Bühler technologies EGK 2A Ex, Installation And Operation Instructions Manual

Page 1: ...ons Original instructions Sample gas cooler EGK 2A Ex BE450020 01 2020 Bühler Technologies GmbH Harkortstr 29 D 40880 Ratingen Tel 49 0 21 02 49 89 0 Fax 49 0 21 02 49 89 20 E Mail analyse buehler technologies com Internet www buehler technologies com ...

Page 2: ... 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 ...

Page 3: ...inciple 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 start...

Page 4: ...nical 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 ii Bühler Technologies GmbH BE450020 01 2020 ...

Page 5: ...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 ad...

Page 6: ...anger 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...

Page 7: ...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 inst...

Page 8: ...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 sever...

Page 9: ...om 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 ins...

Page 10: ...osive 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 agains...

Page 11: ...ere 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 selec...

Page 12: ...ide 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 10 Bühler Technologies GmbH BE450020 01 2020 ...

Page 13: ... 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 e...

Page 14: ... 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 perist...

Page 15: ...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 th...

Page 16: ...oltage 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 discon...

Page 17: ...urfaces 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 conde...

Page 18: ...sing 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 ...

Page 19: ...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 wi...

Page 20: ...er 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 ...

Page 21: ...tect yourself from toxic acidic gasses when performing maintenance Wear ap propriate protective equipment CAUTION Gas emanation The heat exchangers mustn t be pressurised when being removed CAUTION Tilting risk Damage of the device Secure the device against any sudden translocation during maintenance CAUTION Hot surface Risk of burns Depending on the operating parameters the air heat exchanger at ...

Page 22: ...er every 8 000 h or 1 year Replace hose Customer Pump cover CP X1 every 16 000 h or 2 years Visually inspect for cracks in the cover Customer Knurled nuts CP X1 when replacing the hose retighten all knurled nuts hand tight Customer When operating hours years is specified whichever comes first applies 7 2 Maintenance DANGER Danger to life and explosion during installation and maintenance The unit m...

Page 23: ...100 Item no 45 90 999 6 Observe the warnings in chapter Maintenance page 19 De energise supply and status outlet and depressurise the system Loosen the four screws in the corners of the front on the black terminal box Carefully lift of cover The control elements are attached to the to the electronics with cables Turn the cover and put down on the cooler Be careful not to tension the cables Remove ...

Page 24: ...placing the starting capacitor Item no 91 0407 0001 Observe the warnings in chapter Maintenance page 19 De energise supply and status outlet and depressurise the system Disconnect gas connections Remove the cooler and put in a safe location Loosen the four screws in the corners of the front on the black terminal box Carefully lift of cover The control elements are attached to the to the electronic...

Page 25: ...cover and secure with three screws tightening torque 0 4 Nm Attach the display cable to the electronics and secure the X4 plug connection Reconnect all wires per drawing 47 170 10 3 in the appendix the cable colours are specified Close the terminal box observing the following items No foreign objects contaminants or moisture may be inside it Tighten the terminal box at a tightening torque of 4 Nm ...

Page 26: ...the failure Problem Malfunction Possible cause Action Indicator doesn t light No power supply Connect to power Protective device protective motor switch was triggered see item protective device is triggering in this table Electronics defective Replace or have replaced If the error re curs check the power supply for malfunc tions Display flashes Stop Pressure monitor was triggered During first star...

Page 27: ...r additional information see chapter Parts replacement page 21 8 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 suppl...

Page 28: ...n again and the cooler restarted per chapter Operation and controls page 15 8 4 Press switches respond during initial start up DANGER Explosion hazard The following description does not apply if the pressure controls on the cooler are triggered within the first minute In this case there is a serious malfunction resulting in a potential explosion hazard After transport in some cases more coolant ca...

Page 29: ... TV SS I PVDF plastic 45 01 028 Two leg heat exchanger DTV PVDF plastic 45 01 028I Two leg heat exchanger DTV I PVDF plastic When connecting please note the specific values of the cooler and the correct version when order spare parts example heat exchanger or electronics 8 6 1 Spare Parts and Accessories Item no Description 91 320 200 09 Protective motor switch for installation outside Ex area 230...

Page 30: ...try of use for disposing of elec tronic components and devices as well as hazardous materials during disposal As an EU member state you have the option to return Bühler Technologies GmbH products to us When returning the product the completed and signed RMA decontamination declaration must be attached to the packaging You will find the form in the appendix of these instructions or simply request i...

Page 31: ... 1 0 1 1 1 1 C6H5C2H3 Styrene 1 0 1 1 1 0 C6H5CH3 Toluol methylbenzene 1 1 1 1 1 1 H2O Water 1 1 1 1 1 1 H2 Hydrogen 1 0 1 0 1 0 Tab 2 Durability list 0 no information available 1 durability suitability very good 2 durability suitability good 3 limited suitability 4 not suitable Two values are specified per medium Left number value at 20 C right number value at 50 C Important information The table...

Page 32: ...EGK 2A Ex 11 User book Please make copies Maintained on Unit no Operating hours Remarks Signature 30 Bühler Technologies GmbH BE450020 01 2020 ...

Page 33: ...ter Weight incl heat exchanger approx 37 kg Electric supply 115 V or 230 V 50 60 Hz terminals Power input 250 VA 230 V or 300 VA 115 V Protection Protective motor switch breaking capacity 1 5 kA or higher 115 V version 3 2 A 230 V version 1 3 A Status output fuse Breaking capacity 1 5 kA or higher Dimensioned per the status contact switch ing capacity and customer application see type examination ...

Page 34: ...nergy load from the gas is therefore determined by the tolerated rise in the dew point The following limits are specified for a normal standard operating point of τe 65 C and ϑG 90 C The maximum volume flow vmax in Nl h of cooled air is indicated so after moisture has condensed If the values fall below τe and ϑG the flow vmax may be increased For example on the TG heat exchanger the parameter trip...

Page 35: ...l 48 ml 129 ml 28 25 ml 28 25 ml 21 21 ml Gas connections metric G1 4 i GL 14 6 mm 4 DN 4 6 6 mm tube GL14 6 mm 4 DN 4 6 Gas connections US NPT 1 4 i GL 14 1 4 4 1 4 1 6 1 4 tube GL14 1 4 4 1 4 1 6 Condensate out connection metric G3 8 i GL 25 12 mm 4 G3 8 i Tube 10 mm 6 mm GL18 10 mm 4 DN 5 8 Condensate out connection US NPT 3 8 i GL 25 1 2 4 NPT 3 8 i Tube 3 8 1 4 GL18 3 8 4 3 16 5 16 1 Max cool...

Page 36: ...d documents Wiring diagram 47 170 10 3 Declaration of Conformity KX450007 Gas Cooler Examination Certificate Examination Certificate for Components RMA Decontamination Statement 34 Bühler Technologies GmbH BE450020 01 2020 ...

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Page 53: ...omponent intended for use in potentially explosive atmospheres given in Annex II to the Directive The examination and test results are recorded in the confidential reports listed in Section 14 2 9 Compliance with the Essential Health and Safety Requirements with the exception of those listed in the schedule to this certificate has been assured by compliance with the following documents IEC 60079 0...

Page 54: ...chable and are retained captive screws All boxes are fitted with closed cell silicone rubber gaskets Entries may be provided either through the side walls or the rear of the box and external and internal earthing facilities are provided Variation 1 dated 28 September 2001 This variation introduced the following changes i The recognition of a minor revision of the information marked on the label Va...

Page 55: ...NTS 14 1 Drawings Refer to Certificate Annexe 14 2 Associated Sira Reports and Certificate History Issue Date Report File no Comment 0 19 January 2000 R51X6055E The release of prime certificate 1 28 September 2001 53V7936 The introduction of Variation 1 2 23 July 2002 R53A9009A The prime certificate was re issued to permit the following The incorporation of variation 1 The lower ambient temperatur...

Page 56: ...ure that The device does not adversely affect the minimum IP rating of the enclosure There are no special conditions of for safe use conditions of certification associated with the device that will impinge upon the use and installation of the Enclosure e g These components shall not be used for applications where there is a high risk of mechanical damage The coding reflects the worst case item fit...

Page 57: ...2 Issue 2 Number Sheet Rev Date Description ABT 10259 1 of 1 C 25 Jun 02 External Label BPG ABT 10305 1 of 1 A 16 Nov 99 BPG Enclosures ABT 10304 1 of 1 A 16 Nov 99 BPG Manufacturing Specification Issue 3 Number Sheet Rev Date Sira stamp Description ABT 10305 1 of 1 B 07 Mar 08 BPG Enclosures Issue 4 Number Sheets Rev Date Sira Stamp Description ABT 10259 1 of 1 D 30 Mar 12 BPG Nameplate Empty Enc...

Page 58: ...s and IECEx certified devices are required for IECEx certified enclosures If trunking is fitted non metalic slotted trunking may be used for T6 rated applications If the box is rated other than T6 then metallic slotted trunking must be used 1 Using the mounting dimensions data provided either in the product catalogue data sheets or on the drawings supplied as part of the project documentation mark...

Page 59: ...rcuit at all times when power is connected to the enclosure contents Maintenance Routine maintenance is likely to be a requirement of local Health and Safety legislation The laws of the applicable country must be considered and maintenance checks carried out accordingly Additional periodic checks that are advisable to ensure the efficiency of ABTECH range enclosures are Activity Frequency 1 Check ...

Page 60: ...aminated Ja kontaminiert mit Yes contaminated with explosiv explosive entzündlich flammable brandfördernd oxidizing komprimierte Gase compressed gases ätzend caustic giftig Lebensgefahr poisonous risk of death gesundheitsge fährdend harmful to health gesund heitsschädlich health hazard umweltge fährdend environmental hazard Bitte Sicherheitsdatenblatt beilegen Please enclose safety data sheet Das ...

Page 61: ...ersetzen Sie vor der Inbetrieb nahme die Verkabelung wieder in den ursprünglichen Zustand Fragen Sie im Zweifel beim Hersteller nach weiteren Informationen Analysing defective assemblies is an essential part of quality assurance at Bühler Technologies To ensure conclusive analysis the goods must be inspected unaltered if possible Modifications or other damages which may hide the cause or render it...