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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