Bühler technologies EGK 2A Ex Manuel utilisateur
Gas Analysis
Installation and Operation Instructions
Original instructions
Sample gas cooler
EGK 2A Ex
BE450020
09/2019
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: [email protected]
Internet: www.buehler-technologies.com
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 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 2019
Document information
Document No......................................................... BE450020
Version.........................................................................09/2019
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
2 Safety instructions.........................................................................................................................................................................................................4
2.1 Important notices................................................................................................................................................................................................4
2.2 General hazard warnings ................................................................................................................................................................................. 5
3 Product description ....................................................................................................................................................................................................... 7
3.1 General description ............................................................................................................................................................................................ 7
3.2 Functional principle of the cooler .................................................................................................................................................................. 7
4 Transport and storage ..................................................................................................................................................................................................8
5 Installation and connection ........................................................................................................................................................................................9
5.1 Installation site requirements.........................................................................................................................................................................9
5.2 Connecting the gas- and condensate connections ...................................................................................................................................9
5.3 Electrical connections and potential equalisation.................................................................................................................................. 10
5.4 Testing insulation resistance..........................................................................................................................................................................11
6 Operation and controls ...............................................................................................................................................................................................12
6.1 Switching on the sample gas cooler ............................................................................................................................................................ 12
6.2 Operation of the menu functions .................................................................................................................................................................13
6.2.1 Menu navigation overview.............................................................................................................................................................. 13
6.2.2 Detailed description of the operational principle ....................................................................................................................14
6.3 Description of the menu functions.............................................................................................................................................................. 14
6.3.1 Main menu...........................................................................................................................................................................................14
6.3.2 Submenu............................................................................................................................................................................................... 15
7 Maintenance.................................................................................................................................................................................................................. 16
7.1 Maintenance........................................................................................................................................................................................................17
7.1.1 Testing the pressure monitoring circuit...................................................................................................................................... 17
7.1.2 Checking the starting capacitor / the starting capacitors ..................................................................................................... 17
7.1.3 Cleaning the condenser (air heat exchanger)............................................................................................................................ 17
7.2 Parts replacement..............................................................................................................................................................................................17
7.2.1 Replacing the heat exchanger ........................................................................................................................................................18
7.2.2 Replacing the Pt100 ...........................................................................................................................................................................18
7.2.3 Replacing the electronics .................................................................................................................................................................19
7.2.4 Replacing the starting capacitor....................................................................................................................................................19
7.2.5 Replacing the display ....................................................................................................................................................................... 20
8 Service und repair .........................................................................................................................................................................................................21
8.1 Troubleshooting ................................................................................................................................................................................................22
8.2 Safety instructions ............................................................................................................................................................................................23
8.3 Checking / resetting the pressure monitor switch..................................................................................................................................23
8.4 Press switches respond during initial start-up ........................................................................................................................................24
8.5 Spare parts and accessories ...........................................................................................................................................................................24
9 Disposal........................................................................................................................................................................................................................... 25
10 Durability list.................................................................................................................................................................................................................26
11 User book (Please make copies) ............................................................................................................................................................................... 27
12 Appendices.....................................................................................................................................................................................................................28
12.1 Technical Data....................................................................................................................................................................................................28
12.2 Dimensions .........................................................................................................................................................................................................29
12.3 Heat exchanger..................................................................................................................................................................................................29
12.3.1 Heat exchanger description ........................................................................................................................................................... 29
12.3.2 Heat exchanger overview................................................................................................................................................................ 29
12.4 Performance data..............................................................................................................................................................................................30
iBühler Technologies GmbHBE450020 ◦ 09/2019
EGK 2A Ex
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 pres-
sure- and temperature limits.
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 it also contains the item number:
Cooler Power supply Item no.
EGK 2A Ex base unit 230 V, 50/60 Hz 45 902 000 000
EGK 2A Ex base unit 115 V, 50/60 Hz 45 901 000 000
The heat exchanger model and number with which your cooler is equipped depends on your purchase order. The heat ex-
changer options are:
Heat exchanger Material Item no.
Single-leg heat exchanger TS Stainless steel 1.4571 45 10 023
Two-leg heat exchanger DTS Stainless steel 1.4571 45 01 026
Single-leg heat exchanger TG Duran glass 45 10 013
Two-leg heat exchanger DTG Duran glass 45 01 027
Single leg heat exchanger TV-SS PVDF plastic 45 01 004
Two-leg heat exchanger DTV PVDF plastic 45 01 028
The cooler must be connected via protective motor switch sold separately. For more details please refer to chapter “Electrical
connections and potential equalisation”.
When connecting, please note the specific values of the cooler, and the correct version when order spare parts (example: heat
exchanger or electronics).
1.3 Type plate
Example:
Sample Gas Cooler EGK 2A Ex
100086648 459020000000 001
II 2 G Ex pxb eb mb q [ia] IIC T4 Gb
230 V 50/60 Hz
BVS 03 ATEX E 301 X; CE0158
Year: 2018
Manufacturer including
address
Model designation
Blast protection marking
Serial no., Item no.
Mains voltage
Approval number
Year of manufacture
1.4 Scope of delivery
– Cooler
– Product documentation (brief instruction + CD)
– Connection-/mounting accessories (optional)
3Bühler Technologies GmbHBE450020 ◦ 09/2019
EGK 2A Ex
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 of the device will void the war-
ranty provided by Bühler Technologies GmbH,
– complying with the threshold values specified in the data sheet and the instructions,
– monitoring equipment / protection devices are connected correctly,
– service and repair work not described in these instructions are performed by Bühler Technologies GmbH,
– genuine spare parts are used.
In Germany, erecting electrical systems in explosive areas requires compliance with the following regulations:
– EN60079-14 / VDE0165-1 "Explosive atmospheres – Section 14: Electrical installations design, selection and erection"
– Ordinance on Industrial Safety and Health (BetrSichV)
– Ordinance on Hazardous Substances (GefStoffV)
– The applicable national regulations must be observed abroad.
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.
4 Bühler Technologies GmbH BE450020 ◦ 09/2019
EGK 2A Ex
Warning signs
In this manual, the following warning signs are used:
Warning against hazardous situations Warning against possible explosions
Warning against electrical voltage General notice
Warning against respiration of toxic gases Disconnect from mains
Warning against acid and corrosive substances Wear respirator
Warning against potentially explosive atmospheres Wear eye/face protection
Warning against hot surface Wear protection gloves
2.2 General hazard warnings
Installation of the device shall be performed by trained staff only, familiar with the safety requirements 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 ob-
served.
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.
5Bühler Technologies GmbHBE450020 ◦ 09/2019
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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 / condensate. Use
gloves, respirator and face protector under certain circumstances.
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.
6 Bühler Technologies GmbH BE450020 ◦ 09/2019
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3 Product description
3.1 General description
A sample gas cooler is used to lower the moisture content, thus the dew point of a sample gas. This is intended to on one hand
lower measurement accuracies through volume influence, on the other to avoid for moisture to condense further along the
measuring path and cause damage, particularly to the delicate measuring cell of the analyser.
The sample gas cooler is therefore a part of conditioning, which is illustrated as a typical flow chart below.
calibration gas
Fig.1: A100060 Flow Chart
1 Probe 6 Condensate drain
2 Line 7 Fine filter
3 Reversing tap for calibration 8 Moisture detector
4 Gas pump 9 Flow meter with control valve
5 Gas cooler 10 Analyser
The cooling circuit cool a cooling block (left front of the unit) to a defined temperature. The actual heat exchangers are placed in-
side this cooling block, thus also cooled.
The warm, "moist" sample gas is fed into the inlet at the top of the heat exchanger, where it is cooled, and exits through the out-
put at the top. The water vapour condenses on the cooling surfaces of the heat exchanger and drains to the bottom, where the
condensate output of the heat exchanger is located.
From there, the condensate can then be collected in a receptacle or drained directly using an automatic condensate drain or
peristaltic pump. An automatic condensate drain can only be used if the heat exchanger has excess pressure.
As already mentioned in the preface, there are various heat exchanger models and materials. When making your selection,
please be sure to pay particular attention to the durability (see Durability list) and the approved pressure levels (see enclosed
data sheet).
3.2 Functional principle of the cooler
On principle, the cooling circuit is constructed just as a refrigerator. In place of the cooled interior, it has the cooling block men-
tioned above. A compressor is switched on or off within a tolerance range.
After switching on the cooler the block temperature will be displayed. The display will flash until the (set) temperature range
around the preset initial dew point has been reached. The display will indicate an error in form of a flashing error message. The
electronics also provides this differentiation as a potential-free output used in fail-safe control. Thus a power failure is also re-
ported to the master display. Within the two ranges the LED may be steady or flash. For a detailed description of the various
states illustrated, please refer to chapter Operation .
7Bühler Technologies GmbHBE450020 ◦ 09/2019
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4 Transport and storage
The sample gas cooler must be transported in the original packaging or a suitable alternative. It must be transported upright.
Never place it on its side during transport, as oil could otherwise leak from the compressor and enter the cooling circuit. This can
result in cooler start-up problems or failure.
During extended periods of non-use, protect the cooler against moisture and heat. It must be stored in a covered, dry, vibration-
and dust-free location at temperatures between -20°C and +40°C.
8 Bühler Technologies GmbH BE450020 ◦ 09/2019
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