Bühler technologies EGK 10 User manual

Gas Analysis
Installation and Operation Instructions
Original instructions
Sample gas cooler
EGK 10
BE450005
04/2021
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
E-Mail: [email protected]
Internet: www.buehler-technologies.com

Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
Internet: www.buehler-technologies.com
E-Mail: [email protected]
Read this instruction carefully prior to installation and/or use. Pay at-
tention particularly to all advises and safety instructions to prevent in-
juries. Bühler Technologies can not be held responsible for misusing
the product or unreliable function due to unauthorised modifications.
All rights reserved. Bühler Technologies GmbH 2021
Document information
Document No..........................................................BE450005
Version......................................................................... 04/2021

EGK 10
Contents
1 Introduction..................................................................................................................................................................................................................... 2
1.1 Intended use .........................................................................................................................................................................................................2
1.2 Types .......................................................................................................................................................................................................................2
1.3 Scope of delivery.................................................................................................................................................................................................. 2
1.4 Ordering Instructions......................................................................................................................................................................................... 2
2 Safety instructions......................................................................................................................................................................................................... 3
2.1 Important advice................................................................................................................................................................................................. 3
2.2 General hazard warnings .................................................................................................................................................................................4
3 Transport and storage .................................................................................................................................................................................................. 5
4 Installation and connection ........................................................................................................................................................................................6
4.1 Installation site requirements.........................................................................................................................................................................6
4.2 Installation ............................................................................................................................................................................................................6
4.3 Electrical connections ........................................................................................................................................................................................ 7
5 Operation and control ..................................................................................................................................................................................................9
5.1 Use of menu functions ......................................................................................................................................................................................9
5.1.1 Overview of the menu items...........................................................................................................................................................10
5.1.2 Detailed description of the operational principle ....................................................................................................................10
5.2 Description of menu functions ......................................................................................................................................................................11
5.2.1 Main menu............................................................................................................................................................................................11
5.2.2 Submenu................................................................................................................................................................................................11
6 Maintenance...................................................................................................................................................................................................................12
7 Service and repair..........................................................................................................................................................................................................13
7.1 Troubleshooting .................................................................................................................................................................................................13
7.2 Safety instructions............................................................................................................................................................................................ 14
7.3 Opening the housing ........................................................................................................................................................................................15
7.4 Replacing the fuse of the cooler.................................................................................................................................................................... 16
7.5 Replacing the fan................................................................................................................................................................................................17
7.6 Replacing the power supply board .............................................................................................................................................................. 18
7.7 Replacing the controller board MCP1 .......................................................................................................................................................... 18
7.8 Replacing the display ....................................................................................................................................................................................... 19
7.9 Cleaning and removal of the heat exchanger........................................................................................................................................... 19
7.10 Replacing the hoses of the peristaltic pump (option) ............................................................................................................................ 19
7.11 Spare parts and accessories .......................................................................................................................................................................... 20
7.11.1 Spare Parts and Accessories ...........................................................................................................................................................20
8 Disposal............................................................................................................................................................................................................................21
9 Appendices.....................................................................................................................................................................................................................22
9.1 Technical Data....................................................................................................................................................................................................22
9.2 Flow parameter TS10 ........................................................................................................................................................................................22
9.3 Dimensions .........................................................................................................................................................................................................23
10 Attached documents...................................................................................................................................................................................................24
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1 Introduction
1.1 Intended use
This unit is intended for industrial use in gas analysis systems. It's an essential component for conditioning the sample gas to
protect the analysis instrument from residual moisture in the sample gas.
Please note the specifications in the data sheet on the specific intended use, existing material combinations, as well as pressure
and temperature limits.
1.2 Types
The device is delivered with different configurations. The part number given on the type plate informs you about the specific
configuration of your device.
1.3 Scope of delivery
– Cooler
– Product documentation
– Connection-/mounting accessories (optional)
1.4 Ordering Instructions
The item number is a code for the configuration of your unit. Please use the following model key:
Please note: Every individual gas path must be equipped with peristaltic pump or condensate drain.
4569 X X X X 0 0 0 X Product Characteristics
Voltage
1 115 V
2 230 V
Gas path / Material / Version
0 0 0 without heat exchanger
1 1 0 Single heat exchanger / stainless steel / TS10 G 3/8"
1 1 1 Single heat exchanger / stainless steel / TS10 NPT 3/8"
1 2 1 Single heat exchanger / glass coated inside / TS10 GB NPT 3/8"
Condensate drain 1)
0 without condensate drain
Mounting Accessories
0 without mounting accessories
1 with mounting accessories
2 with feet
3 with mounting accessories and feet
4 with handles
5 with mounting brackets and handles
6 with feet and handles
7 with all mounting accessories
1) Peristaltic pumps cannot be mounted to the cooler. Peristaltic pumps only available for separate installation.
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2 Safety instructions
2.1 Important advice
Operation of the device is only valid if:
– the product is used under the conditions described in the installation- and operation instruction, the intended application
according to the type plate and the intended use. In case of unauthorized modifications done by the user Bühler Technolo-
gies GmbH can not be held responsible for any damage,
– when complying with the specifications and markings on the nameplates.
– the performance limits given in the datasheets and in the installation- and operation instruction are obeyed,
– monitoring devices and safety devices are installed properly,
– service and repair is carried out by Bühler Technologies GmbH,
– only original spare parts are used.
This manual is part of the equipment. The manufacturer keeps the right to modify specifications without advanced notice. Keep
this manual for later use.
Signal words for warnings
DANGER
Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.
WARNING
Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not
avoided.
CAUTION
Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property or
minor or medium injuries if not avoided.
NOTICE
Signal word for important information to the product.
Warning signs
These instructions use the following warning signs:
Warns of a general hazard General information
Warns of voltage Unplug from mains
Warns not to inhale toxic gasses Wear respiratory equipment
Warns of corrosive liquids Wear a safety mask
Warns of explosive areas Wear gloves
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2.2 General hazard warnings
The equipment must be installed by a professional familiar with the safety requirements and risks.
Be sure to observe the safety regulations and generally applicable rules of technology relevant for the installation site. Prevent
malfunctions and avoid personal injuries and property damage.
The operator of the system must ensure:
– Safety notices and operating instructions are available and observed,
– The respective national accident prevention regulations are observed,
– The permissible data and operational conditions are maintained,
– Safety guards are used and mandatory maintenance is performed,
– Legal regulations are observed during disposal,
– compliance with national installation regulations.
– the device is protected from mechanical loads.
Maintenance, Repair
Please note during maintenance and repairs:
– Repairs to the unit must be performed by Bühler authorised personnel.
– Only perform conversion-, maintenance or installation work described in these operating and installation instructions.
– Always use genuine spare parts.
– Do not install damaged or defective spare part. If necessary, visually inspect prior to installation to determine any obvious
damage to the spare parts.
Always observe the applicable safety and operating regulations in the respective country of use when performing any type of
maintenance.
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
DANGER Toxic, corrosive gas/condensate
Sample gas/condensate may be hazardous to health.
a) If necessary, ensure a safe gas/condensate discharge.
b) Always disconnect the gas supply when performing maintenance or repairs.
c) Protect yourself from toxic/corrosive gasses/condensate when performing mainten-
ance. Wear appropriate protective equipment.
DANGER Potentially explosive atmosphere
Explosion hazard if used in hazardous areas.
The device is not suitable for operation in hazardous areas with potentially explosive at-
mospheres.
Do not expose the device to combustible or explosive gas mixtures.
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3 Transport and storage
Only transport the product inside the original packaging or a suitable alternative.
The equipment must be protected from moisture and heat when not in use. It must be stored in a covered, dry and dust-free
room at a temperature of -20 °C to 60 °C (-4 °F to 140 °F).
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4 Installation and connection
4.1 Installation site requirements
The unit is intended for wall-mounted or table-top use in enclosed areas. Adequate protection from the weather must be
provided when used outdoors.
Install the unit leaving enough room below the cooler to discharge the condensate. Leave room above for the gas supply.
Be sure to maintain the approved ambient temperature. Do not obstruct the convection of the cooler. The vents must have
enough room to the next obstacle. The distance must especially be a minimum of 10 cm on the air outlet side.
Ensure adequate ventilation when installing in enclosed housings, e.g. analyser cabinets. If the convection is inadequate, we re-
commend aerating the cabinet or installing a fan to lower the inside temperature.
4.2 Installation
Run the gas supply to the cooler with a downward slope. The gas inputs are marked in red and additionally labelled "IN".
If a large amount of condensate accumulates, we recommend using a condensate trap with automatic condensate drain. Our
condensate drains, 11 LD spec., AK 20 V, or model 165 SS, are suitable.
Glass vessels and automatic condensate drains are available for draining condensate for external mounting below the unit.
When using automatic condensate drains, the sample gas pump must be installed upstream of the cooler (pressure operation)
to ensure proper function of the condensate drain.
If the sample gas pump is located at the cooler outlet (suction operation), we recommend using glass condensate traps or peri-
staltic pumps.
Connecting the condensate drains
Depending on the material, build a connecting line with fittings and tubing or hose between the heat exchanger and condens-
ate drain. For stainless steel the condensate drain can be suspended directly to the connecting tube, for hoses the condensate
drain must be secured separately using a clamp.
The condensate drain can be mounted directly to the heat exchanger.
Condensate lines must always be installed with a slope and a minimum inside diameter of DN 8/10 (5/16”).
Peristaltic pump (optional)
A peristaltic pump may also be installed a little away from the cooler. The bottom of the cooler has two rivet M4 nuts designated
for installing the pump directly below the cooler.
NOTICE
Installing peristaltic pumps CPsingle / CPdouble limits the maximum permissible oper-
ating pressure in the system!
Operating pressure ≤ 1 bar
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4.3 Electrical connections
The operator must install an external separator for the device which is clearly assigned to this device.
This separator
– must be located near the device,
– must be easy for the operator to reach,
– must comply with IEC 60947-1 and IEC 60947-3,
– must separate all live conductors and the status output, and
– must not be attached to the power feed.
WARNING Hazardous electrical voltage
The device must be installed by trained staff only.
CAUTION Wrong mains voltage
Wrong mains voltage may damage the device.
Regard the correct mains voltage as given on the type plate.
WARNING High voltage
Damage to the device in case of insulation testing
Do not proceed insulation tests with high voltage to the device as a whole!
Insulation test
The device is equipped with extensive EMC protection. If insulation tests are carried out the electronic filter devices will be dam-
aged. All necessary tests have been carried out for all concerned groups of components at the factory (test voltage 1 kV or 1.5 kV
respectively, depending on the device).
If you wish to carry out the insulation test by yourself, please test only separate groups of components.
Disconnect the compressor, the fan, the heating or the peristaltic pumps, respectively, and then carry out the insulation tests.
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Plug connection
This device has one EN 175301-803 plug each for the power supply and the signal output. If the lead is connected correctly, these
cannot be confused. Therefore please be sure to correctly reassemble the plugs after connecting the wires. Below you will find
the pin assignments, with the numbers corresponding to those on the plugs:
The supply line cross-sections must be suitable for the rated current. Use a maximum line cross-section of 1.5mm² (AWG16) and
a cable diameter of 8-10mm (0.31-0.39 inch).
power supply
status output
pin assignment
function ok
alarm
Fig.1: A05-100002 Cooler electric supply
The mains supply must be protected with 16 A. The clamping area has a diameter of 8-10mm (0.31-0.39in). If the unit is
equipped with peristaltic pump it must be connected to a power source per the specifications in the respective operating in-
structions.
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5 Operation and control
NOTICE
The device must not be operated beyond its specifications.
After switching on the cooler the block temperature will be displayed. The display will flash until the block temperature has
reached the preset target value (± adjustable alarm range). The status contact is in the Alarm position.
Once the target temperature range has been reached, the temperature will continuously be displayed and the status contact
switches over.
If the display flashes during operation or an error message appears, please refer to bullet “Troubleshooting”.
Please refer to the data sheet for performance data and maximum ratings.
5.1 Use of menu functions
Overview of the operational principal:
Use this short description if you have experience with the device.
Operation is carried out by only the keys with the following functions:
Key Function
– Switch from measurement display to main menu
– Selection of the display menu item
– Accepting the changed value or selection
– Switch to the upper menu item
– Increase of the value of switching the selection
– Temporary display of the alternative measurement display (if option is installed)
– Switch to lower menu item
– Decrease of the value of switching the selection
– Temporary display of the alternative measurement display (if option is installed)
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5.1.1 Overview of the menu items
Displayed is the block temperature with a resolution of 0,5°C/0.75 °F. By pressing the Enter button brings the
display to the Main Menu. The unit of temperature is adjustable in the menu Global Settings (Celsius or Fahrenheit).
store value
adjust value
wait 5s: no storage
Set unit Celsius or Fahrenheit
____ ____
____
____
____
____
____
____
____
____
____
____
____
____
E1_2
Display of current temperature and operating state
Main Menu Submenu Setting range
Display ____
Current temperature
Parameter
Parameter
Temperature
Display
Alarm high
Parameter
Alarm Low
Parameter
Top Settings
Exit
Exit
Cooler display Set temperature
Alarm hysteresis Upper alarm
Cooler temperature
Lower alarm
Alarm hysteresis
Exit Submenu
Global Settings
Exit Main Menu
Adjust the set point:
2°C...20°C / 35.6°F...68°F
Set the upper alarm threshold above
setpoint: tEMP 1°C...7°C / 1.8°F...12.6°F
Set the lower alarm threshold below
setpoint: tEMP -1°C...-3°C / -1.8...-5.4F
tEMP
A Hi
A Lo
E
___
___
____
C
toP
E
C - F
5.1.2 Detailed description of the operational principle
The detailed description will guide you through the menu step by step.
Connect the unit to the power supply and wait for the startup procedure to complete. At first the software version im-
plemented on the unit will be displayed for a brief period. The unit will then switch directly into measured value dis-
play.
Pressing the button will take you from display mode to the main menu. (The control will continue running whilst in
menu mode.)
Use these buttons to navigate the main menu.
After confirming a main menu item the associated submenu will open
Here you can configure operating parameters:
Cycle through the submenu to configure the parameters,
then confirm the menu item to be changed.
You can now set values within specific limits.
After confirming the value the system will save it. This will automatically return you to the submenu.
If no button is pushed for approx. 5 s, the unit will automatically return to the submenu. Changes to values will not be
saved.
The same applies to the sub- and main menu. The system will automatically return to display mode without saving
the (last) value changed. Parameters which were previously changed and saved will be retained and not reset.
NOTICE!After saving values with the Enter key they will be applied to the control.
ETo exit the main or submenu, select menu item E (Exit).
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5.2 Description of menu functions
5.2.1 Main menu
Cooler
From here you will be able to access to all relevant cooler settings. The related submenu allows you
to select the target temperature and alarm thresholds.
Globale settings (ToP Settings)
Selection of the global temperature unit, either degree Celsius (C) or degree Fahrenheit (F).
Note: This menu item has no sub-item. The temperature unit is directly selected.
Exit main menu
Display → E
Selecting this will return you to display mode.
5.2.2 Submenu
Cooler -> nominal temperature (temperature)
This setting determines the nominal temperature for the cooler temperature. The value can be set to
a range from 2 °C (35.6 °F) to 20 °C (68 °F).
Note: The standard value at delivery is 5 °C (41 °F) (unless otherwise agreed). If the temperature is changed
the indicator may blink, until the new operating range has been reached.
Cooler -> upper alarm limit (alarm high)
Here you can set the upper threshold for the visual signal and the alarm relay. The alarm limit is set
to a range from 1 °C (1.8 °F) to 7 °C (12.6 °F) in relation to the cooler temperature setting.
Note: The standard value at delivery is 3 °C (5.4 °F) (unless otherwise agreed).
Cooler -> lower alarm limit (alarm low)
Here you can set the lower threshold for the visual signal and the alarm relay. The alarm limit is set
to a range from -1 °C (-1.8 °F) to -3 °C (-5.4 °F) in relation to the cooler temperature setting.
Note: The standard value at delivery is -3 °C (-5.4 °F) (unless otherwise agreed).
Exit submenu
Selecting this item returns to the main menu.
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6 Maintenance
The basic version of the cooler requires no special maintenance.
However, it may have different options depending on the cooler model. In this case the following maintenance must be per-
formed regularly:
–Optional peristaltic pump: Check hoses
During maintenance, remember:
– The equipment must be maintained by a professional familiar with the safety requirements and risks.
– Only perform maintenance work described in these operating and installation instructions.
– When performing maintenance of any type, observe the respective safety and operation regulations.
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
DANGER Toxic, corrosive gas/condensate
Sample gas/condensate may be hazardous to health.
a) If necessary, ensure a safe gas/condensate discharge.
b) Always disconnect the gas supply when performing maintenance or repairs.
c) Protect yourself from toxic/corrosive gasses/condensate when performing mainten-
ance. Wear appropriate protective equipment.
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7 Service and repair
This chapter contains information on troubleshooting and correction should an error occur during operation.
Repairs to the unit must be performed by Bühler authorised personnel.
Please contact our Service Department with any questions:
Tel.: [phone] or your agent
If the equipment is not functioning properly after correcting any malfunctions and switching on the power, it must be inspected
by the manufacturer. Please send the equipment inside suitable packaging to:
Bühler Technologies GmbH
- Reparatur/Service -
Harkortstraße 29
40880 Ratingen
Germany
Please also attach the completed and signed RMA decontamination statement to the packaging. We will otherwise be unable to
process your repair order.
You will find the form in the appendix of these instructions, or simply request it by e-mail:
[email protected].
7.1 Troubleshooting
Problem / Malfunction Possible cause Action
No display – Mains voltage interrupted – Connect to mains; verify
– the plug is inserted correctly
– Fuse defective – Check fuse and replace, if necessary
Cooler doesn’t start up – Compressor housing temperature too high – Allow to cool down and ensure adequate
ventilation
Display flashes due to:
– Excess temperature – Operating point not yet reached – Wait (max. 20 min)
– Cooling output too low despite the cooler
running
– Ensure the vents are not covered (heat
buildup)
– Flow rate / dew point / gas temperature too
high
– Maintain limits / install pre-separator
– Built-in fan stopped – Check and replace if necessary
– Temperature low – Control unit failure – Send in cooler
Condensate inside the gas
output
– Condensate trap full – Empty condensate trap
– Valve inside the automatic condensate drain
may be stuck
– Flush in both directions
– Cooler overload – Maintain limits
Reduced gas flow rate – Gas circuit clogged – Remove and clean heat exchanger
– Condensate output iced over – Send in cooler
No cooling – Compressor doesn’t start up – Compressor PTC not cooled down sufficiently.
Wait 5 minutes and try again.
Fuse is triggering – Increased compressor current consumption
due to faulty compressor start-up
– Compressor PTC not cooled down sufficiently.
Wait 5 minutes and try again.
Error Messages in the Display
The display alternates between the temperature and error message,
Problem / Malfunction Possible cause Action
Error 01 – Interruption – Temperature sensor failure: Send in cooler
Error 02 – Short circuit – Temperature sensor failure: Send in cooler
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7.2 Safety instructions
– The device must be operated within its specifications.
– All repairs must be carried out by Bühler authorised personnel only.
– Only perform modifications, servicing or mounting described in this manual.
– Only use original spare parts.
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
DANGER Toxic, corrosive gas/condensate
Sample gas/condensate may be hazardous to health.
a) If necessary, ensure a safe gas/condensate discharge.
b) Always disconnect the gas supply when performing maintenance or repairs.
c) Protect yourself from toxic/corrosive gasses/condensate when performing mainten-
ance. Wear appropriate protective equipment.
CAUTION Health hazard in case of leaking cooling circuit / heat exchanger
The cooling circuit is filled with coolant R134a.
The heat exchanger is filled with a coolant based on glycol.
In case of leaking / broken cooling circuit / heat exchanger:
a) Avoid contact with skin or eyes.
b) Do not ingest or inhale coolant.
ðDue to the small amount of coolant no health hazards need be feared.
ðDo not put the device back to operation if leakage of the cooling circuit happend.
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7.3 Opening the housing
– Close gas supply.
– Switch off and unplug the device.
– Disconnect gas connections
– Loosen the screws on the cover.
– Lift off cover:
– All components are now freely accessible.
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Fig.2: A100036 EGK 10 Overview
1 Heat exchanger sample gas (filled with glycol-based
coolant)
5 Mains plug
2 Display ABT 400 6 Alarm plug
3 Compressor with closed cooling circuit, charged with
R134a
7 Liquefier
4 Electronics with power/control board, fuse and MCP1 8 Fan
7.4 Replacing the fuse of the cooler
– Open the device as described in chapter Opening the housing [> page15].
– The fuse is placed on the PBC beneath a plastic cap. Replace the fuse and push down the plastic cap. Regard the supply
voltage for selecting the correct value of the fuse.
Example:
– Fix the cover. Fasten the screws.
– Reconnect hoses.
– Reconnect power supply.
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7.5 Replacing the fan
– Open the device as described in chapter Opening the housing [> page15].
– For better accessibility to the fan, remove the electronics. For this, unscrew the screws at the bottom of the housing and re-
move the card holder.
– Disconnect the plug at the fan.
– Remove the 2 screws on the left and right side of the fan.
– Replace the fan and reassemble the device in reverse order.
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7.6 Replacing the power supply board
– Open the device as described in chapter Opening the housing [> page15].
– Remove all cables.
– Terminal diagram EGK:
no jumper set
Heating
Fan
Compressor
Peristaltic pump
Peristaltic pump
Fig.3: A100042 Power supply board
– Unscrew the screws at the corners of the PCB.
– Replace the power supply board and reassemble the device in reverse order.
7.7 Replacing the controller board MCP1
– Open the device as described in chapter Opening the housing [> page15].
– Pull the controller board MCP1 of the power supply board.
– Insert the new MCP1. Regard the mounting direction: The electronics components must point upwards!
– Reassemble the device in reverse order.
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