Bühler technologies EGK 2-19 User manual

Analysentechnik
Installation and Operation Instructions
Original instructions
Sample gas cooler
EGK 2-19 (+)
BE450010
08/2017
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 2017
Document information
Document No..........................................................BE450010
Version......................................................................... 08/2017

EGK 2-19 (+)
Contents
1 Introduction..................................................................................................................................................................................................................... 2
1.1 Intended use ......................................................................................................................................................................................................... 2
1.2 Types .......................................................................................................................................................................................................................2
1.3 Scope of delivery.................................................................................................................................................................................................. 2
1.4 Ordering instructions ........................................................................................................................................................................................2
1.4.1 Gas cooler models with one heat exchanger ...............................................................................................................................2
1.4.2 Gas cooler models with two heat exchangers .............................................................................................................................3
1.4.3 Gas cooler type with two heat exchangers in series ................................................................................................................. 4
2 Safety instructions......................................................................................................................................................................................................... 5
2.1 Important advice................................................................................................................................................................................................. 5
2.2 General hazard warnings .................................................................................................................................................................................6
3 Transport and storage .................................................................................................................................................................................................. 7
4 Installation and connection........................................................................................................................................................................................8
4.1 Installation site requirements.........................................................................................................................................................................8
4.2 Installation ............................................................................................................................................................................................................8
4.2.1 Peristaltic pump connector (optional) .......................................................................................................................................... 8
4.3 Electrical connections ........................................................................................................................................................................................9
4.4 Signal outputs....................................................................................................................................................................................................10
5 Operation and control ................................................................................................................................................................................................. 11
5.1 Use of menu functions .....................................................................................................................................................................................11
5.1.1 Overview of the menu items........................................................................................................................................................... 12
5.1.2 Detailed description of the operational principle .................................................................................................................... 12
5.2 Description of menu functions ......................................................................................................................................................................13
5.2.1 Main menu........................................................................................................................................................................................... 13
5.2.2 Submenu............................................................................................................................................................................................... 13
6 Maintenance...................................................................................................................................................................................................................15
7 Service and repair......................................................................................................................................................................................................... 16
7.1 Troubleshooting ................................................................................................................................................................................................ 16
7.2 Safety instructions.............................................................................................................................................................................................17
7.3 Cleaning and removal of the heat exchanger........................................................................................................................................... 18
7.4 Replacing the fuse of the cooler.................................................................................................................................................................... 18
7.5 Replacing the hoses of the peristaltic pump (option) ............................................................................................................................ 19
7.6 Replacing the filter element (option) .......................................................................................................................................................... 19
7.7 Drying of the moisture detector (option)................................................................................................................................................... 19
7.8 Calibration of the moisture detector (option).......................................................................................................................................... 19
7.9 Spare parts and accessories .......................................................................................................................................................................... 20
7.9.1 Spare parts and accessories............................................................................................................................................................. 21
8 Disposal...........................................................................................................................................................................................................................22
9 Appendices..................................................................................................................................................................................................................... 23
9.1 Gas Cooler Technical Data ..............................................................................................................................................................................23
9.2 Technical Data - Options .................................................................................................................................................................................24
9.3 Heat exchanger..................................................................................................................................................................................................25
9.3.1 Heat exchanger description ............................................................................................................................................................25
9.3.2 Heat exchanger overview.................................................................................................................................................................25
9.4 Performance curves..........................................................................................................................................................................................26
9.5 Dimensions ......................................................................................................................................................................................................... 27
10 Attached documents...................................................................................................................................................................................................28
iBühler Technologies GmbHBE450010 ◦ 08/2017

EGK 2-19 (+)
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
1.4.1 Gas cooler models with one heat exchanger
The item number is a code for the configuration of your unit. Please use the following model key:
452 X X X X X X X X 0 Product characteristic
Gas cooler models (with 1 heat exchanger)
0 Wall mounting
1 19" rack installation
Supply voltage
1 115 V metric screw connections
2 230 V metric screw connections
3 115 V US screw connections
4 230 V US screw connections
Heat exchanger
0 0 without heat exchanger
1 1 Single stainless steel heat exchanger / (PTS and PTS-I)
1 2 Single glass heat exchanger / (PTG)
1 3 Single PVDF heat exchanger / (PTV and PTV-I)
Condensate drain
0 without condensate drain
1 1 CPsingle peristaltic pump with 90° elbow hose connection 1)
3 1 CPsingle peristaltic pump with straight hose connection 1)
Filter
0 Without filter
1 1 filter installed
Moisture detector 2)
0 Without moisture detector
1 1 moisture detector installed
Optional 2)
0 Without option
1 With 4 - 20 mA analogue output for temperature
1) Each heat exchanger is equipped with one peristaltic pump. The supply voltage corresponds with that of the main unit.
2) The “moisture detector” option includes the option “4 - 20 mA analogue output”.
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EGK 2-19 (+)
1.4.2 Gas cooler models with two heat exchangers
The item number is a code for the configuration of your unit. Please use the following model key:
452 X X X X X X X X 0 Product characteristic
Gas cooler models (with 2 heat exchangers)
0 Wall mounting
1 19" rack installation
Supply voltage
1 115 V metric screw connections
2 230 V metric screw connections
3 115 V US screw connections
4 230 V US screw connections
Heat exchanger
0 0 without heat exchanger
2 1 2 single stainless steel heat exchangers / (PTS and PTS-I)
2 2 2 single glass heat exchangers / (PTG)
2 3 2 single PVDF heat exchangers / (PTV and PTV-I)
Condensate drain
0 Without condensate drain
2 2 CPsingle peristaltic pumps with 90° elbow hose connection 1)
4 2 CPsingle peristaltic pumps with straight hose connection 1)
Filter
0 Without filter
1 1 filter installed
2 2 filters installed
Moisture detector 2)
0 Without moisture detector
1 1 moisture detector installed (only possible with 1 filter)
2 2 moisture detectors installed (only possible with 2 filter)
Optional 2)
0 Without option
1 With 4 - 20 mA analogue output for temperature
1) Each heat exchanger is equipped with one peristaltic pump. The supply voltage corresponds with that of the main unit.
2) The “moisture detector” option includes the option “4 - 20 mA analogue output”.
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EGK 2-19 (+)
1.4.3 Gas cooler type with two heat exchangers in series
The item number is a code for the configuration of your unit. Please use the following model key:
452 X X X X X X X X 0 Product characteristic
Gas cooler models (with 2 heat exchangers)
0 Wall mounting
1 19" rack installation
Supply voltage
1 115 V metric screw connections
2 230 V metric screw connections
3 115 V US screw connections
4 230 V US screw connections
Heat exchanger
0 0 Without heat exchanger
1 6 2 single glass heat exchangers/ (2x PTG-2)
1 7 2 single PVDF heat exchangers/ (2x PTV-2 or PTV-2-I)
Condensate drain
0 Without condensate drain
2 2 CPsingle peristaltic pumps with 90° elbow hose connection 1)
4 2 CPsingle peristaltic pumps with straight hose connection 1)
Filter
0 Without filter
1 1 filter installed
Moisture detector 2)
0 Without moisture detector
1 1 moisture detector installed (only possible with 1 filter)
Optional 2)
0 Without option
1 With 4 - 20 mA analogue output for temperature
1) Each heat exchanger is equipped with one peristaltic pump. The supply voltage corresponds with that of the main unit.
2) The “moisture detector” option includes the option “4 - 20 mA analogue output”.
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EGK 2-19 (+)
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.
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.
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
The product should only be transported inside the original packaging or a suitable alternative.
When not in use, the equipment must be protected from moisture and heat. They must be stored in a covered, dry and dust-free
room at a temperature between -20 °C and 60 °C.
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4 Installation and connection
4.1 Installation site requirements
The unit is only intended for use in enclosed areas in a 19” rack or wall-mounted. 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”).
4.2.1 Peristaltic pump connector (optional)
Coolers ordered with attached peristaltic pump already have it installed and wired. Heat exchangers ordered at the same time
are already installed and connected to the peristaltic pump.
The ø6 connection for the pump’s condensate output must be carefully and properly connected with a suitable hose and hose
clamp.
NOTICE
Installing peristaltic pumps CPsingle / CPdouble limits the maximum permissible oper-
ating pressure in the system!
Operating pressure ≤ 1 bar
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