i-Cons is a Peltier sample conditioner in a 19-inch cabinet with pump, filter, condensate and flow sensors, blowback and heated-hose control, and Modbus. It suits samples at 120 to 550 C and up to 60 C dew point, excluding HCl, HF and H2S. SGI-320 adds the analysers.
Why i-Cons and SGI-320
Less to design and wire
The components of a sampling panel come built in and pre-wired, which saves panel space and integration time.
Faults stopped before the analyser
The sample pump trips on condensate, blowback starts automatically on flow failure, and the system shuts down on a hardware fault.
Maintenance on schedule
Remaining life of filters, pump tubes and pump kits is tracked and reported over Modbus, with a reminder before replacement is due.
Specifications
| Item | Specification | Notes |
|---|---|---|
| Cooler | Peltier, one PTFE heat exchanger | Sample flow up to 240 LPH (4 LPM); outlet 5 C |
| Sample into the cooler | Up to 160 C; dew point up to 65 C; dust below 3 micron | |
| Fine filter | 0.1 micron coalescing | Long-life SS condensate sensor |
| Pump | Free flow 5 LPM with fast loop valve; optional 8 LPM | 8 LPM for sample lines of 60 to 90 m |
| Heated hose | 30, 45, 60, 75 or 90 m; 40 W/m, 230 V AC; 1/4 inch OD PTFE tube | Temperature set by user, Pt100 feedback |
| Inputs | Pt100 from the heated hose; digital inputs for calibration in progress, zero, span 1 and span 2 | Potential-free contacts from the analyser |
| Outputs | Triac for the heated hose SSR or contactor; relay 1 alarm or fault; relay 2 probe blowback valve | Relays SPST, 230 V AC 1 A |
| Communication | Modbus RTU over RS 485 | Read values, status, set-up and maintenance history; write set-up and operate calibration valves |
| Display | Backlit LCD, 4 x 20, with 7 keys | |
| Enclosure | 19 inch rack or panel, 310 x 483 x 285 mm, about 16 kg | Safe area, IP 20; 230 V AC 50 Hz, 600 VA excluding heat tracer; ambient 10 to 40 C |
| Wetted materials | SS316, PTFE, Viton, silicone, engineering plastic | |
| SGI-320 | Probe, heated line, conditioner and analysers as one system | NO, SO2, CO, CO2, O2; optional NOx converter and remote auto-calibration |
From the current Sarvesh product datasheets and company profile. Specifications may change without notice as products improve. The final responsibility to check that a product meets the process and analyser requirement remains with the customer.
Key features
- Plug-and-play complete sample handling system with menu-driven controller
- Built-in sample pump, peristaltic pump with auto-drain, condensate sensor, flow detector, auto-cal valves and fine filter
- Controls probe blowback, sample valve and heated hose; pulsating blowback; automatic blowback on flow failure
- Pump trips on condensate detection, during calibration and on hardware fault
- Fail-safe fault relay, alarm and fault history, maintenance reminders for filters, auto-drain tubes and pump
- Digital input from the analyser stops the pump during calibration
How it works
Most extractive analyser faults begin in the sample path. i-Cons treats the path as one system. It runs the blowback, keeps the heated hose at temperature, cools and dries the gas with a Peltier cooler, and trips the pump the moment it sees condensate or a flow failure. It records usage of consumables and prompts for replacement before they fail.
SGI-320 is the same engineering delivered as a ready-to-use analyser system: a sample probe with auto-blowback, a heated line, the conditioning and the analysers, with optional NOx converter and remote auto-calibration. It is described in detail on the stack and emission monitoring page.
Requirements and limits
- Not suitable for samples containing HCl, HF, H2S or other highly corrosive, toxic or flammable gases.
- Suitable for samples where SO2, NOx and CO are below 1000 ppm.
- Safe area only.
On site: utilities and calibration gases
What to have ready at your plant before installation and commissioning.
| Item | Requirement | Notes |
|---|---|---|
| Power | 230 V AC, 50 Hz, 600 VA for i-Cons, plus the analyser | Heat tracing excluded |
| Heated hose and probe | A separate power supply | |
| Instrument air | 1/2 inch connection at 6 bar near the tapping point | For probe blowback |
| Location | An air-conditioned, dust-free room for the analyser and i-Cons | |
| Calibration gases | Zero and span gases for the analysers, in 10 litre cylinders with regulators |
Options and ordering
- Probe: SP-200 unheated for low dew point samples, SP-300 heated for high dew point samples, or SP-300 with blowback tank; insertion length 500, 1000 or 1500 mm
- Prefabricated heated hose in 30, 45, 60, 75 or 90 m lengths
- Internal auto-calibration solenoid valves, 24 V DC: zero and span, zero and two spans, or zero and three spans
- Remote calibration check: Modbus commands switch the zero, span 1 and span 2 valves, as CPCB guidelines ask
- Catchpot or water separator with an external peristaltic pump controlled by i-Cons; high-flow sample pump for 60 to 90 m lines
Selection guidance
Choose i-Cons for combustion, flue gas, process and emission analysis where the sample is hot, wet or dusty and you want fewer components and diagnostics. Choose SGI-300 for a cooler only. Choose SGI-320 for a complete multi-gas emission system.
Applications
Application pages where this is part of the recommended solution:
- Stack and emission monitoring
- Boiler and furnace oxygen (flue gas)
- Thermal oxidiser and scrubber efficiency
- Steel plant process gases
- Pyrolysis, gasification and syngas
Compatible products
SP and SRP sample probes
Heated and non-heated probes with blowback, and retractable probes, in SS316, Inconel or ceramic.
View SP and SRP sample probes
ACCURRA-S
Online analyser for trace, percent and purity O2, CO, CO2, CH4 and dew point; can measure two gases from one sample.
View ACCURRA-S
ACCURRA-Zr
Zirconia percent O2 analyser for furnaces and boilers, single-point air calibration, options to 1400 C.
View ACCURRA-Zr
SGI-300 / SGI-320
Peltier sample cooler with integrated pump, filter and condensate detector; SGI-320 for emission monitoring.
View SGI-300 / SGI-320Frequently asked questions
What does i-Cons replace?
The usual sampling panel: cooler, pump, filter, condensate detector, flow detector and the control wiring between them.
How far can the sample line be?
Up to 60 m with the standard pump; the high-flow pump, 8 LPM free flow, supports 60 to 90 m.
Where can I not use it?
On samples containing HCl, HF or H2S, or other highly corrosive, toxic or flammable samples.
Is SGI-320 the same as i-Cons?
SGI-320 applies the i-Cons design to a complete emission monitoring system that includes the analysers.