Buhler EGK 10 Installation And Operation Instructions Manual

Brand: Buhler

Model: EGK 10

Type: Installation And Operation Instructions Manual

Installation and Operation Instructions

Sample gas cooler

EGK 10

BE450005 ◦ 05/2015

Original instructions

Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen

Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20

Internet: www.buehler-technologies.com

E-Mail: [email protected]

Read this instruction carefully prior to installation and/or use.

Pay attention particularly to all advises and safety instructions

to prevent injuries. Bühler Technologies can not be held re-

sponsible for misusing the product or unreliable function due to

unauthorised modifications.

Document information

Document No. ....................................BE450005

Version .................................................. 05/2015

Installation and Operation Instructions

Sample gas cooler EGK 10

Contents

1 Introduction..........................................................................................................................................................2

1.1 Intended Use .................................................................................................................................................2

1.2 Types .............................................................................................................................................................2

1.3 Scope of delivery ...........................................................................................................................................2

2 Safety instructions ..............................................................................................................................................3

2.1 Important advice ............................................................................................................................................3

2.2 General hazard warnings...............................................................................................................................4

3 Transport and storage ........................................................................................................................................5

4 Installation and connection ................................................................................................................................6

4.1 Installation site requirements .........................................................................................................................6

4.2 Installation......................................................................................................................................................6

4.3 Electrical connections ....................................................................................................................................7

5 Operation and control .........................................................................................................................................8

5.1 Operation of the menu functions....................................................................................................................8

5.1.1 Overview of the menu items .............................................................................................................. 9

5.1.2 Detailed description of the operational principle ................................................................................ 9

5.2 Description of the menu functions ...............................................................................................................10

5.2.1 Main menu ....................................................................................................................................... 10

5.2.2 Submenu.......................................................................................................................................... 10

6 Maintenance....................................................................................................................................................... 11

7 Service und repair ............................................................................................................................................. 12

7.1 Troubleshooting ...........................................................................................................................................12

7.2 Safety instructions .......................................................................................................................................13

7.3 Opening the housing....................................................................................................................................13

7.4 Replacing the fuse of the cooler ..................................................................................................................15

7.5 Replacing the fan.........................................................................................................................................15

7.6 Replacing the power supply board ..............................................................................................................16

7.7 Replacing the controller board MCP1..........................................................................................................17

7.8 Replacing the display...................................................................................................................................17

7.9 Cleaning and removal of the heat exchanger ..............................................................................................17

7.10 Replacing the fuse of the peristaltic pump (option - only housing version)..................................................18

7.11 Replacing the hoses of the peristaltic pump (option)...................................................................................18

7.12 Spare parts and accessories .......................................................................................................................18

8 Disposal..............................................................................................................................................................19

9 Attached documents .........................................................................................................................................20

DE450007 EGK10............................................................................................................................................... 21

KX450001_EGK1_EGK1-2_EGK4S_EGK10..................................................................................................... 25

Declaration of Contamination status............................................................................................................... 26

iBE45000505/2015

Installation and Operation Instructions

Sample gas cooler EGK 10

Introduction

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 sheets 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 in-

forms you about the specific configuration of your device.

1.3 Scope of delivery

– Cooler

– Product documentation (brief instruction + CD)

– Connection-/mounting accessories (optional)

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Safety instructions

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 instruc-

tion, the intended application according to the type plate and the intended use. In case of un-

authorized modifications done by the user Bühler Technologies GmbH can not be held re-

sponsible 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 instruc-

tion 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 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

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Safety instructions

2.2 General hazard warnings

Installation of the device shall be performed by trained staff only, familiar with the safety require-

ments and risks.

Check all relevant safety regulations and technical indications for the specific installation place.

Prevent failures and protect persons against injuries and the device against damage.

The operator of the system must secure that:

– safety and operation instructions are accessible and followed,

– local safety regulations and standards are obeyed,

– performance data and installation specifications are regarded,

– safety devices are installed and recommended maintenance is performed,

– national regulations for disposal of electrical equipment are obeyed.

Maintenance, repair:

– Repairs on the device must be carried out by Bühler authorized persons only.

– Only perform modifications, maintenance or mounting described in this manual.

– Only use original spare parts.

When carrying out maintenance works of any kind, the relevant health and safety regulations of

the country of use must be observed.

DANGER Electrical voltage

Electrocution hazard.

a) Disconnect the device from power supply.

b) Make sure that the equipment cannot be reconnected to mains unintention-

ally.

c) The device must be opened by trained staff only.

d) Regard correct mains voltage.

DANGER Toxic and corrosive gases / condensate

Sample gas / condensate can be hazardous.

a) Take care that the gas is exhausted in a place where no persons are in

danger.

b) Before maintenance turn off the gas supply and make sure that it cannot be

turned on unintentionally.

c) Protect yourself during maintenance against toxic / corrosive gases / con-

densate. Use gloves, respirator and face protector under certain circum-

stances.

DANGER Potentially explosive atmosphere

Explosion hazard if used in hazardous areas.

The device is not suitable for operation in hazardous areas with potentially ex-

plosive atmospheres.

Do not expose the device to combustible or explosive gas mixtures.

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Transport and storage

3 Transport and storage

The device should be only transported in the original case or in appropriate packing.

If the device is not used for some time, protect it against heat and humidity. Store the device in

a roofed, dry, and dust free room. Temperature should be between -20 °C and 60 °C (-4 °F and

140 °F).

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Installation and connection

4 Installation and connection

4.1 Installation site requirements

The unit is intended for wall-mounted or table-top use in enclosed areas. Adequate protection

from the weather must be provided when used outdoors.

Install the unit leaving enough room below the cooler to discharge the condensate. Leave room

above for the gas supply.

Be sure to maintain the approved ambient temperature. Do not obstruct the convection of the

cooler. The vents must have enough room to the next obstacle. The distance must especially be

a minimum of 10 cm on the air outlet side.

Ensure adequate ventilation when installing in enclosed housings, e.g. analyser cabinets. If the

convection is inadequate, we recommend aerating the cabinet or installing a fan to lower the in-

side 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 pre-separ-

ator before the cooler. Our fluid separators with automatic condensate drain, 11LD spec.,

AK20V or model 165 SS, are suitable.

Glass vessels and automatic condensate drains are available for draining condensate for ex-

ternal mounting below the unit. 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 traps or peristaltic pumps.

Connecting the condensate drains

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 suspen-

ded directly to the connecting tube, for hoses the condensate drain must be secured separately

using a clamp.

The condensate drain can be mounted directly to the heat exchanger.

Condensate lines must always be installed with a slope and a minimum inside diameter of DN

8/10 (5/16”).

Peristaltic pump (optional)

A peristaltic pump may also be installed a little away from the cooler. The bottom of the cooler

has two rivet M4 nuts designated for installing the pump directly below the cooler.

NOTICE

Installing peristaltic pumps limits the maximum approved operating pressure

in the system!

Operating pressure ≤ 0.5 bar

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Installation and connection

4.3 Electrical connections

WARNING Hazardous electrical voltage

The device must be installed by trained staff only.

CAUTION Wrong mains voltage

Wrong mains voltage may damage the device.

Regard the correct mains voltage as given on the type plate.

WARNING High voltage

Damage to the device in case of insulation testing

Do not proceed insulation tests with high voltage to the device as a whole!

Insulation test

The device is equipped with extensive EMC protection. If insulation tests are carried out the

electronic filter devices will be damaged. All necessary tests have been carried out for all con-

cerned groups of components at the factory (test voltage 1 kV or 1.5 kV respectively, depending

on the device).

If you wish to carry out the insulation test by yourself, please test only separate groups of com-

ponents.

Disconnect the compressor, the fan, the heating or the peristaltic pumps, respectively, and then

carry out the insulation tests.

Connection via plug

The device is equipped with connectors according to DIN 43650 for mains and status output. If

the cables are mounted properly, they cannot be interchanged. Please make sure that the con-

nectors are remounted correctly after connecting the cable. The following figures show the pin

assignment with respect to the numbers printed on the connector.

power supply

status outputpin assignment

function ok

alarm

Fig.2: A05-100002 Cooler electric supply

The mains supply must be protected with 16 A. The clamping area has a diameter of 8-10 mm.

If the unit features a peristaltic pump, it must be connected to a power source separately.

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Operation and control

5 Operation and control

NOTICE

The device must not be operated beyond its specifications.

After turning on the power supply the display shows the actual temperature of the cooling block.

The display blinks until the (set) temperature range with respect to the pre-set output dew point

is reached. The status contact is switched to "Alarm".

If the temperature range is reached, the actual temperature is shown constantly and status con-

tact switches back.

If the display starts blinking during operation or if an error message is displayed see chapter

"Troubleshooting".

For performance limits see datasheet.

5.1 Operation of the 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 in-

stalled)

– Switch to lower menu item

– Decrease of the value of switching the selection

– Temporary display of the alternative measurement display (if option is in-

stalled)

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Operation and control

5.1.1 Overview of the menu items

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

____

E1_2

Display of current temperature and operating state

Main Menu

Submenu

Setting range

Display

____

Current temperature

Parameter

Temperature

Display

Alarm high

Parameter

Alarm Low

Parameter

Top Settings

Exit

Cooler display

Set temperature

Alarm hysteresis

Upper alarm

Cooler temperature

Lower alarm

Alarm hysteresis

Exit Submenu

C - F

Global Settings

Exit Main Menu

Adjust the set point:

2°C...20°C / 35.6°F...68°F

Set the upper alarm threshold above

setpoint: tEMP 1°C...7°C / 1.8°F...12.6°F

Set the lower alarm threshold below

setpoint: tEMP -1°C...-3°C / -1.8...-5.4F

tEMP

A Hi

A Lo

___

____

toP

5.1.2 Detailed description of the operational principle

The detailed description will guide you through the menu step by step.

Connect the unit to the power supply and wait for the startup procedure to complete. At

first the software version implemented on the unit will be displayed for a brief period.

The unit will then switch directly into measured value display.

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 previ-

ously changed and saved will be retained and not reset.

NOTICE!After saving values with the Enter key they will be applied to the control.

To exit the main or submenu, select menu item E (Exit).

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Operation and control

5.2 Description of the menu functions

5.2.1 Main menu

Cooler

This item allows all relevant settings for the cooler. In the corresponding

submenu nominal temperature and alarm limits may be selected.

Globale settings (ToP Settings)

Selection of the global temperature unit, either degree Celsius (C) or de-

gree Fahrenheit (F).

Note: This menu item has no sub-item. The temperature unit is directly selected.

Exit main menu

Selecting this item returns to the display mode.

5.2.2 Submenu

Cooler -> nominal temperature (temperature)

This setting determines the nominal temperature for the cooler temperat-

ure. 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 re-

lay. 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 re-

lay. 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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Maintenance

6 Maintenance

If the cooler is delivered in basic configuration, no special maintenance is necessary.

Nevertheless, depending on the configuration different options or accessories may be installed.

In this case, follow the maintenance schedule in regular intervals.

– Option peristaltic pump: Checking the hoses

– Option filter: Checking the filter element

– Option moisture detector: Calibrating the moisture detector

NOTICE!Obey all safety advices and operating rules during any maintenance work.

– Maintenance of the device shall be performed by trained staff only, familiar with the safety re-

quirements and risks.

– Only perform maintenance work described in this manual.

– Regard all relevant safety regulations and internal operating instructions during maintenance.

DANGER Electrical voltage

Electrocution hazard.

a) Disconnect the device from power supply.

b) Make sure that the equipment cannot be reconnected to mains unintention-

ally.

c) The device must be opened by trained staff only.

d) Regard correct mains voltage.

DANGER Toxic and corrosive gases / condensate

Sample gas / condensate can be hazardous.

a) Take care that the gas is exhausted in a place where no persons are in

danger.

b) Before maintenance turn off the gas supply and make sure that it cannot be

turned on unintentionally.

c) Protect yourself during maintenance against toxic / corrosive gases / con-

densate. Use gloves, respirator and face protector under certain circum-

stances.

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Service und repair

7 Service und repair

If the device shows irregularities see this chapter for troubleshooting.

Repairs on the device must be carried out by Bühler authorized persons only.

If you need help or more information

call: +49-(0)2102-498955 or your local agent

If the device doesn’t work correctly after elimination of failures and turning power on, the device

must be checked by the manufacturer. Please ship the device with suitable packing to

Bühler Technologies GmbH

- Reparatur/Service -

Harkortstraße 29

40880 Ratingen

Deutschland

In Addition, attach the filled in and signed Declaration of Decontamination status to the packing.

Otherwise, your repair order cannot be processed!

The form can be requested by e-mail to [email protected].

7.1 Troubleshooting

Problem / Failure Possible cause Solution

No display – no power – check power supply

– fuse blown – check fuse and change it if ne-

cessary

Cooler not running – high temperature at the com-

pressor casing

– wait until cooled off and care

for enough ventilation

Status-LED blinks with:

– High temperature – operational temperature not

yet reached

– wait for 20 minutes maximum

– cooling capacity to low, even

though cooler is running

– make sure that air can circu-

late free and that ventilation

louvers are not obstructed

– gas flow / dew point / gas tem-

perature to high

– check application parameters,

install pre-separator

– fan broken – check fan, replace if neces-

sary

– Low temperature – controller defect – send cooler for inspection

Condensate in gas outlet – condensate vessel full – drain vessel

– stuck valve in automatic con-

densate drain

– flush both directions

– cooler overloaded – check limiting parameters

Reduced gas flow – clogged gas path – check / flush heat exchanger

– condensate outlet clogged by

ice

– send cooler for inspection

Display of an error

The display toggles between temperature and error messages.

Error 01 – broken wire – Temperature sensor defect:

send cooler for repair

Error 02 – short circuit – Temperature sensor defect:

send cooler for repair

Tab.2: Troubleshooting

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Service und repair

7.2 Safety instructions

– The device must be operated within its specifications.

– All repairs must be carried out by Bühler authorised personnel only.

– Only perform modifications, servicing or mounting described in this manual.

– Only use original spare parts.

DANGER Electrical voltage

Electrocution hazard.

a) Disconnect the device from power supply.

b) Make sure that the equipment cannot be reconnected to mains unintention-

ally.

c) The device must be opened by trained staff only.

d) Regard correct mains voltage.

DANGER Toxic and corrosive gases / condensate

Sample gas / condensate can be hazardous.

a) Take care that the gas is exhausted in a place where no persons are in

danger.

b) Before maintenance turn off the gas supply and make sure that it cannot be

turned on unintentionally.

c) Protect yourself during maintenance against toxic / corrosive gases / con-

densate. Use gloves, respirator and face protector under certain circum-

stances.

CAUTION Health hazard in case of leaking cooling circuit / heat exchanger

The cooling circuit is filled with coolant R134a.

The heat exchanger is filled with a coolant based on glycol.

In case of leaking / broken cooling circuit / heat exchanger:

a) Avoid contact with skin or eyes.

b) Do not ingest or inhale coolant.

ð Due to the small amount of coolant no health hazards need be feared.

ð Do not put the device back to operation if leakage of the cooling circuit hap-

pend.

7.3 Opening the housing

– Turn off gas supply.

– Switch the device off and disconnect power supply.

– Loosen gas fittings.

– Loosen the screws of the cover.

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Service und repair

– Lift off the top cover.

– Now all components are accessible.

Fig.4: A100036 EGK 10 Overview

1 Heat exchanger sample gas (filled with

glycol-based coolant)

5 Mains connector

2 Display ABT 400 6 Alarm connector

3 Compressor with closed cooling circuit,

filled with R134a

7 Condenser

4 Electronica with power supply board,

fuse and controller board MCP1

8 Fan

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Service und repair

7.4 Replacing the fuse of the cooler

– Open the device as described in chapter Opening the housing [_page13].

– The fuse is placed on the PBC beneath a plastic cap. Replace the fuse and push down the

plastic cap. Regard the supply voltage for selecting the correct value of the fuse.

Example:

– Fix the cover. Fasten the screws.

– Reconnect hoses.

– Reconnect power supply.

7.5 Replacing the fan

– Open the device as described in chapter Opening the housing [_page13].

– For better accessibility to the fan, remove the electronics. For this, unscrew the screws at the

bottom of the housing and remove the card holder.

– Disconnect the plug at the fan.

– Remove the 2 screws on the left and right side of the fan.

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Service und repair

– Replace the fan and reassemble the device in reverse order.

7.6 Replacing the power supply board

– Open the device as described in chapter Opening the housing [_page13].

– Remove all cables.

– Terminal diagram EGK:

no jumper set

Heating

Fan

Compressor

Peristaltic pump

Fig.6: A100042 Power supply board

– Unscrew the screws at the corners of the PCB.

– Replace the power supply board and reassemble the device in reverse order.

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Service und repair

7.7 Replacing the controller board MCP1

– Open the device as described in chapter Opening the housing [_page13].

– Pull the controller board MCP1 of the power supply board.

– Insert the new MCP1. Regard the mounting direction: The electronics components must point

upwards!

– Reassemble the device in reverse order.

7.8 Replacing the display

– Open the device as described in chapter Opening the housing [_page13].

– Disconnect the flat ribbon cable from the display.

– Unscrew the 3 nuts and replace the display ABT 400.

– Reassemble the device in reverse order.

7.9 Cleaning and removal of the heat exchanger

Heat exchangers only need to be replaced or maintained when plugged or damaged. If they are

clogged, we recommend checking if using a filter will avoid future occurrences.

– Close the gas supply.

– Switch off the device and unplug from the mains.

– Disconnect the gas connections and condensate drain.

– Pull the heat exchanger up and out.

– Clean the cooling nest (hole inside the cooler block).

– Flush the heat exchanger until all contaminants have been removed.

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Service und repair

– Grease the cooled outside surface external surface with silicone grease.

– Reinsert the heat exchanger into the cooling nest with a rotating movement.

– Reconnect the gas supply and condensate drain.

– Reconnect to power.

7.10 Replacing the fuse of the peristaltic pump (option - only

housing version)

– Turn off gas supply.

– Switch the device off and disconnect power supply.

– Remove the insulation cover from the fuse holder at the pump’s mounting bracket. For this,

push the cover using a screw driver and quarter-turn it to the left.

– Replace the fuse and refit the insulation cover by quarter-turning it to the right.

– Reconnect power supply.

7.11 Replacing the hoses of the peristaltic pump (option)

– Turn off gas supply.

– Switch the device off and disconnect power supply.

– Remove the supplying and draining hoses from the pump (Take care of the safety instruc-

tions!).

– Loosen the centre knurled screw but do not remove it. Push the screw downwards.

– Pull off the cover.

– Pull the connections sidewards and remove the hose.

– Replace the hose and remount the pump in reverse order.

– Reconnect power supply.

7.12 Spare parts and accessories

Please also specify the model and serial number when ordering parts.

Upgrade and expansion parts can be found in our catalog.

Available spare parts:

Spare part Part no.

Fan 230 V 44 100 31

115 V 44 000 31

Display ABT 400 91 000 10 124

Controller board MCP 1 91 000 10 125

Mains / Controller board 230 V 91 000 10 133

115 V 91 000 10 134

Fuse cooler 230 V / 115 V 5 x 20mm,

800 mA slow-

blow

91 100 00 001

Fuse peristaltic pump 230 V / 115 V 5 x 20mm,

1A fast-acting

91 100 00 061

Single path heat exchanger TS10 NPT

3/8“

45 100 33

Single path heat exchanger TS10 G3/8“ 45 100 34

Single path heat exchanger, glass coated,

TS10 GB NPT 3/8“

45 100 38

Replacement hose for peristaltic pump

(option), elbow connector

91 240 30 081

Replacement hose for peristaltic pump

(option), straight connector

91 240 30 096

Tab.4: Spare parts and accessories

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Buhler EGK 10 Installation And Operation Instructions Manual

Buhler EGK 10 Installation And Operation Instructions Manual

Buhler EGK 10 Installation And Operation Instructions Manual

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