3 up to < 10 g/m³

Very High Dust Content with dual stage back purging

> 3 up to < 40 g/m3

Highest Dust Contents with dual stage back purging

> 40 up to 280 g/m3 PSG Plus DSBP

Connections

Sample gas // Calibration (test) gas (standard) / Tubing (option) See: PSG Basic

Back purge (standard)

Tubing (option)

2 x G3/8" f (DIN ISO 228/1)

Single stage 12 mm tube

Dual stage 12 mm tube

Filter Heating Type // Isolation See: PSG Basic

Filter Properties Filter // Porosity // Tightness // Dead volume // Dimensions See: PSG Basic

Protective Housing

Dimensions 330 x 205 x 270 mm (L x B x T)

Material // Ambient temperature // Weight // For heating with thermostat control // Protection class connection box

See: PSG Basic

Mounting Flange DN65, PN6, 8-hole, form B according to DIN 2527

Installation angle See: PSG Basic

Materials in Contact with Sample Gas

Housing, flange, gas connections Gaskets

See: PSG Basic

PSG Plus DSBP Options

2 Coax solenoid valves mounted at the probe & wired to connection box, voltage: 24 VDC

Additional insulation of protective housing

for ambient temperatures up to -30 °C

Pressure accumulator 2 l, material stainless steel, mounted at probe

connected with 12 mm tube at coax valves, max. operating pressure: 7 bar, pressure air connection: 12 mm tube





Options for PSG Basic and/or PSG Plus and Plus DSBP

Performance – Gas Sampling Tubes PSG ST

Reliable Gas Sampling for precise representative measurement

For dust concentrations up to 3 g/m3

o without additional options

Temperature resistant tubes up to 1300 °C

o Up to 600 °C or 900 °C also selectable

Sampling length definable

Various tube materials available

o SS 1.4571

o SS 1.4893

o Hastelloy C4

o Kanthal APM

o Corrosion resistant options to be selected

Solutions for nearly all low, medium and high dust applications

o Additional options for very and extreme high dust contents

Sample mounting

o R3/4“-male thread fittings

Technical Data – Tubes PSG ST

Tube Material Max. Temp. [°C] Length* L [mm] Max. Length** [mm]

D [mm]

Part No.

Stainless steel SS 1.4571 600

1000 2500 27

80060022

Extension stainless steel SS 1.4571 100 80060645

Hastelloy C4 (very corrosion resistant) 900

1000 2500 25

08060438

Extension Hastelloy C4 100 80060646


1000 2500 27

80060388

Extension stainless steel SS 1.4893 100 80060647

Kanthal APM (corrosion resistant) 1300

1000 1500 27

80060660

Extension Kanthal APM 100 80060661

*Standard length/ standard extension: Other arbitrary intermediate length maybe selected – c.f. **Self-supporting, increased lengths may be selected (if supported at the sampling place due to appropriate measures like e.g. traverses) – c.f.





Performance – Gas Sampling Pre-Filter PSG PF

For dust Concentrations up to 10 g/m3 without back purge

o Requires no dry purge gas at site

o Solution for dust concentrations > 3 g/m3 up to 10 g/m3

Low differential pressure even at high flow rates

Temperature resistant up to 900 °C

Stainless steel or corrosion resistant Hastelloy sinter metal filter

Sample length selectable with extension tube

Service life prolongation and protection against abrasion by deflector

Dust precipitation direct in the process

Large active surface

Long lifetime

Quick and simple mounting

Technical Data – Pre-Filter PSG PF

*Standard length/ standard extension: Other arbitrary intermediate length maybe selected – c.f.

Pre-Filter PSG PF Max. Temp. [°C] Length L [mm] Connection Porosity [µm]

D [mm]

Part No.

Stainless steel SS 1.4571 600 220

G3/4“a 2 45 80060492

520 50 08060572

Hastelloy C4 (corrosion resistant)

900 220

G3/4“a 2 45 80060664

520 50 80060665

Extension tube*


1000 R3/4” a – G3/4” i - 26

80060526

Extension stainless steel 100 80060645

Hastelloy C4 900

1000 R3/4” a – G3/4” i - 26

80060666

Extension Hastelloy C4 100 80060646

Deflector

Stainless steel SS 1.4571 600 220

clamping plate - - 80060493

520 80060632

Hastelloy C4 (corrosion resistant)

900 220

clamping plate - - 80060667

520 80060668





Performance – Heated Gas Sampling Tube PSG HT

Homogeneous heating over entire tube length

o For low dew point sample gas – to avoid condensation

No cold spots

Corrosion resistant out of SS316 / 316L

Controlled heated up to 180 °C - for high acid dew points

In arbitrary lengths up to 2 m available

Internal tube diameter 12-20 mm available

With cable for electrical connection via connection box of PSG Basic & Plus

With thermocouple Fe-CuNi

Protection class IP68

Extensions with unheated tube or pre-filter:

o Tube end with G3/4“ female thread

Low dead volume

Technical Data – Tube PSG HT

Part No.

Process Gas Sampling Conditions PSG HT

Pressure pabs = 50…600 kPa

Temperature max. 250 °C

Flow 30…1500 l/h, referred to 100 kPa and 0 °C

Max. dust concentration 3 g/m³

Connections Extension tube / pre-filter G3/4" i (DIN ISO 228/1) optional 80060674

Heating

Type Fixed resistance heater

Temperature 180 °C

Temperature alarm 150 °C (adjusted at optional temperature controller)

Temperature control (optional)

PID-controller ST49 incl. solid state relay for DIN-rail-mounting 230 V, 50/60 Hz

50078850

PID-controller ST49 incl. solid state relay for DIN-rail-mounting 115 V, 50/60 Hz

50078851

Temperature sensor Fe-CuNi

Design

Standard lengths (others on request)

0.5 m 80060670

1 m 80060671

1.5 m 80060672

2.0 m 80060673

Material Stainless steel SS316 / 316L

Ambient temperature -20 °C to +180 °C

Weight approx. 9 kg (1 m)

Diameter external: 48.3 mm internal: 12 mm (up to 20 mm possible)

Dead volume 113 ml/m (12 mm internal diameter)

Protection class IP68 EN 60529

Electrics

Heat capacity 130 W/m

Voltage 230 VAC, 50…60 Hz (115 VAC on request)

Electrical connection 3 m cable (3 x 1.5 mm2 and 2 x thermocouple)

Electrical standard EN 61010, EN 60519-1

Mounting

Flange Stud bolts on both sides M12 x 40 mm corresponding to DN65 PN6 form B according to DIN 2527

Material Flange gasket Klingersil DN65 PN6, 4 x nut M12, 4 x spring washers and washers

Installation angle 10 ° - 35 ° inclination to horizontal position (rec-ommended)

Materials in con-tact with sample gas

Tube, flange, connections Stainless steel SS316 / 316L





Performance – Pressure Reduction Valve PSG PR

Option for single stage back purge at PSG Basic

Option for single and dual stage back purge at PSG Plus & Plus DSBP

Safe protection of analyzer and gas conditioning components against damage

Reliable reduction of pressure peaks at sample gas outlet while back purging

o Reducing 6 bar (70000hPaabs) for successful back purge

o Protection of sensitive Analyzer components against high pressure

Reduction to max. 800 mbar at outlet

Increase of back purge efficiency

Dual function with connection for heated sample line

Dismountable for simple cleaning

Quick and simple mounting

Self-cleaning effect

Corrosion resistant

Temperature resistant

Compact design

The pressure reduction valve PSG PR can be used only without Pre-Filter PSG PF

Technical Data – Pressure Reduction Valve PSG PF

PSG PR

Part No. 80060195 80060675

Max. pressure sample gas outlet PSG Plus mbar 800

Closing pressure at 180 °C hPa abs. > 1.800

May. flow rate Nl/h 1000

Max. pressure bar (hPa abs.)

6 (70000)

Connections 6 mm – ¼“ RT m 8 mm – ¼“ RT m

Max. media temperature °C +250

Materials of media wetted parts SS 1.4571

Ambient temperature °C -40…+320

Design Data

Length mm 37.9 38.7

Weight kg approx. 0.04

Mounting threaded joint





Dimensions and Descriptions

Heated Gas Sampling Probe PSG Basic

Dimensions in mm

PSG Basic Filter

PSG Basic with Protection Box, Back Purge and Calibration (Test) Gas Inlet

PSG Basic with Back Purge and Calibration Gas in-let & Sample Gas Outlet

PSG Basic with Connecting Flange (Test) and Sample Gas In-let





Heating sleeve incl. PT100 Ring heater self-regulating

PID-controller ST49 & solid-state relays (25A) with heat sink for DIN-rail-mounting, heating sleeve only

Removable insulation jacket

Common Options for PSG Basic, PSG Plus and Plus DSBP

PSG Basic Dimensions PSG Basic with Protection Box, Back Purge Inlet and Calibration (Test) Gas Inlet





Heated Gas Sampling Probe PSG Plus

PSG Plus Filter

PSG Plus with Protection Box: Back Purge Inlets via Filter Element & Chamber and Calibration (Test) Gas Inlet

PSG Plus with Flange and Sample Gas Inlet Back Purge Inlets via Filter & Chamber and Calibration (Test) Gas Inlet





PSG Plus with back purge inlets via filter element & chamber and calibration gas inlet

PSG Plus w/o protective housing

PSG Plus lid design PSG Plus filter change w/o tools

PSG Plus Comfortable Filter Change

PSG Plus with protection box





Heated Gas Sampling Probe PSG Plus DSBP

PSG Plus DSBP - Standard

Dimensions in mm

PSG Plus DSBP with Protection Box and 2 Coax Solenoid Valves

2 Coax Solenoid Valves





PSG Plus DSBP - Options

PSG Plus DSBP with 2 Coax Valves and a 2 l Pressure Accumulator

Addition al DSBP Insulation

DSBP Coax solenoid valve for back purge DSBP 2 l Pressure Accumulator





Gas Sampling Tubes PSG ST

Dimensions in mm

Gas Sampling Pre-Filter PSG PF

Length L: 220 / 520 mm (also Deflector)

Extension tube L: Standard Length = 1000 mm / Extension = 100 mm





Heated Gas Sampling Tube PSG HT

Dimensions in mm

The four Standard Length Variations of Heated Probe Type

Length 1 500 mm

Length 2 1000 mm

Length 3 1500 mm

Length 4 2000 mm

Other Lengths on request – c.f.

Pressure Reduction Valve PSG PR

Dimensions in mm

PSG PR is available for tubing with 6 mm O.D. or 8 mm O.D.




Installation

Unpacking

Danger of breakage - only for special PSG probe tube! Only a special silicon carbide tube is fragile (c.f.).

Step Action

1 Unpack the tube, the filter unit and, if applicable, the temperature controller.

2 Make sure that any accompanying accessories do not get lost.

3 Check the contents of the delivery to ensure that is complete by comparing the actual goods with the dispatch note

Keep the packing material for possible future transport. If damage has occurred during transport due to improper handling, please submit a damage report to the transport institution within seven days.

Probe Tube Installation in General

Only the silicon carbide tube (special version – on request) must be installed vertically.

Corrosion risk! The heated gas sampling tube PSG HT must be put into operation immediately after as-sembly and installation; otherwise there is a risk of corrosion!

Probe Tube and Filter

Possible combinations of the probe tubes and filters units:

Probe Tube Type Filter Unit Types Type of Assembly

Unheated PSG Basic/Plus Bolted

Heated PSG Basic/Plus Flange: DN65 PN6

Step Action

1 Install the customer-supplied wall tube with assembly flange into the wall of the flue gas duct or chimney according to the planning documents.

2 Use the green seal from accessories pack to seal the space between the probe tube and the wall tube.

3 Insert the pre-assembled gas sampling system in the wall tube.

4 Screw the assembly flange to the flange of the filter unit.




Installation

Installation of PSG Basic, PSG Plus and Plus DSBP

Wall Tube Mounting of PSG Probe with Filter Unit

The following table states the recommended mounting angle of the PSG filter unit:

Mounting angle 10˚ 15˚ 20˚ 25˚ 30˚ 35˚

xmin mm 229 248 268 287 307 324

Connect the sample gas line to gas port B at the sample gas connection of the filter unit by means of a clamp ring screw fitting (not in the scope of supply and delivery).

Possible leakage! When tightening the screw connection, relieve the pressure on the gas port, e.g. by holding back with a suitable spanner. Otherwise there is a danger that the gas port is twisted and becomes un-tight or breaks off.

If probe back purging is available, connect the compressed air lines to gas port C (Single stage back purge) If test gas is to be fed in at the probe, connect the test gas line to gas port B. If the PSG Basic filter unit is operated at ambient temperatures below -20 °C, additional heating must be provided.




Installation

Gas Connections

PSG Basic Gas Connections

A Sample gas outlet, G1/4” B Calibration (test) gas inlet, G1/4” C Back purge (single stage) gas inlet, G3/8”

A

C

B




Installation




Installation

PSG Plus and Plus DSBP Gas Connections

A Sample gas outlet, G1/4” B Calibration (Test) gas inlet, G1/4” C Back purge gas inlet (chamber & tube), G3/8” D Back purge gas inlet (filter), G3/8”

D

A B

C




Installation

PSG Plus Gas Connections




Installation

PSG Plus DSBP Gas Connections




Installation

Gas and Electrical Connections PSG Basic and PSG Plus

PSG Basic

A Fitting, sample gas connection for tubing: 6 mm / 1/4” B Plug, G1/4”, calibration (test gas) for tubing 6 mm / 1/4” 1 Terminal box 2 2 pcs. cable gland M16 (Pt100 and reserve) 3 3 pcs. cable gland M20 (230 V / 115 V) 4 Cable gland M16 (230 V / 115 V) 5 Cable gland M16 (Pt100) 6 Bulkhead fitting, calibration / test gas connection for tubing: 6 mm / 1/4” 7 Mounting clamp 8 Bulkhead fitting, instrument air connection for tubing: 12 mm / 1/2” 9 Bulkhead fitting, sample gas outlet connection for tubing: 6 mm / 1/4”




Installation

PSG Plus

A Bulkhead fitting, calibration / test gas connection for tubing: 6 mm / 1/4” B Bulkhead fitting, instrument air via filter for tubing: 12 mm / 1/2” C Bulkhead fitting, back purge via filter chamber & probe tube for tubing: 12 mm / 1/2” D Bulkhead fitting, sample gas outlet connection for tubing: 6 mm / 1/4” 1 Calibration / test gas tube, VA 1.4571 / 316, 6 x 1 mm 2 Back purge tube, CU, 12 x 1 mm 3 Terminal box, IP66 4 2 pcs. cable gland M16 (Pt100 and reserve) 5 3 pcs. cable gland M20 (230 V / 115 V) 6 Back purge tube, CU, 12 x 1 mm 7 Mounting clamp 8 Cable gland M16 (230 V / 115 V) 9 Cable gland M16 (Pt100)




Installation

Installation of PSG Basic Components

Filter unit Filter

Heating Sleeve Insulation

Terminal Protective Box




Installation

PSG Basic Filter Unit Components

1 Flange clamp 3” 2 Filtering Unit 3 Probe housing 4 Stainless steel ring 5 Upper filter holder 6 O-ring seal 45 x 3 mm 7 O-ring seal 59 x 4 mm 8 O-ring seal 50 x 4 mm 9 Filter stone 10 O-ring seal 45 x 3 mm 11 Lower filter holder

1

2

3

11

10

9

8

7

6

5

4




Installation

PSG Plus & Plus DSBP Filter Unit Components

1 T-handle 2 Bridge 3 Detaching disk 4 Locking screw 5 Upper filter holder 6 Flange 7 O-ring seals 8 Filter stone 9 Bridge holding device 10 Probe housing 11 Lower filter holder

1

2

3 4

5

6

10

9

7

8

7

11




Operation & Maintenance

Operating Instructions

This Operating Instruction contains the information that is required to install, put into operation, operate and maintain

probe tubes (unheated and heated) and filter unit types (PSG Basic and PSG Plus) safely and as specified. The Operating Instruction also contains information about the operation of the temperature controller. The complete Oper-ator's Manual of the temperature controller is a constituent of the scope of supply and delivery. If the information in this operator's manual does not cover a particular situation, PSG Service will be pleased to supply additional information as required.

Quick Guide for the Installation

We recommend strongly to read the complete instruction manual to get the complete in-

formation about the product! Just in case of a Short Form Manual (Quick Guide) you can use this short form – but take in mind: Not all important messages are included in the Quick Guide!

Step Action

1 Unpack the supplied equipment (see chapter “Installation”,section “Unpacking”)

2 Install the probe tube, see sections “Probe Tube Installation in General” and “Probe Tube and Filter”.

Install gas sampling tube PSG ST (unheated type)

Install gas sampling pre-filter PSG PF

Install heated gas sampling tube PSG HT

3 Mounting of the filter unit, see sections “Probe Tube and Filter” and “Installation of PSG Basic, PSG Plus and Plus DSBP”.

Mounting the PSG Basic filter unit (see section “PSG Basic Gas Connections”)

Mounting the PSG Plus filter unit (see section “PSG Plus and Plus DSBP Gas Connections”)

4 Electrical connections (see section “ Gas and Electrical connections PSG Basic and PSG Plus”)

Electrical connections for heated gas sampling tube PSG HT

Electrical Connections for the PSG Basic & Plus Filter Units

Electrical Connections for the Temperature Controller After you have carried out these steps, the probe tube and the filter unit are operative.

Please refer to the planning documents for the installation. Please also refer to the technical data (see chapter "Technical Description", see section “Technical Data”). The wall tube must be installed at the sampling point before the probe is installed!





Inspection and Maintenance - PSG Basic and PSG Plus

Danger of burns!

The work described in this chapter requires specialist knowledge. As a result, it may only be carried out by persons who are qualified and specially trained. The metal parts may have high temperatures as a result of operation.

Health hazard! Dependent on the substances which it comes into contact with during operation, the filter element could be contaminated with toxic or corrosive substances. Always wear suitable

protective clothing for cleaning work. Filter Unit Cleaning interval - PSG Basic and PSG Plus:

The operating life of filter elements depends on the operating conditions. If necessary, you can remove it so that you can make a visual inspection and clean mechanically the element from impurities or exchange it. If the filter stone is obviously damaged, you must replace it with a new one. When this is the case is also depending on the operating conditions. This is to be identified during operation.

PSG Basic - Filter Unit Maintenance

Filter Unit Dismounting

Step Action

1 Loosen the flange clamp (1) with the help of the wing nut and remove it




Operation & Maintenance Step Action

2 Pull the ring to remove the complete filter unit (2) using the stainless-steel ring (4) from the housing

If the filter unit - due to heavy pollution, corrosion, etc. - cannot be pulled out, so the dual function of the clamp is used to press the filter element:

Insert the bottom edge of the clamp (1) into the conical groove

Screw the clamp (1) to the end





Step Action

3 Accordingly, the filter unit (2) is slightly raised and can be pulled out using the ring (4)





Filter Stone Replacement

Step Action

1 Unscrew the lower filter holder (11) with help of a web

2 Remove the filter stone

3 Replace O-ring seals (6,10)

4 Insert the new filter stone (or clean the old one)

5 Screw the lower filter holder (11)

Filter Unit Installation

Step Action

1 Replace upper O-ring seals (7, 8)

2 Insert the filter unit (2) into the housing (3)

3 Insert manually the flange clamp (1) and tighten by hand

Toxic substances may be present due to being in contact with sample gas containing acidic and / or alkaline compo-nents.





PSG Plus - Filter Unit Maintenance

Filter Unit Dismounting

Never undo or tighten up the hexagon screws 5! They have been adjusted at the factory, so that the detaching disk 3 can be easily moved.

Step Action

1 Turn the T-handle 1 of the filter removal device 1–3 in a counter-clockwise direction. This pulls the filter element 8 out of the casing 10 via the detaching disk 3.

Toxic substances may be present due to being in contact with sample gas containing acidic and / or

alkaline components.

2 Turn bridge 2 until it can be pulled off the bridge holding device 9 through the elongated holes

3 Pull out the filter element 8 with bridge 2 and detaching disk 3.





Filter Stone Replacement

To carry out this work, you require:

A new filter stone (with new O-rings from the accessory set)

Step Action

1 Unscrew the lower filter holder (11) with help of a web

2 Remove the filter stone

3 Replace O-ring seals (7)

4 Insert the new filter stone (or clean the old one)

5 Screw the lower filter holder (11)




Automated Filter Cleaning – Back Purge

PSG Gas Sampling Pre-Filter PF

The gas sampling pre-filter PSG PF is installed direct in the process. This way dust precipitation happens direct in the chimney and the large additional active filter surface is increasing total filter surface. A self-cleaning effect direct in the gas path creates an automatic filter cleaning thus extending the maintenance time. For up to 10 g/m3 dust content this is an alternative to back purge which requires dry, oil-free and greaseless compressed air.

Filter Element Back Purge with Compressed Air

Purpose of Back Purging

Automated filter cleaning can be provided to maintain and/ or extend the operability of the filter unit and for very high dust contents it is mandatory. This is carried out by back purging with pulsed compressed air. The dirty particles are detached from the filter surface by the pulsed compressed air and blown into the process area. For up to 10 g/m3 dust content this is an alternative for a pre-filter or a solution to achieve longer maintenance intervals. For > 10 g/m3 a single back purge is required and for > 40 g/m3 a dual back purge is mandatory and offered with PSG Plus only. The following are considered in this chapter:

The relevant connections for the respective filter unit.

The recommended program runs for the pulsed compressed air.

Requirements for the Compressed Air

The compressed air for back purge needs to fulfil the following requirements:

Dry: with a dew point of < -20 °C

Clean: oil-free & greaseless instrument air

Pressure: 4 to 6 bar (70,000 hPaabs)

Cleaning Intervals

Select the cleaning and maintenance intervals being suitable to your individual operating conditions. Irrespective of your operational routine intervals, it is necessary to clean the filter when it becomes blocked by particles of dust, dirt or corrosion. These circumstances become especially apparent when there is a pressure drop at the sample gas outlet.




Circuit Diagram – Gas Sampling Probes

Circuit Diagram - PSG Basic





Circuit Diagram – PSG Basic with Thermostat Control





Circuit Diagram - PSG Plus





Circuit Diagram - PSG Plus with Thermostat Control




Troubleshooting To locate and eliminate the cause of a temperature failure, proceed as follows:

Stop the measuring gas transport.

Check whether a gas sampling probe overtemperature condition has been detected. If that is the case, first

o Press the RESET key of the temperature regulator at the gas sampling probe (connection box)

Check electrical supply!

Allow extra time for the system to heat up.

Check all fuses and all electrical contacts of the gas sampling probe, including those of the temperature sensor and temperature regulator, along with the relay contact.

Check the heater elements.

Check all of the mentioned components items for proper operation.

Check all gas lines including filter element for presence of condensate, and clean or replace as required. After elimination of any failure and after gas sampling probe has reached its temperature, the measurement can go on.




Return, Disposal & Lifetime – CE & ISO Certificate

Return of Material

Danger of burns!

The work described in this chapter requires specialist knowledge. As a result, it may only be carried out by persons who are qualified and specially trained. The metal parts may have high temperatures as a result of operation.

Electric shock! You must disconnect the voltage for the current circuit, in which the electrical equipment is integrated, when putting the device out of service.

Otherwise there is a danger of electric shock.

Health hazard! Dependent on the substances which it comes into contact with during operation, the filter element could be contaminated with toxic or corrosive substances. Always wear suitable

protective clothing for cleaning work.

Procedure for Return of Equipment

Step Action

1 Clean the filter (see Chapter 5 "OPERATION & MAINTENANCE", see section 5.2.) before return of the equip-ment.

2 Remove the gas sampling system from the assembly flange of the bushing tube and hermetically seal the as-sembly flange with a blind flange.

3 Before switching off the heater by disconnecting the power supply to the gas sampling system: Take care for sufficient purge (at minimum 10 minutes) of the probe to remove any toxic or aggressive gas components - especially to avoid condensation and for protection of personnel.

4 Hermetically seal the connections of the gas sampling system.

If you want to send a device for maintenance or repair to AGT-PSG GmbH & Co. KG, please follow the instructions in the forms - Return Forms and Declaration of Contamination. Please fill in these forms completely. Send the device along with the form DDP (Delivery Duty Paid – AGT-PSG will ac-cept deliveries only if freight and customs to our company are fully paid - see address).





Proper Disposal

Depending on the service conditions, the filter stone could be contaminated with dangerous substances. Depending on the contamination, the filter stone must be disposed in accordance with good professional practice and the currently applicable local regulations.

End of Lifetime

If the product has reached the end of lifetime, proceed as follows: Secure a return authorization from AGT-PSG Sales or from your Representative before returning any equipment. Equip-

ment must be returned with complete identification in accordance with AGT-PSG instructions. Otherwise we cannot accept it. In no event AGT-PSG will be responsible for equipment without proper authorization and identification.

Packing for return

In case of a proper authorization:

Original Packing not Available

If the original packing material is no longer available, wrap the device in bubble foil or corrugated cardboard. When shipping overseas, also heat-seal the device air-tight in 0.2 mm thick polyethylene, including a desiccant (e.g. silica gel). The amount of desiccant used should be adequate for the package volume and the probable shipping time (at least 3 months).

Packing in an Adequate Box

Pack the device in an adequately large box lined with shock absorbent material (e.g. foam material). The thickness of the cushioning material should be adequate for the weight of the device and the mode of shipping. The box should also be lined with a double layer of bitumen paper for overseas shipping.

Marking of the Box

Mark the box "Fragile! Handle with care!“





Packaging and Shipping

If you want to send a device for maintenance or repair to AGT-PSG, please note the following information on packaging and shipping:

Please use the original packaging of the device. If this is not available, use another stable packaging in which the device is well protected from the weather and mechanical damage. Handle with care. Heavy blows could cause irreparable damage.

AGT-PSG will only accept deliveries that are not physically damaged. Ensure a transport in perfect upright posi-tion. Turning it upside down some parts could be irreparably damaged. It is best to tie down the individual package on a pallet. Do not stack. Mark your package with appropriate icons:

Fill in this form and the subsequent declaration of decontamination completely. Send the device along with the forms DPP (Delivery Duty Paid – AGT-PSG will only accept deliveries if freight and customs are fully paid) to: AGT-PSG GmbH & Co.KG Weißkirchener Straße 3 D-61449 Steinbach/Ts. Germany

Inform AGT-PSG by email ([email protected]) about the shipment of the cooler and the approximate delivery date. Please attach scans of the filled in documents.

Sender-/Return-Delivery-Adress and Contact Partner

Sender: Return-delivery to:

____________________________________ ____________________________________ ____________________________________ ____________________________________ ____________________________________ ____________________________________ ____________________________________ ____________________________________

same address as sender

Contact (name, email, phone):

mailto:[email protected]





Declaration of Contamination Status

Legal regulations prescribe to fill in and sign the declaration of contamination status and send it back. This information is used to protect our employees. Please attach the declaration to the packing. Otherwise your repair cannot be pro-cessed.

Device / Articlenumber / Serialnumber:

Reason for return:

I hereby declare that the device specified above has been properly cleaned an decontaminated and that there are no

risks present when dealing with this device. In other cases, please describe the hazards in detail:

Explosives Acute toxidity Flammable Oxidizing

Envoronmental hazard Corrosive Irritant toxidity Health hazard

Liquid Solid Powdery Gaseous

Please include the current material safety data sheet of the hazardous material!

Company, Contact Location, Date, Stamp, Signature




AGT-PSG EC Declaration of Conformity – CE Marking




AGT-PSG Declaration of Conformity – Actual ISO 9001 Certificate

psg basic & psg plus gas sampling probes · 2020. 9. 3. · agt-psg gmbh & co.kg errors and...

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