Bühler technologies CU-EMA+ Owner's manual

Gas Analysis
Installation and Operation Instructions
Original instructions
Cooling unit
CU-EMA+
BE440029
10/2020
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 2020
Document information
Document No......................................................... BE440029
Version.........................................................................10/2020

CU-EMA+
Contents
1 Introduction..................................................................................................................................................................................................................... 2
1.1 Intended use .........................................................................................................................................................................................................2
1.2 Overview ................................................................................................................................................................................................................2
1.3 Scope of delivery.................................................................................................................................................................................................. 2
1.4 Ordering instructions ........................................................................................................................................................................................ 3
1.4.1 Cooler with Two In-Line Heat Exchangers.....................................................................................................................................3
2 Safety instructions.........................................................................................................................................................................................................4
2.1 Important advice.................................................................................................................................................................................................4
2.2 General hazard warnings ................................................................................................................................................................................. 5
3 Transport and storage ..................................................................................................................................................................................................6
4 Installation and connection ........................................................................................................................................................................................ 7
4.1 Installation site requirements......................................................................................................................................................................... 7
4.2 Installation ............................................................................................................................................................................................................ 7
4.3 Electrical connections ........................................................................................................................................................................................8
4.3.1 Connection ............................................................................................................................................................................................ 9
4.4 Gas Connections ..................................................................................................................................................................................................9
5 Operation and control ................................................................................................................................................................................................. 11
5.1 Description of functions................................................................................................................................................................................... 11
5.2 Use of menu functions .................................................................................................................................................................................... 12
5.2.1 Lock Menu.............................................................................................................................................................................................12
5.2.2 Menu navigation overview.............................................................................................................................................................. 13
5.3 Description of menu functions ......................................................................................................................................................................15
5.3.1 Main menu........................................................................................................................................................................................... 15
5.3.2 Submenu 1 ............................................................................................................................................................................................16
5.3.3 Submenu 1 (global settings)............................................................................................................................................................ 17
5.3.4 Set favourite menu ............................................................................................................................................................................19
5.3.5 Description of Other Options..........................................................................................................................................................19
6 Maintenance..................................................................................................................................................................................................................20
6.1 Maintenance Intervals..................................................................................................................................................................................... 21
6.2 Cleaning ............................................................................................................................................................................................................... 21
7 Service and repair.........................................................................................................................................................................................................22
7.1 Troubleshooting ................................................................................................................................................................................................22
7.1.1 Error messages on the display........................................................................................................................................................23
7.2 Safety instructions............................................................................................................................................................................................24
7.3 Replacing the hose of the peristaltic pump...............................................................................................................................................25
7.4 Cleaning and Calibrating the Moisture Detector ....................................................................................................................................25
7.5 Cleaning and removal of the heat exchanger...........................................................................................................................................25
7.6 Replacing the Microfuse for the Expansion Module/Regulator..........................................................................................................26
7.7 Replacing the Solenoid Valve.........................................................................................................................................................................27
7.8 Replacing the Relays.........................................................................................................................................................................................27
7.9 Spare parts and accessories ...........................................................................................................................................................................27
7.9.1 Spare parts and accessories.............................................................................................................................................................27
8 Disposal...........................................................................................................................................................................................................................28
9 Appendices.....................................................................................................................................................................................................................29
9.1 Flow Diagram .....................................................................................................................................................................................................29
9.2 Technical Data....................................................................................................................................................................................................30
9.3 Technical Data - Options.................................................................................................................................................................................30
9.4 Outlet.....................................................................................................................................................................................................................31
9.4.1 Heat exchanger description ............................................................................................................................................................ 31
9.4.2 Heat exchanger overview................................................................................................................................................................. 31
9.5 Dimensions .........................................................................................................................................................................................................32
10 Attached documents................................................................................................................................................................................................... 33
iBühler Technologies GmbHBE440029 ◦ 10/2020

CU-EMA+
1 Introduction
1.1 Intended use
This device is an essential component for conditioning the sample gas to protect the downstream analysis instrument from re-
sidual 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 Overview
The CU-EMA+ cooler was designed specifically for the requirements of gas conditioning for continuously measuring emissions
in maritime applications. Dividing the unit into an internal and external section achieves the IP rating required under the stand-
ard without requiring venting the interior. The series connection of the heat exchangers will cool in two cycles to minimise wash
out effects.
The exact item number of the model defined by you is determined by the model code in the category ordering information.
The gas cooler comes standard with peristaltic pump and moisture detector. Additional components which every conditioning
system should feature can optionally be connected:
– Connection for adding instrument air to purge the system,
– Solenoid valve for adding test gas,
– Heated line connection and regulation,
– metric/US style external connections.
Here the approach is to simplify creating a complete system in a cost-efficient way through pre-installed components with
hoses connected. We further paid attention to easy access to wear parts and consumables.
1.3 Scope of delivery
– Cooler unit
– Product documentation
– Heated line (optional)
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1.4 Ordering instructions
1.4.1 Cooler with Two In-Line Heat Exchangers
The item number is a code for the configuration of your unit. Please use the following model code:
4496 2 8 2 2 0 X 1 X X 2 0 0 X 0 0 X X X Product Characteristics
Cooler (with 2 in-line heat exchangers)
2 CU-EMA+: Ambient temperature 50 °C
Certifications
0 Standard applications – CE
Supply voltage
1 115 VAC, 50/60 Hz
2 230 VAC, 50/60 Hz
Heat exchanger
1 2 2 Glass, 2 x MTG-2, metric
1 2 7 Glass, 2 x MTG-2-I, US
1 3 2 PVDF, 2 x MTV-2, metric
1 3 7 PVDF, 2 x MTV-2-I, US
Peristaltic Pumps
2 0 CPdouble with hose nipple, angled
Moisture detector
0 0 0 0 without moisture detector
0 1 0 0 1 moisture detector with adapter
Options
0 0 Without option
0 1 Instrument air purging connection
1 0 Solenoid valve for test gas
1 1 Instrument air purging connection and solenoid valve for test gas
Heated line
0 no heated line
1 ready for self-regulating heated line
2 -
3 -
4 -
5 ready for regulated heated line
65 m regulated heated line *
78 m regulated heated line *
810 m regulated heated line
915 m regulated heated line
*for 115 VAC only these lengths available
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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.
Any unauthorised changes or modifications will void the EU declaration of conformity and approvals of the system.
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
In this manual, the following warning signs are used:
Warning against hazardous situations General notice
Warning against electrical voltage Disconnect from mains
Warning against respiration of toxic gases Wear respirator
Warning against acid and corrosive substances Wear eye/face protection
Warning against potentially explosive atmospheres Wear protection gloves
Warning against hot surface
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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.
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 Electric voltage
Risk of electric shock
a) Always disconnect the unit from the mains before working on it. After shutting off
the power, allow a discharge time of at least 5seconds.
b) Secure the device from accidental restarting.
c) The unit may only be opened by trained, competent personnel.
d) Ensure the correct voltages supply.
DANGER Toxic, corrosive gas/condensate
Sample gas/condensate may be hazardous to health.
a) Purge the device with inert gas or air (only when non-flammable gases inside the gas
path) for some time before connecting the lines or performing maintenance.
b) If necessary, ensure a safe gas/condensate discharge.
c) Check the lines in and on the device for leaks.
d) Always disconnect the gas supply when performing maintenance or repairs.
e) Protect yourself from toxic/corrosive gasses/condensate when performing mainten-
ance. Wear suitable 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.
CAUTION Hot surface
Burning hazard
Let the device cool down before maintaining.
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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. They must be stored in a covered, dry and dust-free
room at a temperature between -20°C to 40°C (-4°F to 104°F).
CAUTION Health hazard/tipping hazard
Transport and carry the products in a way which is not damaging to health.
a) If necessary, use aids to facilitate transport and installation.
b) Avoid damage to the product. Handle the product with care.
c) Avoid sudden acceleration.
d) Do not turn the device upside down or stack other items on top of it.
e) Please note the warnings on the packaging (such as "This Side Up", "Fragile", etc.).
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4 Installation and connection
4.1 Installation site requirements
The following requirements must be met during installation:
– Never install the device near sources of heat or vibration, in direct sunlight, or near high frequencies or magnetic fields. The
operator must install a lightning arrester and overvoltage protection.
– Consider the electromagnetic compatibility of nearby equipment when selecting the installation site.
– To maintain electrical safety, never operate the device in atmospheres with an oxygen content above 21 %.
– The device must be anchored to the wall, which must be able to support the weight.
– Please refer to chapter Appendix/Technical Data for the max. ambient temperature. Operation outside the limits will void
the warranty for this device.
– Do not obstruct the convection of the device. Leave adequate space between the vents and the nearest object. The clearance
must especially be a minimum of 10 cm on the air outlet side. The air intake and outlet must be clear. Heat may otherwise
build up.
– Protect from shock and impact.
– Never expose the display components to external forces.
– Never install the device outdoors.
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.
4.2 Installation
Install the device in the specified position, see chapter Dimensions [> page32].
CAUTION Damage/installation
Avoid damage to the product. Handle the product with care.
If wall brackets are required for installing the device, ensure these meet DIN EN 61010-1.
NOTICE Please note:
At the time of delivery, the device has a leak rate of less than 1.5mbar/h at a test pres-
sure of 160mbar and an ambient temperature of 20°C.
Check the system for leaks following transport and installation before starting it. The op-
erator must include this in his risk/safety assessment and if necessary take additional
measures to prevent explosion and/or health hazards.
When changing the factory settings, please document the factory presets as well as the
changed values.
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4.3 Electrical connections
All connection lines can be fed into the device through the cable glands at the bottom.
Include strain relief for the connection cables. The supply line cross-sections must be suitable for the rated current and meet
local regulations.
The signal and supply lines of the device must be properly connected.
Please note the clamping points of the following cable glands:
Thread Clamping range
M25 11.0mm – 17.0mm
M20 6.0mm – 12.0mm
Run the lines so the insulation will not be damaged. If necessary, secure the lines with suitable means and avoid excess line
lengths.
The power supply must be connected as per chapter Connection [> page9] or per the wiring diagrams.
The power and voltage supply for the components may require the following separators:
RCD, main switch and circuit breaker or fuses
If applicable, the following requirements must be met for operation:
– The RCD must shut off the load within the prescribed period (200 ms at 115 VAC, 40 ms at 230 VAC). It must be suitable for the
maximum load.
– The main switch must be installed near the device, easy to access and marked as a separator.
– The circuit breaker/fuses protect all supply lines but not the earth conductor.
The fuses should be arranged side by side, have the same rating/characteristic, and not be connected to the neutral wire of
multi-phase equipment.
Please refer to chapter Technical Data [> page30] for the applicable separator data.
DANGER Electric voltage
Risk of electric shock
a) Always disconnect the unit from the mains before working on it. After shutting off
the power, allow a discharge time of at least 5seconds.
b) Secure the device from accidental restarting.
c) The unit may only be opened by trained, competent personnel.
d) Ensure the correct voltages supply.
DANGER Potential equalisation
Connect the system’s potential equalisation to the potential equalisation on site. Stray
electric currents may not flow through this connection.
WARNING Hazardous electrical voltage
The device must be installed by trained staff only.
WARNING Electric voltage
Insulation test will damage the device
Do not test the electric strength if the entire unit is under high voltage!
CAUTION Wrong mains voltage
Wrong mains voltage may damage the device.
Regard the correct mains voltage as given on the type plate.
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