Bühler technologies EGK 2A Ex User manual

Gas Analysis
Installation and Operation Instructions
Original instructions
Sample gas cooler
EGK 2A Ex
BE450020
01/2020
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......................................................... BE450020
Version.........................................................................01/2020

EGK 2A Ex
Contents
1 Introduction..................................................................................................................................................................................................................... 3
1.1 Intended use .........................................................................................................................................................................................................3
1.2 Design types.......................................................................................................................................................................................................... 3
1.3 Type plate .............................................................................................................................................................................................................. 3
1.4 Scope of delivery.................................................................................................................................................................................................. 3
1.5 Ordering instructions ........................................................................................................................................................................................4
2 Safety instructions.........................................................................................................................................................................................................6
2.1 Important notices................................................................................................................................................................................................6
2.2 General hazard warnings ................................................................................................................................................................................. 7
3 Product description .......................................................................................................................................................................................................9
3.1 General description ............................................................................................................................................................................................9
3.2 Functional principle of the cooler ..................................................................................................................................................................9
4 Transport and storage ................................................................................................................................................................................................ 10
5 Installation and connection ....................................................................................................................................................................................... 11
5.1 Installation site requirements........................................................................................................................................................................ 11
5.2 Connecting the gas- and condensate connections ..................................................................................................................................11
5.3 Peristaltic pump connector (optional)........................................................................................................................................................ 12
5.4 Electrical connections and potential equalisation.................................................................................................................................. 12
5.5 Testing insulation resistance......................................................................................................................................................................... 14
6 Operation and controls ...............................................................................................................................................................................................15
6.1 Switching on the sample gas cooler .............................................................................................................................................................15
6.2 Use of menu functions .................................................................................................................................................................................... 16
6.2.1 Menu navigation overview..............................................................................................................................................................16
6.2.2 Detailed description of the operational principle .................................................................................................................... 17
6.3 Description of menu functions ......................................................................................................................................................................17
6.3.1 Main menu........................................................................................................................................................................................... 17
6.3.2 Submenu...............................................................................................................................................................................................18
7 Maintenance.................................................................................................................................................................................................................. 19
7.1 Maintenance Schedule ................................................................................................................................................................................... 20
7.2 Maintenance...................................................................................................................................................................................................... 20
7.2.1 Testing the pressure monitoring circuit.....................................................................................................................................20
7.2.2 Cleaning the condenser (air heat exchanger)............................................................................................................................ 21
7.3 Parts replacement............................................................................................................................................................................................. 21
7.3.1 Replacing the heat exchanger ........................................................................................................................................................ 21
7.3.2 Replacing the Pt100 ...........................................................................................................................................................................21
7.3.3 Replacing the electronics ................................................................................................................................................................ 22
7.3.4 Replacing the starting capacitor................................................................................................................................................... 22
7.3.5 Replacing the display ........................................................................................................................................................................23
7.3.6 Replacing the hoses of the peristaltic pump (option) .............................................................................................................23
7.3.7 Replacing the Peristaltic Pump (Optional)..................................................................................................................................23
8 Service and repair.........................................................................................................................................................................................................24
8.1 Troubleshooting ................................................................................................................................................................................................24
8.2 Safety instructions ............................................................................................................................................................................................25
8.3 Checking/Resetting Pressure Monitoring Switches ...............................................................................................................................26
8.4 Press switches respond during initial start-up ........................................................................................................................................26
8.5 Checking the Starting Capacitor...................................................................................................................................................................26
8.6 Spare parts and accessories ...........................................................................................................................................................................27
8.6.1 Spare Parts and Accessories ............................................................................................................................................................27
9 Disposal...........................................................................................................................................................................................................................28
10 Durability list.................................................................................................................................................................................................................29
11 User book (Please make copies) ...............................................................................................................................................................................30
12 Appendices......................................................................................................................................................................................................................31
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12.1 Technical Data.....................................................................................................................................................................................................31
12.2 Dimensions .........................................................................................................................................................................................................32
12.3 Heat exchanger.................................................................................................................................................................................................. 32
12.3.1 Heat exchanger description ............................................................................................................................................................32
12.3.2 Heat exchanger overview.................................................................................................................................................................33
12.4 Performance data.............................................................................................................................................................................................. 33
13 Attached documents...................................................................................................................................................................................................34
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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.
The device is suitable for use in explosive areas Zone1 (EPLGb) and Zone2 (EPLGc), explosion groups IIA, IIB and IIC, as well as
temperature classes T1, T2, T3 and T4.
The permissible ambient temperature range is -20°C≤ Tamb ≤45°C.
Markings on the sample gas cooler include ignition protection types Expxbebmbq[ia]IICT4Gb. The erection specifications
(e.g. EN/IEC60079-14) must be observed.
The device may only be used as specified in the operating instructions and the related technical documentation. The specifica-
tions on the specific intended use, existing material combinations, as well as pressure- and temperature limits must be ob-
served. The cooler is not a safety device when used properly.
Improper use, modifications not authorised by the manufacturer and incorrect operation contrary to the parameters specified
in this operating manual will void any warranty and manufacturer liability.
1.2 Design types
These operating instructions describe the main units for voltages 230 V, 50/60 Hz and 115 V, 50/60 Hz.
Please refer to the nameplate to identify your cooler. In addition to the job number, this also contains the item number (also see
chapter Ordering instructions [> page4]).
1.3 Type plate
Example:
EGK 2A Ex, 230V 50/60Hz
-20 °C ≤ Ta ≤ 45 °C
[serial number] [MM/YYYY]
BVS 03 ATEX E 301 X
Manufacturer and address
Model designation
Temperature range
Serial no., year of manufacture
ATEX certificate no.
ATEX ignition protection marking
IECEx certificate no.
IECEx ignition protection marking
EAC Ex certificate no.
IECEx BVS 19.0027X
Ex pxb eb mb q [ia] IIC T4 Gb
TC RU C-DE.xxxx.xxxx
II 2G Ex pxb eb mb q [ia] IIC T4 Gb
0158
Notified body identification number
1.4 Scope of delivery
– Cooler
– Product documentation
– Connection-/mounting accessories (optional)
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1.5 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 condensate drain.
4590 X X X X X X X 1 Product characteristics (metric connections)
Voltage 1)
1 115 V
2 230 V
Gas path/material/version
0 0 0 without heat exchanger
1 gas path/material/version
1 1 0 1x single heat exchanger/stainless steel/TS
1 2 0 1x single heat exchanger/glass/TG
1 3 0 1x single heat exchanger/PVDF/TV
2 gas paths/material/version
2 1 0 2x single heat exchanger/stainless steel/TS
2 2 0 2x single heat exchanger/glass/TG
2 3 0 2x single heat exchanger/PVDF/TV
2 6 0 1x dual heat exchanger/stainless steel/DTS (10 mm)
2 6 1 1x dual heat exchanger/stainless steel/DTS-6
2 7 0 1x dual heat exchanger/glass/DTG
2 8 0 1x dual heat exchanger/PVDF/DTV 2)
3 gas paths/material/version
3 1 0 1x single heat exchanger + 1x dual heat exchanger/stainless steel/TS+DTS (10 mm)
3 1 1 1x single heat exchanger + 1x dual heat exchanger/stainless steel/TS+DTS-6
3 2 0 1x single heat exchanger + 1x dual heat exchanger/glass/TG+DTG
3 3 0 1x single heat exchanger + 1x dual heat exchanger/PVDF/TV+DTV 2)
4 gas paths/material/version
4 6 0 2x dual heat exchanger/stainless steel/DTS (10 mm)
4 6 1 2x dual heat exchanger/stainless steel/DTS-6
4 7 0 2x dual heat exchanger/glass/DTG
4 8 0 2x dual heat exchanger/PVDF/DTV 2)
Condensate drain
0 0 0 without condensate drain
1 gas path
1 1 1 1x peristaltic pump CPsingle with adapter
1 1 3 1x peristaltic pump CPsingle with screw connection
3 0 0 1x AK20 installed 3)
4 0 0 1x 11 LD V38 installed
2 gas paths
1 2 2 1x peristaltic pump CPdouble with adapter
1 2 4 1x peristaltic pump CPdouble with screw connection
3 0 0 2x AK20 installed 3)
4 0 0 2x 11 LD V38 installed
3 gas paths
1 3 2 1x peristaltic pump CPdouble + 1x peristaltic pump CPsingle with adapter
1 3 4 1x peristaltic pump CPdouble + 1x peristaltic pump CPsingle with screw connection
3 0 0 3x AK20 installed 3)
4 0 0 3x 11 LD V38 installed
4 gas paths
1 4 2 2x peristaltic pump CPdouble with adapter
1 4 4 2x peristaltic pump CPdouble with screw connection
3 0 0 4x AK20 installed 3)
4 0 0 4x 11 LD V38 installed
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4590 X X X X X X X 1 Product characteristics (US connections)
Voltage 1)
1 115 V
2 230 V
Gas path/material/version
0 0 0 without heat exchanger
1 gas path/material/version
1 1 5 1x single heat exchanger/stainless steel/TS-I
1 2 5 1x single heat exchanger/glass/TG-I
1 3 5 1x single heat exchanger/PVDF/TV-I
2 gas paths/material/version
2 1 5 2x single heat exchanger/stainless steel/TS-I
2 2 5 2x single heat exchanger/glass/TG-I
2 3 5 2x single heat exchanger/PVDF/TV-I
2 6 5 1x dual heat exchanger/stainless steel/DTS-I (3/8")
2 6 6 1x dual heat exchanger/stainless steel/DTS-6-I
2 7 5 1x dual heat exchanger/glass/DTG-I
2 8 5 1x dual heat exchanger/PVDF/DTV-I 2)
3 gas paths/material/version
3 1 5 1x single heat exchanger + 1x dual heat exchanger/stainless steel/TS+DTS-I (3/8")
3 1 6 1x single heat exchanger + 1x dual heat exchanger/stainless steel/TS+DTS-6-I
3 2 5 1x single heat exchanger + 1x dual heat exchanger/glass/TG+DTG-I
3 3 5 1x single heat exchanger + 1x dual heat exchanger/PVDF/TV-I+DTV-I 2)
4 gas paths/material/version
4 6 5 2x dual heat exchanger/stainless steel/DTS-I (3/8")
4 6 6 2x dual heat exchanger/stainless steel/DTS-6-I
4 7 5 2x dual heat exchanger/glass/DTG-I
4 8 5 2x dual heat exchanger/PVDF/DTV-I 2)
Condensate drain
0 0 0 without condensate drain
1 gas path
1 1 1 1x peristaltic pump CPsingle with adapter
1 1 3 1x peristaltic pump CPsingle with screw connection
3 0 0 1x AK20 installed 3)
4 0 0 1x 11 LD V38 installed
2 gas paths
1 2 2 1x peristaltic pump CPdouble with adapter
1 2 4 1x peristaltic pump CPdouble with screw connection
3 0 0 2x AK20 installed 3)
4 0 0 2x 11 LD V38 installed
3 gas paths
1 3 2 1x peristaltic pump CPdouble + 1x peristaltic pump CPsingle with adapter
1 3 4 1x peristaltic pump CPdouble + 1x peristaltic pump CPsingle with screw connection
3 0 0 3x AK20 installed 3)
4 0 0 3x 11 LD V38 installed
4 gas paths
1 4 2 2x peristaltic pump CPdouble with adapter
1 4 4 2x peristaltic pump CPdouble with screw connection
3 0 0 4x AK20 installed 3)
4 0 0 4x 11 LD V38 installed
1) Cooler operation inside Ex area only permitted with suitable protective motor switch.
2) Operation with condensate drains and traps not available.
3) Approved for non-flammable and flammable gases explosion class IIB.
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2 Safety instructions
2.1 Important notices
NOTICE
The device is suitable for hazardous areas.
This unit may only be used if:
– The product is being used under the conditions described in the operating- and installation instructions, used according to
the nameplate and for applications for which it is intended. Any unauthorized modifications to the unit will void the war-
ranty provided by Bühler Technologies GmbH,
– The specifications and markings in the type plate must be observed,
– The threshold values in the data sheet and the instructions must be observed,
– Monitoring equipment / protection devices must be connected correctly,
– Service and repair work not described in these instructions are performed by Bühler Technologies GmbH,
– Genuine replacement parts must be used.
Erecting electrical systems in explosive areas requires compliance with the regulation IEC/EN60079-14.
Additional national regulations pertaining to initial operation, operation, maintenance, repairs and disposal must be observed.
These operating instructions are a part of the equipment. The manufacturer reserves the right to change performance-, specific-
ation- or technical data without prior notice. Please keep these instructions for future reference.
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 notice
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
Warns of hot surfaces
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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.
– upstream devices must be designed so that a sample gas cooler failure cannot result in secondary damages. The cooler is not
a safety device when used properly,
– the device is suitable for the respective purpose is (e.g. zone, temperature class, etc.),
– the lightning protection must comply with the applicable local regulations,
– the sample gas cooler is protected from external heat or cold sources.
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 Danger to life and explosion during installation and maintenance
The unit must not be worked on (assembly, installation, maintenance) in explosive at-
mospheres.
DANGER Explosion hazard due to frequency converter operation
The motor could produce incendive leakage currents or potential differences due to fre-
quency converter operation.
Frequency converter operation of the motors prohibited!
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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 Explosion hazard
Life and explosion risk may result from gas leakage due to improper use.
a) Use the devices only as described in this manual.
b) Regard the process conditions.
c) Check tubes and hoses for leakage.
WARNING Risk of breakage
a) Protect the equipment against being hit.
b) Protect the device against falling objects.
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3 Product description
3.1 General description
A sample gas cooler is used to lower the moisture content, thus the dew point of a sample gas. This is intended to on one hand
lower measurement accuracies through volume influence, on the other to avoid for moisture to condense further along the
measuring path and cause damage, particularly to the delicate measuring cell of the analyser.
The sample gas cooler is therefore a part of conditioning, which is illustrated as a typical flow chart below.
Test gas
Fig.1: A100060 Flow chart
1 Probe 6 Condensate drain/peristaltic pump
2 Line (heated) 7 Fine filter
3 Reversing tap for calibration 8 Moisture detector
4 Gas pump 9 Flow meter with control valve
5 Gas cooler 10 Analyser
The cooling circuit cool a cooling block (left front of the unit) to a defined temperature. The actual heat exchangers are placed in-
side this cooling block, thus also cooled.
The warm, "moist" sample gas is fed into the inlet at the top of the heat exchanger, where it is cooled, and exits through the out-
put at the top. The water vapour condenses on the cooling surfaces of the heat exchanger and drains to the bottom, where the
condensate output of the heat exchanger is located.
From there, the condensate can then be collected in a receptacle or drained directly using an automatic condensate drain or
peristaltic pump. An automatic condensate drain can only be used if the heat exchanger has excess pressure.
As already mentioned in the preface, there are various heat exchanger models and materials. When making your selection,
please be sure to pay particular attention to the durability (see resistance list [> page29]) and permissible pressures (see at-
tached data sheet).
3.2 Functional principle of the cooler
On principle, the cooling circuit is constructed just as a refrigerator. In place of the cooled interior, it has the cooling block men-
tioned above. A compressor is switched on or off within a tolerance range.
After switching on the cooler, the block temperature will be displayed. The display will flash until the (set) temperature range
around the preset initial dew point has been reached. The display will indicate an error in form of a flashing error message. The
electronics also provides this differentiation as a potential-free output used in fail-safe control. Thus a power failure is also re-
ported to the master display. For a detailed description of the various states illustrated, please refer to chapter Operation.
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4 Transport and storage
The sample gas cooler must be transported in the original packaging or a suitable alternative. It must be transported upright.
Never place it on its side during transport, as oil could otherwise leak from the compressor and enter the cooling circuit. This can
result in cooler start-up problems or failure.
During extended periods of non-use, protect the cooler against moisture and heat. It must be stored in a covered, dry, vibration-
and dust-free location at temperatures between -20°C and +40°C.
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5 Installation and connection
5.1 Installation site requirements
The unit is intended for use in enclosed areas. Adequate protection from the weather must be provided when used outdoors.
The approved environmental conditions for explosive areas according to the enclosed data sheet must be met.
The sample gas cooler can be used as a stand-alone unit or wall mounted. Do not obstruct the convection. Maintain a clearance
to other objects of at least 10 cm all around the bottom of the cooler. Above the cooler, particularly above the rear vent, maintain
a clearance of at least 40 cm. With respect to components installed above, remember the air emitted upward from the cooler
can be very warm.
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.
When wall mounting the sample gas cooler, be sure the wall or the cabinet provide adequate weight bearing and stability. We
recommend mounting to solid walls with metal wall anchors and M8 screws with washer. Additional requirements (tightening
torque, screw-in depth, etc.) must be selected per the specifications of the metal anchor manufacturer. When mounting inside
control cabinets, we also recommend mounting with M8 bolts directly to the mounting plate.
5.2 Connecting the gas- and condensate connections
CAUTION Explosion hazard
Before using any accessories with the sample gas cooler, verify these parts are suitable
for the purpose and use in explosive atmospheres.
Please note, accessories may limit use of the sample gas cooler with respect to explosion
protection.
On glass heat exchangers the correct position of the seal is important when connecting the gas lines. The seal consists of a silic-
one ring with a PTFE sleeve. The PTFE side must face the glass thread.
Glass PTFE
Fig.2: A100000 Heat exchanger seal
Run the gas supply with a downward slope all the way to the cooler. If a large amount of condensate accumulates, we recom-
mend using a condensate pre-separator before the cooler. Our fluid separators with automatic condensate drain, 11LD spec.,
AK20V or model 165, are suitable.
The gas inputs on the heat exchanger are marked red
When using glass- or PVDF heat exchangers the enclosed cover must be used. In this case remove the cover, pull the hoses
through the cover, connect the hoses to the heat exchanger, and finally replace and secure the cover.
Be careful when connecting the glass- and PVDF heat exchanger, and only tighten the fittings by hand.
DANGER Explosion hazard due to flame propagation
Severe injuries and damage to the system
If the process holds a risk of flame propagation, install a flame arrestor.
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When using automatic condensate drains, the gas pump must be installed ahead of the cooler 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 collectors or
peristaltic pumps.
Glass vessels and automatic condensate drains are available for draining condensate for external mounting below the unit.
Connecting a condensate drain: depending on the material, build a connecting line with fittings and tubing or hose between
the heat exchanger and condensate 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.
Condensate lines must always be installed with a slope and a minimum inside diameter of DN 8/10.
An external peristaltic pump may be installed a little away from the cooler.
Be sure the gas line connections are tight.
5.3 Peristaltic pump connector (optional)
When using peristaltic pumps, these can also be mounted separate from the cooler. An adapter plate is available to mount the
pumps directly below the cooler. The cooler frame features mounts for mounting the plate. Mount with M6 screws and a tight-
ening torque of 6.3Nm.
When ordering the cooler with attached peristaltic pumps, these are already installed but not yet wired. A 3m cable on each
pump allows wiring outside the cooler. Please refer to the separate operating instructions for more information about connect-
ing the peristaltic pump.
Heat exchangers ordered at the same time are already installed and connected to the peristaltic pumps.
NOTICE
Installing peristaltic pumps CPsingle / CPdouble limits the maximum permissible oper-
ating pressure in the system!
Operating pressure ≤ 1 bar
5.4 Electrical connections and potential equalisation
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.
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.
NOTICE When used in explosive areas
Regulation IEC/EN60079-14 must be observed when erecting electrical systems in ex-
plosive areas.
Additional national regulations pertaining to initial operation, operation, maintenance,
repairs and disposal must be observed.
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The sample gas cooler may only be operated with a suitable protective motor switch as overload protection. A suitable approved
version of the protective motor switch protected against explosion is required when installing in an explosive area. A selection
of suitable protective motor switches for safe and for explosive areas are available as accessories (see chapter Spare Parts and
Accessories [> page27]).
The setting of the protective motor switch varies by cooler version. For the correct setting, see chapter Technical Data [>
page31].
The supply line cross-sections must be suitable for the rated current.
The status outlet can also be connected to an intrinsically safe inlet. The specifications for this inlet must be met. The capacity
and inductance of the contact are zero, so that only the cable used must be considered.
Connecting the cooler
– On the black terminal box, loosen the four screws in the corners of the face.
– Carefully lift off the cover: The control elements are attached to the to the electronics with cables.
– Turn the cover and set down on the cooler. Be careful not to tension the cables.
– Feed the cable for the status signal through the front left and the cable for the supply voltage through the front centre cable
fitting.
– Connect according to the drawing in the appendix. The insulation of the individual conductors only need to be stripped by
5 mm. Do not use cable end sleeves.
– The earth connection is placed on a copper rail, see drawing 41/170-10-3. The screw together with the pressure piece should
be screwed into the copper rail at a tightening torque of 2.2Nm.
– Now close the housing, remembering:
– Tighten the 4screws to a tightening torque of approx. 4Nm.
– No foreign objects, contaminants or moisture may be inside the junction box of the sample gas cooler. Close the box dust-
and waterproof (be sure not to crush any cables!). Use the original seal when closing the junction box. Openings not being
used must be covered with approved plugs per Atex. Tighten all screw connections.
– Connect the potential equalisation of the cooler (threaded bolts below the terminal box) to the potential equalisation on
site. Stray electric currents may not flow through this connection.
– Run the lines so the insulation will not be damaged. If necessary, secure the lines with suitable means and ensure the ad-
equate cable relief of the connecting cable.
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5.5 Testing insulation resistance
CAUTION High voltage
Insulation test will damage the device
Do not test the electric strength if the entire unit is under high voltage!
If you wish to check the electric strength again yourself, only do so on the following individual components using 500 VDC.
Please note the following items.
When testing the cooler electronics disconnect the earth connection from the cooler electronics. Short circuit L and N and carry
out the high voltage test against the housing.
NOTICE Following this test be sure to reconnect the earth!
To test the compressor, disconnect its supply line from the controller electronics. Do not disconnect the earth. Short circuit the
main winding, secondary winding and N, and carry out the electric strength test against earth. After completing the test, recon-
nect the compressor.
To test the Starting capacitors, disconnect its supply line from the controller electronics. Do not disconnect the earth. Short cir-
cuit the supply lines, then carry out the electric strength test against earth. After testing is completed, reconnect the starting ca-
pacitor(s).
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6 Operation and controls
NOTICE
The device must not be operated beyond its specifications.
CAUTION Hot surface
Risk of burns
Depending on the operating parameters, the air heat exchanger at the back of the cooler
can reach a temperature of up to 80 °C during operation.
6.1 Switching on the sample gas cooler
Before switching on the unit, check:
– tube- and electrical connections are undamaged and correctly installed.
– no parts of the sample gas cooler have been removed (e.g. terminal box cover).
– protection- and monitoring devices are in place and function (protective motor switch).
– ambient parameters are met.
– Please note rating plate information!
– the motor voltage and frequency matches the mains values.
– electrical connections are securely connected and monitoring devices are connected and set as prescribed!
– air inlets and cooling surfaces are clean, and the air passage is not obstructed (see notices under "Installation site require-
ments")!
– the earth is proper and functional.
– the cooler is properly secured (see chapter Installation and connection [> page11])!
– the junction box cover is closed and the cable glands properly sealed.
– the protective motor switch must be adjusted to the rated current (see chapter Technical Data [> page31]).
– the condensate path is clear. particularly on the option with condensate pump, whether it is controlled together with the
cooler.
Switching on the unit
After switching on the cooler, the block temperature will be displayed.
Once the temperature range has been reached (after approx. 10 minutes, depending on the ambient temperature), the temper-
ature display will be steady, and the status contact will switch over.
If the display flashes during operation or an error message appears, please refer to chapter Troubleshooting [> page24].
Please refer to chapter Appendices [> page31] for performance data and limits.
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6.2 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)
6.2.1 Menu navigation overview
Displayed is the block temperature with a resolution of 0.5 °C / 0.9 °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
____ ____
____
____
____
____
____
____
____
____
____
____
____
____
P5__
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
Reset
Exit
Cooler display Set temperature
Alarm hysteresis Upper alarm
Cooler temperature
Lower alarm
Alarm hysteresis
Exit Submenu
C - F
Global Settings
Factory settings
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
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C
toP
rSt
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E
Exit
Exit Main Menu
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6.2.2 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).
6.3 Description of menu functions
6.3.1 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.
Factory setting -> Reset (rSt)
Resets operating parameters to the default values. Reboot..
Exit main menu
Display → E
Selecting this will return you to display mode.
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6.3.2 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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