M&C 03G6000, Instruction Manual

Page 1: ...Gas Conditioning Unit Series PSS SS M05 for Marine Application Instruction Manual Version 1 01 00 ...

Page 2: ...hesitate to contact M C or your M C authorized distributor You will find all the addresses in the appendix of this manual For additional information about our products and our company please go to M C s website www mc techgroup com There you will find the data sheets and manuals of our products in German and English This Operating Manual does not claim completeness and may be subject to technical ...

Page 3: ...the Tubing 20 12 1 Media Connections 20 12 2 Electrical Connections 22 12 3 Electrical Installation 23 13 Starting 24 13 1 Function Sequence and LED Function Display 25 14 Closing Down 26 15 Maintenance 27 15 1 Maintenance Cooler 28 15 1 1 Replacing the Heat Exchangers 28 15 2 Maintenance Peristaltic Pump 29 15 2 1 Changing the Pump Tubing 30 15 2 2 Changing Contact Pulleys and Springs 31 15 2 3 R...

Page 4: ...ctions 2 to 5 20 Figure 5 Media connection for downstream analyzer 21 Figure 6 Cable glands 23 Figure 7 Terminals X1 X2 X3 24 Figure 8 Changing the pump tubing 30 Figure 9 Different pump tube sizes 31 Figure 10 Disassembly of pump head and driver 31 Figure 11 Check of axes and rolls 32 Figure 12 Sectional drawing MP F 36 Figure 13 Wiring diagram part 1 44 Figure 14 Wiring diagram part 2 45 ...

Page 5: ...ructions and warnings closely Read this manual carefully before commissioning and operating the device If you have any questions regarding the product or the application please don t hesitate to contact M C or your M C authorized distributor 2 DECLARATION OF CONFORMITY CE Certification The product described in this operating manual complies with the following EU directives RoHS Directive The requi...

Page 6: ...according to DNV GL can be found in the technical data of this instruction manual Check that the location is weather protected It should not be subject to direct rain or liquids This device is NOT certified to be installed or operate in explosive hazardous areas Installation maintenance inspections and any repairs of the devices must be carried out only by qualified skilled personnel in compliance...

Page 7: ...trained in the repair of such devices of automation technology and who are authorised to operate to earth and to designate circuits and devices systems in accordance with the standards of safety technology 3 3 ELECTRICAL VOLTAGE All work including in particular work on live components must be carried out in accordance with current applicable safety guidelines The gas treatment device must in this ...

Page 8: ...tely used products and does not cover the consumable parts Please find the complete warranty conditions in our terms and conditions The warranty includes a free of charge repair in our production facility or the free replacement of the device If you return a device to M C please be sure that it is properly packaged and shipped with protective packaging The repaired or replaced device will be shipp...

Page 9: ...e n t i o n Attention indicates that an unintended result or situation can occur if the corresponding information is not taken into account Note Note indicates important information relating to the product or highlights parts of the documentation for special attention Qualified personnel Qualified personnel are experts who are familiar with the installation mounting commissioning and operation of ...

Page 10: ...glasses Protect your eyes while working with chemicals or sharpe objects Wear safety glasses to avoid getting something in your eyes Wear protective clothes Working with chemicals sharpe objects or extremly high temperatures requires wearing protective clothes ...

Page 11: ...omponents such as cooler peristaltic pump bellow valve pump flowmeter with sensor and components for auto calibration of the analyzer 6 1 SERIAL NUMBERS The serial number plate is located on the right side of the stainless steel housing Note Please refer to this serial number if you have any questions about the device or if you need to order spare parts or consumables 6 2 POWER SUPPLY The valid su...

Page 12: ...dle valve to adjust the flow through the cooler E1 The sample gas enters the gas conditioning device through the cooler The bellow pump M1 pumps the gas through the solenoid valve Y1 the filter FI1 and the flowmeter FM1 The 3 2 way solenoid valve Y1 is used for the auto calibration function of the analyzer The solenoid valve Y1 is controlled by the analyzer To auto calibrate the analyzer air is fe...

Page 13: ...ream analyzer The error messages can be routed to the signalling terminal block Note Detailed technical information on the built in analysis device as the sample gas cooler the pumps etc can be found in the attached operating instructions The technical documentation supplied and the instructions contained must be observed at all times ...

Page 14: ...perature Max 80 kJ h Sample gas connection inlet Ø 6 mm tube Sample gas connection outlet tubing connection DN 4 6 Condensate connection tubing connection DN 4 6 Condensate removal Peristaltic pump SR25 2W Sample gas pump MP F05 Ready for operation Approx 10 min Power consumption 250 VA up to max 1600 VA with heated sample gas line Mains power supply 230 V 10 50 or 115 V 10 60 Hz Electrical connec...

Page 15: ...id valve for test gas feeding Sample gas pump MP F 05 with needle valve Filter FP 2T D Filter porosity 2 μm with integrated liquid alarm sensor LA Flow meter FM40 with flow monitoring FA 20mo Peristaltic pump SR25 for continuous automatic condensate drainage Figure 2 Dimensions and design SS M05 ...

Page 16: ...a temperature deviation of 3 C 5 4 F from the factory set point 5 C 41 F The peristaltic pump removes the accumulated condensate Downstream the cooler there is a micro filter with a 2 μm filter element and integrated liquid alarm sensor LA In case of leaking the liquid alarm sensor switches off the sample gas pump automatically A PTFE bellows pump is attached to the outside of the housing This pum...

Page 17: ... equipment Do not lift move or carry the device without help A second person is required to lift move or carry the device Before installation and commissioning of the gas conditioning device the operating instructions of the components used must be read and followed Note The fan must have a minimum distance of 200 mm to adjacent devices or boundaries Install the gas conditioning device with a mini...

Page 18: ...ecessary 11 1 CONNECTING THE SAMPLE GAS LINE Note Do not mix up connections The upper heat exchanger connection is the inlet the side heat exchanger connection is the outlet and the lower heat exchanger connection is the condensate outlet The sample gas line is connected to the inlet of the external heat exchanger The heated part of the sample gas line should end approx 30 cm in front of the heat ...

Page 19: ...01 00 19 Connect the heated sample gas line as follows 1 Connect heated sample line E2 to the inlet of the heat exchanger A1 At least 60 mm unheated tube should be at the end of the heated line 2 Check tightness 3 Connect sample gas outlet ...

Page 20: ...o the media connection 2 Media connection 3 is the condensate outlet of the peristaltic pump The media connection 3 must be lead to a condensate collecting container supplied by the customer Bulkhead fittings 4 and 5 are connected to the inlet and outlet of the pump Media connection 2 Media connection 3 Bulkhead fittings connected to the pump in outlet Figure 4 Media connections 2 to 5 The output ...

Page 21: ...nsation tubing are to be assembled as follows Remove the union nut from the sealing ring couplings by turning it anti clockwise The nut should be removed from the thread with great care to ensure that the loose sealing ring in the nut is not lost Place the union nut over the connecting tubing Place the sealing ring over the connecting tubing with the thicker bead towards the nut Place the tubing o...

Page 22: ... fuse corresponding to the nominal current over current protection for electrical details see technical data The PSS 5 gas conditioning system is available with either 230 V 50 Hz or with 115 V 60 Hz for circuit diagram see Appendix Fuse protection is provided by a 16 A circuit breaker as standard Fuse protection is provided by a 16 A circuit breaker as standard This is located on the terminal sup...

Page 23: ... Connect the mains power supply see X1 in circuit diagram a Terminal X1 Position Wire 1 L 11 N 18 PE 2 Use shielded cables to connect the following alarms Liquid alarm and Flow alarm see X2 in circuit diagram a Liquid alarm terminal X2 Position Wire 1 MC 2 NO 3 NC b Flow alarm terminal X2 Position Leiter 4 MC 5 NO 6 NC 3 Connect the solenoid valve Y1 see X3 in circuit diagram a Solenoid valve 24 V...

Page 24: ...onditioning system with a heated sample gas line the temperature must be checked at the temperature controller 3 Connect power to the system cables 4 Switch circuit breaker 1 to position ON 5 Switch circuit breaker 2 to position ON with optional sample gas line Carry out the following steps for commissioning 1 Switch on the fuses circuit breakers of the gas treatment device a F2 heated sample tube...

Page 25: ...t by the ECP 1150M electronic control unit Switching on the gas cooler The upper red LED turns on as soon as the gas cooler is connected to the power outlet The temperature of the gas cooler is higher than 8 C 46 4 F Normal operating mode After about 10 minutes the temperature of the gas cooler drops to under 8 C 46 4 F The upper red LED turns off The collective status alarm is deactivated If an e...

Page 26: ...of a long term closing down for example after a series of measurements has been completed it is recommended to backflush the gas conditioning system with ambient air or inert gas Under normal conditions the equipment only needs to be backflushed for 3 to 5 minutes Condensate residue should also be removed from the system Aggressive condensate possible Media residues in tubing Chemical burns caused...

Page 27: ... the filter FI2 C Check for condensate in the lines after the gas cooler C Check the temperature of the Peltier sample gas cooler E1 C Replace hoses of the peristaltic pump M2 C Replace valve plate and O rings of the bellow valve pump M1 M Replace bellows of the below valve pump M1 M M M C personnel or other trained personnel C Customer 1 Maintenance work must be carried out only by suitably train...

Page 28: ... We recommend the following procedures and in this order for replacement of the heat exchangers 1 Release the upper gas connections and lower condensate connections Warning Aggressive condensate Wear safety glasses and appropriate protective clothing 2 Pull the heat exchangers upwards with rotation out of the cooling block Replace the heat exchangers as follows 1 Dry and clean the push in opening ...

Page 29: ...an be found at www mc techgroup com Before starting any maintenance work make sure that any work done on the device is in compliance with all relevant regulations and standards Warning Inhalation hazard possible if using toxic or asphyxiant gases Purge peristaltic pump with inert gas or air before opening If the pump is used for toxic gas or asphyxiant oxygen displacing gas it needs to be purged w...

Page 30: ... S bolt 3 Tubing set 4 contact pulley 5 springs Figure 8 Changing the pump tubing For changing the pump tubing please proceed as follows 1 Unplug the pump from the mains voltage The device needs to be voltage free 2 Open tube connections at the pump 3 Press conveying belt at the recessed grips and turn S bolt clockwise up to limit stop 4 Take away conveying belt and remove the old tubing set from ...

Page 31: ... While mounting make sure that the center of rotation and the driver are aligned Use genuine spare parts only Follow these instructions to change the contact pulley and springs 1 Disconnect the peristaltic pump from power supply 2 Unscrew nuts of the pump head wrench size 5 5 1 Pump head nuts 2 Pump head 3 Springs 4 Groove 5 Driver roll carrier 6 Collar of the shaft bore Figure 10 Disassembly of p...

Page 32: ...ght and left springs for the first delivery When spare springs are ordered for simplified storage only one type will be delivered right spring which can be used for all four springs and will replace without any problems the initial springs The replacement springs guarantee full functionality when all four springs are replaced 7 Make sure that contact pulleys move easily on the axis After remountin...

Page 33: ...and synthetic rubber parts Use oil free compressed air to clean the parts if available Aggressive condensate possible Media residues in tubing Chemical burns caused by aggressive media possible Wear protective gloves and protective glasses Wear proper protective clothing 15 2 5 REPAIR INFORMATION Note When sending the peristaltic pump to M C customer service for repair please indicate the type of ...

Page 34: ...fore servicing Warning High voltage Working without disconnecting the power supply may cause an electrical shock Disconnect power supply before any assembly maintenance or disassembly Secure the pump against accidental restart Aggressive condensate possible Chemical burns possible due to aggressive media For general electrical and mechanical work on the pump wear personal protective equipment PPE ...

Page 35: ...Check in suitable intervals Replace when damaged with original parts in perfect condition Equipotential bonding Check equipotential bonding between pump enclosure and motor The equipotential bonding needs to be lower than 0 3 Ohm Use lock washers for the screws Additional components accessories During maintenance any upstream filters separators or coolers must be checked for proper functioning Not...

Page 36: ...es B back into the cleaned valve seats Make sure that the valve plates are in the correct position 2 Install the upper pump head A and then the pressure ring H again Align both so that the screws fit into the threads in the housing 3 Check that the bellows are seated correctly The bellows must be attached to the connecting rod 4 Fasten the pressure ring H with the four hexagon socket screws G Firs...

Page 37: ...e of the boreholes in the valve seat with your fingers and blow pressured air into the other borehole This will loosen the lower pump head D 6 Unscrew the bellows E from the connection rod Please make sure to leave any spacers which might be there on the threaded pin 7 Screw new bellows hand tight onto the connection rod After replacing the bellows please follow these steps to re assemble the pump...

Page 38: ...t then select the adjacent pair Repeat in the same sequence going for a hand tight setting 6 Then tighten the four hexagon socket screws alternately in the same sequence with a torque to a value of 5 Nm 3 69 ft lbs 7 Screw the crankcase cover back on again Tighten the three hexagon socket screws F wrench 3 mm by hand 15 3 3 CLEANING INSTRUCTIONS When changing valve plates and bellows inspect all p...

Page 39: ...tch is in position 1 OK Check the fine fuse on connector block OK Cooler does not function Cooler alarm registers excess temperature Cooler turns off sample gas pump automatically Ambient temperature too high OK Cooler failure check manual ECP1150M OK Middle LED on cooler is green Cooler works but gas flow is interrupted Sample gas pump doesn t work Check voltage on clamps X1 14 and X1 9 ok Sample...

Page 40: ...tion manual Adjust needle valve to the desired flow Middle LED on cooler is green Cooler and sample gas pump are working condensate in sample gas line Peristaltic pump tubing defective Peristaltic pump not working WARNING Aggressive condensate Use personal protective equipment Change pump tubing see instruction manual peristaltic pump SR25 1 OK Peristaltic pump SR25 1 defective Check peristaltic p...

Page 41: ...ilter body F 120G D of glass with GL25 condensate connection thread R 1 1 1 90F0020 Union nut GL 25 R 1 1 1 90F0025 PTFE sealing ring GL 25 12mm Ø R 1 1 1 Peristaltic pump SR25 1 and gas pump MP F05 90P1007 SR25 pump hose with PVDF tube connectors DN 4 6 mm C 1 2 4 90P1110 Valve plate MP F C 2 4 6 95P0035 O Ring FEP 18x2 MP F R 2 4 6 95P0030 Pump head MP F lower part material PTFE S 95P0025 Pump h...

Page 42: ...lowmeter glass FM40 R 2 4 6 Diverse 90K6030 Fine fuse 4A T 5mmx20mm for PSS R 5 5 5 90G0020 Fine fuse 10A T 5mmx20mm for PSS with option temp controller and heated sample line R 5 5 5 Hose and hose fittings 05V3215 Bulkhead union SV PVDF DN 4 6 PSS 5 optional PVDF Polyvinylidenfluoride R 2 2 2 05V6600 Sealing ring 4 6 PVDF see above R 5 10 10 05V6505 Union nut M10 4 6 PP see above R 5 10 10 05V660...

Page 43: ...c techgroup com Instruction manual electric gas cooler ECP1150M Universal Filters FP FT FPK FS FSS Data sheet 7 1 Instruction manual bellows pump with needle valve MP F05 Instruction manual peristaltic pump SR25 1 Liquid alarm sensor LA1S and electronic controllers type LA1 4 Data sheet 8 1 Flow meter FM40 Data sheet 9 2 Ball valves L PV 1 Data sheet 11 1 Temperature controller 701 Data sheet 4 2 ...

Page 44: ...44 SS M05_Marine 1 01 00 www mc techgroup com Figure 13 Wiring diagram part 1 ...

Page 45: ...www mc techgroup com SS M05_Marine 1 01 00 45 Figure 14 Wiring diagram part 2 ...

Page 46: ...46 SS M05_Marine 1 01 00 www mc techgroup com ...

Page 47: ...www mc techgroup com SS M05_Marine 1 01 00 47 ...

Page 48: ...48 SS M05_Marine 1 01 00 www mc techgroup com ...