Industrial flue gas probes

Instruction manual2

1 Contents

1

Contents

1

Contents ...................................................................................................32

Safety and the environment ....................................................................4
2.1. About this document ........................................................................4
2.2. Ensure safety...................................................................................4
2.3. Protecting the environment ..............................................................5

3

Specifications ..........................................................................................6
3.1. Use ..................................................................................................6
3.2. Technical data .................................................................................7

4

Product description ...............................................................................11

5

Using the product ..................................................................................13

6

Maintaining the product ........................................................................15
6.1. Checking / cleaning / replacing the particle filter............................15
6.2. Cleaning / replacing the preliminary filter .......................................18
6.3. Cleaning / replacing metal sampling tube ......................................20
6.4. Cleaning / replacing the ceramic tube ...........................................21
6.5. Replacing unheated gas sampling hose ........................................226.6. Cleaning the gas path in the probe handle ....................................23
6.7. Replacing the thermocouple ..........................................................27

7

Tips and assistance...............................................................................30
7.1. Recommendations and application instructions.............................30
7.2. Tightening torques for screw connections .....................................30
7.3. Accessories and spare parts .........................................................313

2 Safety and the environment

2

Safety and the environment

2.1.

About this document
Use> Please read this documentation through carefully andfamiliarize yourself with the product before putting it to use. Pay
particular attention to the safety instructions and warning advice
in order to prevent injuries and damage to the products.
> Keep this document to hand so that you can refer to it whennecessary.
> Hand this documentation on to any subsequent users of the
product.

2.2.

Ensure safety
CAUTION
Danger of burning on hot surfaces!
> Always wear heat-resistant gloves when touching the probe
shaft.
> Allow the probe shaft to cool down after a measurement,
before touching it or placing it in the transport packaging.
> Only operate the product properly, for its intended purpose andwithin the parameters specified in the technical data. Do not
use any force.
> Temperatures given on probes/sensors relate only to themeasuring range of the sensors. Do not expose handles andfeed lines to any temperatures in excess of 70 °C unless they
are expressly permitted for higher temperatures.
> Do not operate the instrument if there are signs of damage at
the housing, mains unit or feed lines.
> Do not perform contact measurements on non-insulated, live
parts.
> Do not store the product together with solvents. Do not use any
desiccants.
> Only perform maintenance and repair work on this instrumentthat is described in the documentation. Follow the prescribedsteps exactly. Use only original spare parts from Testo.

4

2 Safety and the environment> Any additional work must only be carried out by authorized
personnel. Testo will otherwise refuse to accept responsibility
for the proper functioning of the measuring instrument after
repair and for the validity of certifications.
> The industrial flue gas probe must not be used in explosive
environments.
> When connecting the heated industrial flue gas probe, ensure
correct mains voltage as specified on the type plate.
> Before opening the probe housing of the heated industrial fluegas probe, pull out the mains plug.
Safety-related symbols on heated industrial flue gas probes
SymbolExplanation
If the product is not used in strict compliancewith this documentation, the intended
protection may be impaired.
> Operate the product only as described inthis documentation.
> Please consult your dealer or the
manufacturer if in doubt.
Risk of burns due to hot surface.

Use heat-resistant gloves for protection
against harmful thermal effects.

2.3.

Protecting the environment> At the end of its useful life, send the product to the separate
collection for electric and electronic devices (observe local
regulations) or return the product to Testo for disposal.

5

3 Specifications

3

Specifications

3.1.

Use
The industrial flue gas probes have been designed for the following
tasks / applications:• Extractive sampling of the flue gas being analyzed at industrial
plants with◦ high temperatures of > 1000 °C◦ large sampling diameters◦ wet flue gas to prevent distorted readings (heated industrial
flue gas probe up to 600 °C)
The industrial flue gas probes are used in conjunction with thefollowing flue gas analyzers:• testo 340• testo 350
The industrial flue gas probes come in two pre-configured sets. A
system-specific sampling solution can be put together using otheraccessories.

6

3 Specifications

3.2.

Technical data
GeneralFeatureValuesOverpressure in the fluegasmax. 100 mbar

Negative pressure in theflue gastesto 340: max. 200 mbar
testo 350: max. 300 mbar

Ambient temperature-5 to +45 °C

Storage temperature-20 to +50 °C

Unheated handle (item no. 0440 0649)
FeatureValuesTemperature resistance

600 °C

Handle - probe shaft
connection

Internal thread G 1/4

Handle - thermocouple
connection

Internal thread M8 x 1

Hose connection

Adapter with hose nozzle, 7 mm outer
diameterMaterial

Stainless steel 1,4404

Unheated gas sampling hose (item no. 0554 3354)
FeatureValuesLength4000 mm

Design2-chamber hose with Teflon inner hose

Particle filter

To protect the measuring instrumentfrom particulate matter and dirt
Material: PE porous 10 µm

73 Specifications

Unheated sampling tube up to 1200 °C (item no. 0600 7617)
FeatureValuesTemperature resistance

1200 °C

Dimensions

Length 1053 mm,
Probe shaft: Ø 12 mm,
Threaded socket: Ø 17 mm

Connection

Thread G 1/4

Material

2.4856 alloy 625

OptionProbe extension (extension tube item
no. 0600 7617)
Probe preliminary filter (item no. 0600
7616) can be attached

Unheated sampling tube up to 1800 °C (item no. 0600 7805)
FeatureValuesTemperature resistance

1800 °C

Dimensions

Ø 12 mm, length 1000 mm

HandleAdapter with O-ring, Tmax: 220 °C;
Ø 22 mmMaterial

Ceramic Al2O3 >99.7%

Thermocouple (item no. 0430 0088)

8

FeatureValuesTemperature recorderType K NiCr-Ni, insulated Class 1

Sheathed cable

2.4816 alloy 600

Length TC

1200 mm; optional length 2200 mm(item no. 0600 7615) available

Diameter

2 mm

Measuring range-200 to +1200 °C

Cable length

4.0 m

3 Specifications

Heated sampling tube (item no. 0600 3502)
FeatureValuesTemperature resistance

up to 600 °C

Voltage supply

230 V/50 Hz

Power consumption

400 W

Dimensions

Ø 25 mm, length: 1110 mm

Ready for operation

within 15 min.

Heating temperature>180 °C

OptionProbe extension (extension tube) (itemno. 0600 7617)
Probe preliminary filter (item no. 0600
7616) can be attached

Heated gas sampling hose (item no. 0600 3501)
FeatureValuesDesignCorrugated hose with Teflon inner hose

Dimensions

Length: 4000 mm
Corrugated hose: Ø 28 mm
Silicone caps: Ø 34 mm

Heating temperature
range>120 °C

Ready for operation

within 15 min.

Outside temperature

max. +45 °C

Voltage supply

230 V/50 Hz

Power consumption

160 W

Bending radiusmin. 200 mm

Preliminary filter (item no. 0600 7616)
FeatureValuesOperating temperature

max. 1000 °C

Dimensions

Ø 32.6 mm, length 110 mm

Filter seat

Material:1.4841
Connecting thread: G 1/4

9

3 Specifications

FeatureValuesFilter nut

Material: 1.4841
Thread: G 1/4

Filter element

Dimensions: Ø 30 mm, length 75 mm
Material: porous silicon carbide
Particle size: 10 μm

Filtration grade for
gases

2 μm

Safety cotter pin

DIN 94, dimensions: 2.0 x 16 mm,Material: stainless steel A4

Warranty

10

FeatureValuesThermocouple

12 months

Heated sampling tube

24 months

Heated hose

24 months

Sampling / extension
tube

24 months

Unheated hose

24 months

Unheated handle

24 months

Warranty terms

see website www.testo.com/warranty

4 Product description

4

Product description
Industrial flue gas probe set 1200 °C (0600 7610)

1

Unheated handle

2

Unheated metal sampling tube

3

Preliminary filter (optional)

4

Instrument connections

5

Unheated gas sampling hose

6

Particle filter

7

Thermocouple type K

8

Gas path

11

4 Product description

Industrial flue gas probe set 1.800 °C (0600 7620)

1

Unheated handle

2

Unheated ceramic sampling tube

3

Unheated gas sampling hose

4

Instrument connection

5

Particle filter

6

Gas path

Industrial flue gas probe set, heated (0600 7630)

121

Heated sampling tube

2

Preliminary filter (optional)

3

Heated gas sampling hose

4

Instrument connection

5

Probe heater connection cable

6

Probe heater

7

Thermocouple type K

5 Using the productPos: 28 /TD/Überschriften/6. Produkt verwenden @ 0\mod_1173774928554_79.docx @ 328 @ 1 @ 1

5

Using the product
Heated industrial flue gas probe> The heated industrial flue gas probe is designed for amains voltage of 230 V!
> Uncoil the coiled gas sampling hose correctly so that
there is no torsional strain.
> Lay the gas sampling hose so that it is protected fromthe wind and the weather, because depending on thewind/weather conditions, there is considerable loss ofheat at the outer sheath.
> When installing in closed rooms please ensure that
there is sufficient ventilation to prevent heat build-up.
> To prevent damage• Do not route the gas sampling hose over sharpedges or via feedthroughs.
• When securing, make sure that the gas sampling
hose is not squashed.
• There should be no moving or bending stresses on
the connections themselves. When installing, please
ensure a minimum bending radius of 200 mm.
> Following final installation, visually inspect the heatedindustrial flue gas probe for any damage.
> After the mains plug has been plugged in, the total
heating up time is approx. 20 minutes.
> Once the heating up time has elapsed, the heatedsampling tube is very hot and should only be touchedwith heat-resistant gloves.
CAUTION
Danger of burning on hot surfaces!
> Always wear heat-resistant gloves when touching the probe
shaft.
> Allow the probe shaft to cool down after a measurement,
before touching it or placing it in the transport packaging.

13

5 Using the product

Checking the thermocouple> Make sure that the thermocouple of the industrial flue gas probe
does not touch the probe shaft. Bend the thermocouple back ifnecessary.
Aligning the industrial flue gas probe> Align the industrial flue gas probe in the flue gas duct so thatthe tip is in the centre of flow (area of the highest flue gas
temperature).
Optional- Mount extension tube.
- Mount preliminary filter.
- Install thermocouple 2200 mm.

14

6 Maintaining the product

6

Maintaining the product

6.1.

Checking / cleaning / replacing the particle
filterChecking the particle filter:
Check the particle filter of the industrial flue gas probe regularly for• Damage to and contamination of the housing• Filter saturation of the PE filter
Visual inspection
Cleaning the particle filter housing:> If there are any signs of contamination, clean the particle filter
housing.

1. Open the filter cover of the housing
2. Remove dirt using a cloth.
3. Put the filter cover on and lock it: turn slightly clockwise15

6 Maintaining the productReplacing the particle filter housing:> In the event of any damage to the housing, replace the particle
filter (item no. 0440 0668).

1. Remove bend protection springs and hose connections fromthe particle filter by turning clockwise.
2. Attach new particle filter to the hose connections.
If the saturation level is low, the PE filter can be inserted in
the new housing.
3. Push the bend protection springs over the hose connections bypressing and simultaneously turning clockwise.
Checking the PE filter:
Check the particle filter of the industrial flue gas probe regularly forfilter saturation.
Carry out a test.
- Measuring instrument is switched on.

> Remove bend protection spring and hose connection from theparticle filter by turning clockwise.
- The measurement gas pump now sucks in ambient air via thefilter. Filter needs replacing if:• Flow rate < 0.6 l/min testo 350• Flow rate < 0.2 l/min testo 340
16

6 Maintaining the product

If the flow rate value is >0.6 l/min (testo 350) or > 0.2 l/min(testo 340), the particle filter is not yet saturated. We
recommend checking the handle, the preliminary filter andthe sampling tube.
Replacing the PE filter:> If the PE filter is visibly saturated: replace the PE filter.
1. Open the filter cover of the housing

2. Remove the spent PE filter.
3. Insert new PE filter. Insert the PE filter into the filter holder as
far as it will go.
4. Put the filter cover on and lock it: turn slightly clockwise.

17

6 Maintaining the product6.2.

Cleaning / replacing the preliminary filter
Check the preliminary filter of the industrial flue gas probe regularly
for contamination: visual inspection> In the event of any visible contamination, clean or replace thepreliminary filter.
1. Fix the sampling tube securely in place.

2. Press the ends of the safety cotter pin together with pliers andslide upwards.

3. Remove safety cotter pin.

4. Remove the preliminary filter (size SW17) from the samplingtube (size SW13) using wrenches.

18

6 Maintaining the product5. Open preliminary filter using wrenches (size SW17).

6. Remove screw connections from the preliminary filter.
7. Clean the preliminary filter.
ATTENTION
Do not clean preliminary filter in liquids or ultrasonically.
Damage due to improper cleaning!
> Soot or particle deposits on the preliminary filter can bebrushed off using a wire brush. Then blow compressed air
through the preliminary filter.
8. Put together, screw together and tighten the cleaned or new
preliminary filter and insert safety cotter pin, see Tightening
torques for screw connections, page 30.
It is recommended that the thread of the prefilter to grease
with a commercial ceramic paste.
9. Tighten the preliminary filter (size SW17) on the sampling tube
(size SW13) using wrenches, see Tightening torques for screw
connections, page 30.
10. Disengage the sampling tube.

19

6 Maintaining the product6.3.

Cleaning / replacing metal sampling tube
Check the sampling tube of the industrial flue gas probe regularly
for contamination: visual inspection> In the event of any visible contamination, clean or replace thesampling tube.
CAUTION
Hot probe shaft!
Risk of burns!
> Allow the probe shaft to cool down before you touch or pack it!
1. Fix the sampling tube securely in place.

2. Remove the sampling tube (size SW13) from the handle (sizeSW19) using wrenches.
If necessary remove preliminary filter from the samplingtube.
3. Cleaning the sampling tube
> Brush off soot or particle deposits on the sampling tube using awire brush.
> Scrape out the inside of the sampling tube using a sturdy wire(e.g. Ø 3 mm). Hold the tube at a slight angle, so that thedislodged particles fall out.
> Then blow compressed air through the sampling tube.
4. Screw cleaned or new sampling tube onto the handle andtighten, see Tightening torques for screw connections, page 30.
If necessary screw preliminary filter onto the sampling tube.
5. Disengage the sampling tube.
20

6 Maintaining the product6.4.

Cleaning / replacing the ceramic tube
Check the sampling tube of the industrial flue gas probe regularly
for contamination: visual inspection> In the event of any visible contamination, clean or replace thesampling tube.
CAUTION
Hot probe shaft!
Risk of burns!
> Allow the probe shaft to cool down before you touch or pack it!
CAUTION
Fragile ceramic sampling tube!
> Avoid mechanical loads.

1. Remove sampling tube from the handle.
2. Cleaning the sampling tube
> Scrape out the inside of the sampling tube using a sturdy wire(e.g. Ø 3 mm). Hold the tube at a slight angle, so that thedislodged particles fall out.
> Then blow compressed air through the sampling tube.
3. Check handle- If the O-ring in the handle is damaged, the handle must be
replaced.
4. Insert a cleaned or new sampling tube into the handle as far as
it will go.

21

6 Maintaining the product

6.5.

Replacing unheated gas sampling hose
Check the unheated gas sampling hose of the industrial flue gas
probe regularly for damage and contamination: visual inspection
Replacing the gas sampling hose

1. Undo all hose clamps on the gas sampling hose.
2. Remove all bend protection springs from the hose connections
and the thermocouple clamping screw by turning clockwise.
3. Remove hose connections from the particle filter, gas pathconnection and gas path plug by turning clockwise.
4. Remove bend protection springs from the hose connections.

5.
6.
7.
8.

Undo the thermocouple clamping screw connection.
Pull the thermocouple approx. 100 mm out of the probe handle.
Push bend protection spring over the thermocouple.
Remove the thermocouple cable, starting at the instrument
plug, from the slotted tube.
9. Insert the thermocouple cable, starting at the instrument plug,
into the slotted tube of the new gas sampling hose.
10. Push the bend protection spring over the slotted tube.

22

6 Maintaining the product11. Carefully thread the thermocouple up to 50 mm through theclamping screw and the probe handle into the probe shaft.
12. Tighten clamping screw using a wrench (size SW8), with 1 3/4
turns.
When refitting the same clamping screw, this is tightenedwith a 1/4 turn more.
13. Push bend protection springs over the clamping screw.
14. Attach bend protection springs to the hose connections for theparticle filter, gas path connection and gas path plug.
15. Connect the particle filter, gas path connection and gas pathplug to the hose connections.
16. Push the bend protection springs over the hose connections bypressing and simultaneously turning clockwise.
17. Fasten hose clamps to the gas sampling hose.

6.6.

Cleaning the gas path in the probe handle
Check the gas path in the handle regularly for contamination.
1. Fix sampling tube and handle securely in place.

2. Remove the sampling tube (size SW13) from the handle (sizeSW19) using wrenches.
23

6 Maintaining the product3. Undo upper hose clamp.
4. Remove bend protection springs from the thermocouple
clamping screw.

5. Undo the thermocouple clamping screw using a wrench (sizeSW8).

6. Carefully pull out thermocouple.

24

6 Maintaining the product

ATTENTION
Never pull on the connection cable when removing thethermocouple from the handle.
Damage due to inappropriate handling!
> Hold thermocouple tightly in front of the ferrule and carefully
pull it out of the handle.

7. Undo the clamping screw connection using a wrench (sizeSW12).

8. Remove bend protection spring and gas path hose at the gas
path connection by turning clockwise.

25

6 Maintaining the product9. Insert the cleaning brush into the probe handle.
10. Push the cleaning brush through to the tip of the probe handle
and pull out.
11. Repeat steps 9 and 10 several times depending on the degreeof contamination.

12. Clean gas path connection.
13. Repeat step 11 several times depending on the degree ofcontamination.
14. Attach hose to the gas path connection and push bend
protection springs over the gas path connection by pressing
and turning clockwise simultaneously.
15. Tighten clamping screw connection on the probe handle using awrench (size SW12), see Tightening torques for screw
connections, page 30.
16. Screw clamping screw on the clamping screw connection byhand as far as it will go.

26

6 Maintaining the product17. Carefully thread the thermocouple up to 50 mm through theclamping screw and the probe handle and into the probe shaft.
18. Tighten clamping screw using a wrench (size SW8), with 1 3/4
turns.
When refitting the same clamping screw, this is tightenedwith a 1/4 turn more.
19. Push bend protection springs over the clamping screw.
20. Fasten upper hose clamp to the gas sampling hose.
21. Screw sampling tube onto the handle and tighten, see
Tightening torques for screw connections, page 30.

6.7.

Replacing the thermocouple
Before replacing the thermocouple, disconnect theindustrial flue gas probe from the Testo measuring
instrument.

1. Undo all hose clamps on the gas sampling hose.

27

6 Maintaining the product2. Remove bend protection springs from the thermocouple
clamping screw.

3. Undo the thermocouple clamping screw using a wrench (sizeSW8).

4. Carefully pull out thermocouple.

5. Remove the thermocouple cable, starting at the instrument
plug, from the slotted tube.

28

6 Maintaining the product

ATTENTION
Never pull on the connection cable when removing thethermocouple from the handle.
Damage due to inappropriate handling!
> Hold thermocouple tightly in front of the ferrule and carefully
pull it out of the handle.
6. Remove bend protection spring from the thermocouple.
7. Attach bend protection spring to the new thermocouple.
8. Insert the new thermocouple cable, starting at the instrument
plug, into the slotted tube.
9. Push the bend protection spring over the tube.

10. Carefully thread the new thermocouple up to 50 mm throughthe clamping screw and the probe handle into the probe shaft.
11. Screw the clamping screw by hand as far as it will go. Thentighten using a wrench (size SW8) with 1 3/4 turns.
When refitting the same clamping screw, this is tightenedwith a 1/4 turn more.

12. Carefully bend thermocouple 90° between ferrule and clamping
screw connection. Do not kink the thermocouple.
13. Push bend protection springs over the clamping screw.
14. Fasten hose clamps to the gas sampling hose.

29

7 Tips and assistance7

Tips and assistance

7.1.

Recommendations and application
instructions
Application / problem

Recommendation / solution

The screw connections are
difficult to undo following
usage at high temperatures(>600 °C).

Grease the threads of the screw
connections with a standard
ceramic paste before use.

In the event of heavy dust
loads (e.g. measurement on arotary kiln), the particle filter
gets clogged very quickly.

To achieve a longer service life,
replace the particle filter with astandard fuel filter. The
measurement period can last 10 to
20 min as a result.

A filter cake forms on theprobe shaft tip during
measurement.

The filter cake can be knocked offeither straight after measurement
or once the cooling time has
elapsed.

If we have not been able to answer your question, please contact
your dealer or Testo Customer Service. For contact details, see theback of this document or visit the website www.testo.com/servicecontact.

7.2.

30

Tightening torques for screw connections
Screw connections

Tightening torqueHandle - probe shaft

20 Nm

Probe shaft - probe shaft

20 Nm

Handle - gas path hose
adapter

6 Nm

Handle - TC clamping
screw connection

10 Nm

Probe shaft - preliminary
filter

20 Nm

Preliminary filter:
Filter nut - Filter seat

hand screwd

7 Tips and assistance

7.3.

Accessories and spare parts
Description

Item no.

Probe preliminary filter for dusty/dirty flue gases

0600 7616

Extension/sampling tube, length 1000 mm, up to
max. 1200 °C

0600 7617

Transport case for flue gas probes

0516 7600

Thermocouple, length 2200 mm, up to max. 1200 °C 0600 7615
Particle filter (housing incl. PE filter)0440 0668

PE filter (10 pcs.)

0554 3371

Unheated probe handle

0440 0649

Spare thermocouple 1200 mm

0430 0088

Seal ring for thermocouple, stainless steel

0170 0474

Clamping screw connection for thermocouple

0400 0083

Unheated gas sampling hose0554 3354

Spare filter element0133 0043

Replacement ceramic sampling tube 1.800 °C

0440 0669

Adapter for ceramic sampling tube

0190 0186

O-ring for adapter

0135 0312

31

0970 0394 en 04