BE450008 EGK 2 Ex - buehler

Transcription

Sample gas cooler
EGK 2 Ex
Installation and Operation Instructions
Original instructions
BE450008 ◦ 05/2015
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 responsible for misusing the product or unreliable function due to
unauthorised modifications.
All rights reserved. Bühler Technologies GmbH 2015
Document information
Document No. ....................................BE450008
Version .................................................. 05/2015
Sample gas cooler EGK 2 Ex
Contents
Contents
1 Introduction.......................................................................................................................................................... 2
1.1 Intended Use ................................................................................................................................................. 2
1.2 Design types .................................................................................................................................................. 2
1.3 Type plate ...................................................................................................................................................... 2
1.4 Scope of delivery ........................................................................................................................................... 2
2 Safety instructions .............................................................................................................................................. 3
2.1 Important notices ........................................................................................................................................... 3
2.2 General hazard warnings............................................................................................................................... 4
3 Product description............................................................................................................................................. 6
3.1 General description........................................................................................................................................ 6
3.2 Functional principle of the cooler ................................................................................................................... 6
4 Transport and storage ........................................................................................................................................ 7
5 Installation and connection ................................................................................................................................ 8
5.1 Installation site requirements ......................................................................................................................... 8
5.2 Connecting the gas- and condensate connections........................................................................................ 8
5.3 Electrical connections and potential equalisation .......................................................................................... 9
5.4 Testing insulation resistance ....................................................................................................................... 10
6 Operation and controls ..................................................................................................................................... 11
6.1 Switching on the sample gas cooler ............................................................................................................ 11
6.2 Operating the sample gas cooler................................................................................................................. 11
7 Maintenance....................................................................................................................................................... 12
7.1 Maintenance ................................................................................................................................................ 13
7.1.1 Testing the pressure monitoring circuit ............................................................................................ 13
7.1.2 Checking the starting capacitor / the starting capacitors ................................................................. 13
7.1.3 Cleaning the condenser (air heat exchanger).................................................................................. 13
7.2 Parts replacement........................................................................................................................................ 13
7.2.1 Replacing the heat exchanger ......................................................................................................... 13
7.2.2 Replacing the Pt100......................................................................................................................... 14
7.2.3 Replacing the electronics................................................................................................................. 14
7.2.4 Replacing the starting capacitor....................................................................................................... 15
8 Service und repair ............................................................................................................................................. 16
8.1 Troubleshooting ........................................................................................................................................... 17
8.2 Safety instructions ....................................................................................................................................... 18
8.3 Checking / resetting the pressure monitor switch ........................................................................................ 18
8.4 Press switches respond during initial start-up ............................................................................................. 19
8.5 Spare parts and accessories ....................................................................................................................... 19
9 Disposal.............................................................................................................................................................. 20
10 Durability list...................................................................................................................................................... 21
11 User book (Please make copies)...................................................................................................................... 23
12 Attached documents ......................................................................................................................................... 24
47027083............................................................................................................................................................. 25
DE450010 EGK 2 Ex .......................................................................................................................................... 26
KX450007 EGK 2 Ex .......................................................................................................................................... 30
BVS03ATEXE301X............................................................................................................................................. 31
SEV10ATEX0154X ............................................................................................................................................. 39
Sira 99ATEX3172U............................................................................................................................................. 41
Declaration of Contamination status............................................................................................................... 48
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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 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
EGK 2 Ex base unit
EGK 2 Ex base unit
Power supply
230 V, 50/60 Hz
115 V, 50/60 Hz
Item no.
45 902 000 000
45 901 000 000
The heat exchanger model and number with which your cooler is equipped depends on your
purchase order. The heat exchanger options are:
Heat exchanger
Single-leg heat exchanger TS
Two-leg heat exchanger DTS
Single-leg heat exchanger TG
Two-leg heat exchanger DTG
Single leg heat exchanger TV-SS
Two-leg heat exchanger DTV
Material
Stainless steel 1.4571
Stainless steel 1.4571
Duran glass
Duran glass
PVDF plastic
PVDF plastic
Item no.
45 10 023
45 01 026
45 10 013
45 01 027
45 01 004
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:
Manufacturer's address
Type description
Messgaskühler EGK 2 Ex
Type of protection
II 2G Ex px e mb q [ia] IIC T4 Gb
Order no., part-no. and
year of construction
Power supply
10098317 459021100000 Bj: 2013
230 V 50/60 Hz
ce0158 BVS 03 ATEX E 301 X
Number of certificate
1.4 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 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 warranty 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:
– EN 60079-14 / VDE 0165-1 "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-, specification- 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
05/2015
Signal word for important information to the product.
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Safety instructions
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 observed.
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.
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Safety instructions
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.
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Product description
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. 2: A100060 Flow Chart
1
2
3
4
5
Probe
Line
Reversing tap for calibration
Gas pump
Gas cooler
6
7
8
9
10
Condensate drain
Fine filter
Moisture detector
Flow meter with control valve
Analyser
The cooling circuit cool a cooling block (left front of the unit) to a defined temperature. The actual heat exchangers are placed inside 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 output 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 mentioned above. A compressor is switched on or off within a tolerance range.
The operating mode of the cooler is indicated by an LED, with green indicating the cooler is
within the operating range, and red it is outside of this range or an error has occurred. The electronics also provides this differentiation as a potential-free output used in fail-safe control. Thus
a power failure is also reported 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.
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Transport and storage
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.
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Installation and connection
5 Installation and connection
5.1 Installation site requirements
The unit is intended for use in enclosed areas. Adequate protection from the weather must be
provided when used outdoors. The approved environmental conditions for explosive areas according to the enclosed data sheet must be met.
The sample gas cooler can be used as a stand-alone unit or wall mounted. Do not obstruct the
convection. Maintain a clearance to other objects of at least 10 cm all around the bottom of the
cooler. Above the cooler, particularly the rear vent, maintain a clearance of at least 30 cm. With
respect to components installed above, remember the air emitted upward from the cooler can
be very warm.
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 inside temperature.
When wall mounting the sample gas cooler, be sure the wall or the cabinet provide adequate
weight bearing and stability.
5.2 Connecting the gas- and condensate connections
CAUTION
Explosion hazard
Before using any accessories make sure these are appropriate for the application (e.g. Ex-zone / Category, chemical resistance).
On glass heat exchangers the correct position of the seal is important when connecting the gas
lines. The seal consists of a silicone ring with a PTFE sleeve. The PTFE side must face the
glass thread.
Glass
PTFE
Fig. 4: A100000 Heat exchanger seal
Run the gas supply with a downward slope all the way to the cooler. If a large amount of condensate accumulates, we recommend using a condensate pre-separator before the cooler. Our
fluid separators with automatic condensate drain, 11 LD spec., AK 20 V or model 165, are suitable.
The gas inlets on the heat exchanger are marked "E" and/or in red, outlets are marked "A".
When using glass- or PVDF heat exchangers the enclosed cover must be used. In this case remove the cover, pull the hoses through the cover, connect the hoses to the heat exchanger, and
finally replace and secure the cover.
Be careful when connecting the glass- and PVDF heat exchanger, and only tighten the fittings
by hand.
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DANGER
Explosion hazard due to flame propagation
Severe injuries and damage to the system
If the process holds a risk of flame propagation, install a flame arrestor.
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 collectors or peristaltic pumps.
Glass vessels and automatic condensate drains are available for draining condensate for external mounting below the unit.
Connecting a condensate drain: 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 suspended directly to the connecting tube, for hoses the condensate
drain must be secured separately using a clamp.
Condensate lines must always be installed with a slope and a minimum inside diameter of DN
8/10.
An external peristaltic pump may be installed a little away from the cooler.
Be sure the gas line connections are tight.
5.3 Electrical connections and potential equalisation
DANGER
Electrical voltage
NOTICE
When used in explosive areas
In Germany, erecting electrical systems in explosive areas requires compliance
with the following regulations:
- EN 60079-14 / DIN VDE 0165-1 "Explosive atmospheres – Part 14: Electrical
installations design, selection and erection"
- Ordinance on Industrial Safety and Health (BetrSichV)
- Ordinance on Hazardous Substances (GefStoffV)
Abroad, the respective national ordinance must be observed.
The sample gas cooler must be secured with suitable overload protection (protective motor
switch according to certification). A protective motor switch approved for equipment in explosive
areas per ATEX must be used. This type of protective motor switch is available as an accessory
(see attached data sheet).
The supply line diameters must be aligned with the rated current.
In addition, the fuse specifications must be met as indicated in the examination certificate (see
attached).
The status outlet can also be connected to an intrinsically safe inlet. The specifications for this
inlet must be met. The capacity and inductance of the contact are zero, so that only the cable
used must be considered.
Connecting the cooler
– On the black electrical housing loosen the four screws in the corners of the face.
– Carefully lift off the cover: The control elements are attached to the to the electronics with
cables.
– Turn the cover and set down on the cooler. Be careful not to tension the cables.
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– 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.
– Pay particular attention of the earth connection of the mains supply line: All the individual
parts are pre-installed on the threaded bolt at the bottom right inside the housing: Loosen the
nut and remove the nut, washers and ring cable lug. Attach the ring cable lug to the earth
wire of the power cable. Slide on the washers and ring cable lug in the order washer – ring
cable lug – washer – serrated washer, and tighten the nut.
– Now close the housing, remembering:
– No foreign objects, contaminants or moisture may be inside the junction box of the sample
gas cooler. Close the box dust- and waterproof (be sure not to crush any cables!). Use the
original seal when closing the junction box. Openings not being used must be covered with
approved plugs per Atex. Tighten all screw connections.
– Connect the potential equalisation for the cooler (threaded bolt below the electrical housing)
to the potential equalisation on site. Stray electric currents may not flow through this connection.
5.4 Testing insulation resistance
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!
This unit is equipped with extensive EMC protection. Testing the electric strength will damage
electronic filter components. The necessary tests of all assemblies required to be tested were
carried out at the factory (test voltage 1.5 kV).
If you wish to check the electric strength again yourself, only do so on the following individual
components. Please note the following items.
When testing the cooler electronics disconnect the earth connection from the cooler electronics.
Short circuit L and N and carry out the high voltage test against earth.
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, reconnect the compressor.
To test the Starting capacitors, disconnect its supply line from the controller electronics. Do not
disconnect the earth. Short circuit the supply lines, then carry out the electric strength test
against earth. After testing is completed, reconnect the starting capacitor(s).
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Operation and controls
6 Operation and controls
NOTICE
The device must not be operated beyond its specifications.
CAUTION
Hot surface
Risk of burns
Depending on the operating parameters, the air heat exchanger at the back of
the cooler can reach a temperature of up to 80 °C during operation.
6.1 Switching on the sample gas cooler
Before switching on the unit, check:
–
–
–
–
–
–
–
–
–
–
–
–
tube- and electrical connections are undamaged and correctly installed.
no sample gas cooler parts have been removed (e.g. cover).
protection- and monitoring devices are in place and function (protective motor switch).
ambient parameters are met.
Please note rating plate information!
the motor voltage and frequency matches the mains values.
electrical connections are securely connected and monitoring devices are connected and set
as prescribed!
air inlets and cooling surfaces are clean, and the air passage is not obstructed (see notices
under "Installation site requirements")!
precautions have been taken; potential equalisation!
the cooler is properly attached!
the junction box cover is closed and the cable glands properly sealed.
The protective motor switch must be adjusted to the rated current:
– for 230 V version: 1.3 A
– for 115 V version: 3.2 A
6.2 Operating the sample gas cooler
– Connect the mains voltage; the light will flash red.
– Consecutively press buttons "Start1" and "Start2"; the cooler will start up and the light will be
a steady red.
– After some time (approx. 10 minutes depending on the ambient temperature) the light will
change to flashing green. The status output will switch. The operating range (±3K of the temperature setting (typ. 5°C)) has now been reached. The cooler will continue to cool.
– After a while the operating point has been reached and the compressor will switch off. The
light will be steady green.
Once the temperature inside the cooling block rises again, the compressor will start again
and the light flash green again.
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Maintenance
7 Maintenance
– Maintenance of the device shall be performed by trained staff only, familiar with the safety requirements and risks.
– Only perform maintenance work described in this manual.
– Regard all relevant safety regulations and internal operating instructions during maintenance.
– Defective parts must be replaced immediately, and the unit, or the gas circuit, switched off.
DANGER
Electrical voltage
DANGER
Toxic, acidic gasses
Sample gas can be harmful.
a) Switch off the gas supply before performing maintenance and, if necessary,
flush the gas lines with air.
b) If necessary, ensure a safe gas discharge.
c) Protect yourself from toxic / acidic gasses when performing maintenance.
Wear appropriate 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 the back of
the cooler can reach a temperature of up to 80 °C during operation.
Allow the unit to cool down before performing maintenance.
NOTICE
- Always wait at least one minute before opening the electronics housing.
- Always shut off the gas supply before disconnecting the gas connection or
condensate drain components.
- Immediately replace defective parts, and switch off the cooler or the sampling
path.
- The functionality of the safety circuits must be tested annually. If the test outcome is negative, the unit must be sent to the manufacturer.
- Always transport the cooler upright.
- Always observe the requirements of the examination certificate (see attached).
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Maintenance
7.1 Maintenance
The following checks and, if necessary, cleaning must be performed at least once a year. No
additional maintenance is required. A maintenance record should be kept. A master operations
diary can be found at the end of the operating instructions for copying.
DANGER
Spark formation due to electrostatic charge
Always clean plastic housing parts and decals with a damp cloth.
Connect metal housings with earth potential (PE) conductive!
7.1.1 Testing the pressure monitoring circuit
The cooler must be operating and within the operating range (indicator green).
– Press the "Test1" button. The cooler will switch off and the LED will turn flashing red.
– Press the "Start1" button. The cooler will switch back on and the LED will turn green.
– Press the "Test2" button. The cooler will switch off and the LED will turn flashing red.
– Press the "Start2" button. The cooler will switch back on and the LED will turn green.
7.1.2 Checking the starting capacitor / the starting capacitors
There are two oval cut-outs on the right side of the sample gas
cooler. Inside these openings you will see the openings of the
starting capacitor, which are sealed with adhesive tape. This adhesive tape must be undamaged and adhere all over.
7.1.3 Cleaning the condenser (air heat exchanger)
From the top, at the back of the sample gas cooler you will see the ribs of the condenser. These
should be clean. They only need to be cleaned if large amounts of dust or deposits are visible.
Carefully clean with compressed air. Never use harsh cleaning agents.
7.2 Parts replacement
NOTICE
In general, no parts of the sample gas cooler should be defective. We recommend only having the Pt100, electronics, or starting capacitor replaced by the
manufacturer's works or trained customer service. You may perform the replacement according to the following instructions. However, in this event Bühler
Technologies GmbH is not responsible for improper replacement.
7.2.1 Replacing the heat exchanger
For the heat exchanger model, please refer to the item number under chapter Introduction
[_page 2].
Heat exchangers only need to be replaced when clogged or damaged. If they are clogged, we
recommend checking if using a filter will avoid future occurrences.
Please note the warnings under chapter Maintenance [_page 12].
– De-energise and depressurise the system.
– Disconnect the gas connections and condensate drain.
– Pull the heat exchanger up and out.
– Clean the cooling nest (hole inside the cooler block).
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Maintenance
– Apply silicone grease to the cooled outer surface of the new heat exchanger.
– Reinsert the heat exchanger into the cooling nest with a rotating movement.
– Reconnect according to chapter Electrical connections and potential equalisation [_page 9].
7.2.2 Replacing the Pt100
Item no.: 45 90 999 6
– Please observe the warnings in chapter “Maintenance”.
– De-energise (supply and status outlet) and depressurise the system.
– Loosen the four corner screws on the face of the black electrical housing.
– 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 the conductors of the Pt100 from the clamps (top row, far left, see drawing
47/027-08-3 in the appendix) and measure resistance. Depending on its temperature it
should be between approx. 102…110 Ohm. If the measurement differs significantly, it is defective.
– Remove the cover for the pressure controls. To do so, remove the two screws, carefully pull
the lower section forward, and slide the cover upward. You will now see the two pressure
controls.
– Loosen the screw connection of the Pt100 beneath the cooler block and carefully pull out the
Pt 100.
– Loosen the screw connection for the Pt100 cable at the electronics housing and pull the
cable out of the electronics housing.
– Loosen the screw connection from the bracket below the pressure controls, carefully pull the
cable out to the left.
– Insert the new Pt100 sensor through the screw connection using a little silicone grease – Do
not yet tighten the screw connection.
– Feed the cable through the bottom screw connection, behind the pressure controls, and into
the screw connection on the housing. Do not forget the nuts and rubber rings.
– Connect Pt100 (see drawing 47/027-08-3 in the appendix).
– Arrange the cable so it is without tension.
– Tighten the three screw connections.
– Attach the cover for the pressure controls.
– Close the housing, observing the following items: No foreign objects, contaminants or moisture may be inside the junction box of the sample gas cooler. Close the box dust- and waterproof (be sure not to crush any cables!).
– Now restart the cooler according to chapter “Operating the sample gas cooler”. Monitor if the
cooler runs in the operating range.
7.2.3 Replacing the electronics
Note the correct voltage:
230 V: Item no.: 45 90 999 7
115 V: Item no.: 45 91 999 7
– Disconnect all cables. Although the cables are colour coded, you should mark the conductors
if you are unsure.
– Loosen the 4 screws at the top of the board. The electronics can now be removed.
– Install the new electronics using the 4 screws.
– Reconnect all wires per drawing 47/027-08-3 in the appendix; the cable colours are specified.
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Maintenance
– Now restart the cooler according to chapter “Operating the sample gas cooler”.
– Test according to chapter “Testing the pressure monitoring circuit”.
– Allow the cooler to operate and check if it reaches the operating range.
7.2.4 Replacing the starting capacitor
Item no.: 45 90 999 2
NOTICE! This only needs to be replaced if inspection shows damage to the adhesive
strip!
– Disconnect gas connections.
– Remove the cooler and put in a safe location.
– Disconnect the cable(s) of the capacitor(s), disassemble earth. (cf. drawing 47/027-08-3 in
the appendix).
– Loosen the screw connection of the capacitor and remove the cable.
– Remove the back panel of the cooler.
– Loosen the starting capacitor retaining plate at the bottom left.
– Remove the retaining plate with the capacitors.
– Loosen the nut of the capacitor to be replaced and remove the capacitor.
– Cut the cable of the new capacitor to that of the old, but do not yet crimp on the cable lug.
– Install the new capacitor with the nut, but do not yet tighten the nut all the way
– Feed the cable(s) through the grommets of the stack.
– Slide the retaining plate and capacitor(s) into the stack.
– Secure the angle bracket; arrange the adhesive strips of the capacitors toward the sight window at the side of the stack, tighten the capacitor nut.
– Attach the back panel.
– Feed the cable through the screw connections, do not forget the nut and rubber ring.
– Crimp the cable lug to the earth wire.
– Connect the capacitor(s) according to drawing 47/027-08-3 in the appendix.
– The earth must be assembled as specified in the drawing!
– Now restart the cooler according to chapter “Operating the sample gas cooler”.
– Test according to chapter “Testing the pressure monitoring circuit”.
– Allow the cooler to operate and check if it reaches the operating range.
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Service und repair
8 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].
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Service und repair
8.1 Troubleshooting
CAUTION
Risk due to defective device
Personal injury or damage to property
a) Switch off the device and disconnect it from the mains.
b) Repair the fault immediately. The device should not be turned on again before elimination of the failure.
Problem / malfunction
Possible cause
Indicator doesn't light
– No power supply
– Protective device (protective
motor switch) was triggered
– Electronics defective
Indicator flashing red
–
–
–
–
Indicator continuously red –
–
–
–
–
Condensate inside the
gas output
–
–
–
Reduced gas flow rate
–
Protective device is triggering
–
–
–
Action
– Connect
– see there
– Replace or have replaced; If
the error recurs, check the
power supply for malfunctions
Cooler not yet started or the
– Start according to chapter
"Test” button was accidentally
"Operating the sample gas
pressed
cooler [_page 11]"
Pressure monitor was triggered
During first start-up
– See description chapter
"Press switches respond during initial start-up
[_page 19]”
later
– Reset pressure button (see
chapter "Checking / resetting
the pressure monitor switch
[_page 18]”)
Operating range not yet
– Wait a few minutes
reached
Heat input from sample gas is – Maintain / check specifications
too high: Dew point / flow /
gas temperature, or combination thereof, too high
Ambient temperature too high – Maintain / check specifications
Cooler ventilation restricted
– See instructions in chapter "Installation site requirements
[_page 8]”
Insufficient temperature:
– Remove and send in cooler
Sensor or electronics defective
Condensation trap full
– Empty condensation trap
Valve inside the automatic
– Flush in both directions
condensate drain is stuck
Cooler / heat exchanger over- – Maintain limits
loaded
Gas circuit clogged
– Remove and clean or replace
heat exchanger according to
chapter "Replacing the starting capacitor [_page 15]"
Heat exchanger iced over
– Remove and send in cooler
Coil- and terminal short circuit – Measure insulation resistance
Start-up time exceeded
– Check start-up requirements
Tab. 2: Troubleshooting
For additional information please refer to chapter "Parts replacement [_page 13]".
05/2015
BE450008
17
Service und repair
8.2 Safety instructions
–
–
–
–
DANGER
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.
Electrical 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 / condensate. Use gloves, respirator and face protector under certain circumstances.
8.3 Checking / resetting the pressure monitor switch
– Please note warnings under Maintenance [_page 12] .
– Switch off the cooler power supply and secure against restarting.
– Remove cover. To do so unscrew the two screws beneath,
carefully pull the lower section forward and slide the cover up.
You will now see the two pressure controls.
– Wait approx. 3 minutes after switching off the pressure controls
before testing.
– Very carefully press the face of the green button n the upper pressure control. If you feel a
click, the pressure control had been triggered. Do the same with the lower pressure control.
The actual cause for the trigger must be analysed (for assistance see chapter Troubleshooting [_page 17]).
– If neither of the two pressure controls were triggered, or the pressure controls can't be reset,
do not restart the cooler under any circumstances, but send it in for repair.
– Reattach the cover.
– The power supply can now be switched on again and the cooler restarted as described in
chapter Operating the sample gas cooler [_page 11] .
18
BE450008
05/2015
Service und repair
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 can be dissolve in the compressor oil than required
to safely operate the refrigerant circuit. After startup the cooler will then suddenly enter error
mode (flashing red) after a few minutes.
In this case reset the pressure control(s) according to chapter Checking / resetting the pressure
monitor switch [_page 18] and start the cooler. This may be required up to three times before
the refrigerant circuit and particularly the compressor have warmed up sufficiently for n adequate amount of coolant to be in the circuit.
8.5 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
Pt100
Electronics
230 V
115 V
Capacitor
Item no.
45 90 999 6
45 90 999 7
45 91 999 7
45 90 999 2
Tab. 4: Spare parts and accessories
05/2015
BE450008
19
Disposal
9 Disposal
The refrigerant circuit of the cooler contains R134a refrigerant.
Dispose of parts so as not to endanger the health or environment. Follow the laws in the country
of use for disposing of electronic components and devices during disposal.
20
BE450008
05/2015
Durability list
10 Durability list
Heat exchanger:
Formula
Medium
TS, DTS
Concentration V4A
CH3COCH3
C 6H 6
CI2
CI2
C 2H 6
C2H5OH
C 2H 4
C 2H 2
C 6H 5C 2H 5
HF
CO2
CO
CH4
CH3OH
CH3CI2
H3PO4
H3PO4
C 3H 8
C 3H 6O
HNO3
HNO3
HCI
HCI
O2
SF6
H2SO4
H 2S
N2
C 6H 5C 2H 3
C6H5CH3
H 2O
H2
1/1
1/1
10 % wet
4/4
97 %
1/1
2/0
50 %
1/0
1/0
1/0
1/0
3/4
1/1
1/1
technically pure 1/1
1/1
1/1
1-5 %
1/1
30 %
1/1
gaseous
1/0
1/0
1-10 %
1/1
50 %
1/2
1-5 %
2/4
35 %
2/4
1/1
0/0
1-6 %
1/2
1/1
1/0
1/0
1/1
1/1
1/0
Acetone
Benzol
Chlorine
Chlorine
Ethane
Ethanol
Ethylene
Ethyne
Ethylbenzene
Hydrofluoric acid
Carbon dioxide
Carbon monoxide
Methane
Methanol
Methylene chloride
Phosphoric acid
Phosphoric acid
Propane
Propylene oxide
Nitric acid
Nitric acid
Hydrochloric acid
Hydrochloric acid
Oxygen
Sulphur hexafluoride
Sulfuric acid
Hydrogen sulphide
Nitrogen
Styrene
Toluol (methylbenzene)
Water
Hydrogen
TG, DTG
Glass (Teflon coated
seal)
1/1
1/1
1/1
1/0
1/0
1/1
1/0
1/0
1/0
1/0
1/1
1/0
1/1
1/1
1/0
1/1
1/1
1/1
1/0
1/1
1/1
1/1
1/1
1/1
1/0
1/1
1/1
1/1
1/1
1/1
1/1
1/0
TV, DTV
PVDF
3/4
1/3
2/2
1/1
2/0
1/1
1/0
1/0
1/1
2/2
1/1
1/1
1/0
1/1
1/0
1/1
1/1
1/1
2/4
1/1
1/1
1/1
1/1
1/1
0/0
1/1
1/1
1/1
1/0
1/1
1/1
1/0
Tab. 6: 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 tables were listed based on specifications from various raw material manufacturers. The
values solely refer to laboratory tests using raw materials. Components made from these are often subject to impacts which cannot be determined in laboratory testing (temperature, pressure,
05/2015
BE450008
21
Durability list
material strain, impacts of chemical agents, design features, etc.). The values specified can
therefore only serve as a guideline. When in doubt, we recommend performing a test. These
specifications do not infer a legal claim, we exclude any warranty and liability. The chemical and
mechanical durability alone do not suffice to determine the usage property of a product, particularly e.g. the regulations for liquid fuels (Ex-protection) must be observed.
Durability to other mediums available upon request.
22
BE450008
05/2015
User book (Please make copies)
11 User book (Please make copies)
Maintenance
Device-no.
Operation time
Remarks
Signature
performed
(date)
05/2015
BE450008
23
Attached documents
12 Attached documents
–
–
–
–
–
–
24
Wiring diagram: 47/027-08-3
Data sheet: DE/DA 45 0010
Declaration of conformity: KX 45 0007
Gas cooler examination certificate
Examination certificate for components
Decontamination statement
BE450008
05/2015
Sample Gas Cooler
EGK 2 Ex
Accurate measurements of gases require gas samples with
stable dew points even under harsh ambient conditions.
The EGK models provide a CFC-free, compressor-type
cooling system connected to a cooling block. The cooling
block evenly dissipates the heat thus supporting the highly
efficient heat exchangers. The temperature of the cooling
block is regulated by the Bühler Constant Regulating
System. This system allows smooth regulation and eliminates
the disadvantages of the traditional on-off operating mode.
§ ATEX certificate Zone 1 (Cat. 2G)
§ CFC-free
§ Nominal cooling capacity 615 kJ/h
§ 1 or 2 heat exchangers can be
inserted: up to 4 gas paths
§ Self-checking with status output
The controller is self-checking. Significant deviation from the
preset is signalled by a status output. A bi-color LED on the
front shows 4 different operating conditions.
§ 4 operational conditions displayed
Condensate is removed either into condensate vessels or by
automatic condensate drainers which can be attached to the
heat exchangers within the cooler’s outer contour.
§ Easy to install
DE 45 0010
10/2014
Page 1/4
§ Simple operation and test
§ Condensate draining can be mounted
inside of outer shape
D - 40880 Ratingen, Harkortstr. 29
Tel.: + 49 (0) 2102 / 49 89-0 Fax: + 49 (0) 2102 / 49 89-20
e-mail: [email protected]
Technical Data
ATEX-class
Ready for operation
Cooling capacity (at 25 °C)
Ambient temperature
Gas outlet dewpoint (preset)
Dew point stability static
II 2 G Ex px e mb q [ia] IIC T4 Gb
after max. 20 minutes
> 615 kJ/h (170 W)
0 °C to 45 °C
approx. 5 °C
± 0.2 K (with st. steel)
± 0.5 K (with PVDF)
Over whole spec. Range:
±2K
Power supply
230 V, 50/60 Hz or 115 V, 50/60 Hz
Power consumption
250 VA (230 V)
300 VA (115 V)
Fuse
motor protection switch
Potential-free status outputs (fail-safe) 230 V / 3 A AC
24 V / 1 A DC
Protection class electrically
IP 54
Housing material
stainless steel / polyester
Installation
upright or against wall
Dimensions (H x W x D)
approx. 700 mm x 500 mm x 500 mm
Weight incl. 2 heat exchangers
approx. 37 kg
Display
Status LED with 4 conditions:
Green:
Temperature in range
Green flashing: Temperature in range, compressor is running
Red:
Temperature off range, cooling operation
Red flashing: Cooler stooped or service required
Dimensions (mm)
47
3
0
579
39
42
0
A000114X
DE 45 0010
10/2014
Page 2/4
Heat Exchanger
The energy content of the sample gas and, as a result, the required cooling capacity of the gas cooler is determined by 3
parameters: gas temperature JG, dewpoint te (moisture content) and flow v. The outlet dew point rises with increasing energy
content (heat) of the gas. The required cooling capacity is determined by the maximum acceptable level of the outlet dew point.
The following table shows cooler performance assuming the following conditions: te=65°C and JG=90°C. Indicated is the vmax in
Nl/h cooled air (i.e. after the moisture has condensed). If the actual values stay below the parameters te and JG, vmax can be
increased. For example (TG), instead of te= 65°C, JG = 90°C and v = 250 l/h the values te=50°C, JG=80°C and v=350 l/h could be
achieved.
Please contact one of Buhler’s application specialists for assistance and further information.
Heat Exchanger
TS
TG
TV
DTS
DTG
Flow rate vmax
530 l/h
Inlet dewpoint te,max 1)
80 °C
Gas inlet temperature JG,max 1) 3) 180(135) °C
Max. cooling capacity Qmax
450 kJ/h
Gas pressure pmax
160 bar
Pressure drop Dp (v=150 l/h)
8 mbar
Dead volume Vtot
69 ml
Sample gas connections
G 1/4“ i 2)
Condensate out connections
G 3/8“ i 2)
280 l/h
80 °C
135°C
230 kJ/h
3 bar
8 mbar
48 ml
GL 14
GL 25
125 l/h
65 °C
135 °C
120 kJ/h
3 bar
8 mbar
129 ml
DN 4/6
G 3/8” i
2*250 l/h
80 °C
180(135) °C
450 kJ/h
25 bar
each 5 mbar
28/25 ml
tube 6mm
tube 10mm
2*140 l/h
65 °C
135 °C
230 kJ/h
3 bar
each 5 mbar
25/25 ml
GL 14
Gl184
1)
1)
With maximum heat transfer of the heat exchanger and max. cooling capacity of the cooler
2)
NPT-threads upon request
3)
Values in parentheses due to temperature class
4)
Use of automatic condensate drainers and glass vessels not possible
DTV
4)
2*115l/h
65 °C
135 °C
185 kJ/h
2 bar
each 15 mbar
eah 21 ml
DN 4/6
DN 5/8
Performance Data
700
2 x TS/DTS
kJ/h
2 x TG / DTG
600
2 x DTV
500
2 x TV
cooling capacity
400
300
200
100
0
0
5
10
15
20
Ambient temperature
DE 45 0010
10/2014
Page 3/4
25
30
35
40
°C
45
Please indicate with order
Please extract the part number for the cooler fulfilling your requirements from the type code below.
Please note: Each gas path should be equipped with a peristaltic pump or an automatic condensate drain.
Part No. 4 5 9 0
1
2
0 0 0
1 1 0
1 2 0
1 3 0
2
2
2
2
2
2
1
2
3
6
7
8
0
0
0
0
0
0
3 1 0
3 2 0
3 3 0
4 6 0
4 7 0
4 8 0
1)
2)
0 0 0 EGK 2 Ex
Power Supply1)
115 V
230 V
Gas Path / Material / Version
Without heat exchanger
1 Gas Path / Material / Version
1 single path heat exchanger / stainless steel /TS
1 single path heat exchanger / glass / TG
1 single path heat exchanger / PVDF / TV-SS
2 Gas Paths / Material / Version
2 single path heat exchangers / stainless steel / TS
2 single path heat exchangers / glass / TG
2 single path heat exchangers / PVDF / TV-SS
1 dual path heat exchanger / stainless steel / DTS
1 dual path heat exchanger / glass / DTG
2)
1 dual path heat exchanger / PVDF / DTV
1 single path + 1 dual path heat exchanger / stainless steel / TS+DTS
1 single path + 1 dual path heat exchanger / glass / TG+DTG
2)
1 single path + 1 dual path heat exchanger / PVDF / TV-SS+DTV
2 dual path heat exchangers / stainless steel / DTS
2 dual path heat exchangers / glass / TG
2 dual path heat exchangers / PVDF / DTV 2)
Condensate Discharge
Without condensate discharge
0
3
AK20 assembled
4
11 LD V38 assembled
Operating the cooler in the hazardous area is allowed only with sufficient motor protector switch.
Automatic condensate drains or condensate vessel cannot be connected.
Accessories
91 320 200 09
91 320 200 29
91 320 200 32
91 320 200 35
44 100 05
44 100 19
DE 45 0010
10/2014
Page 4/4
Motor protection switch mounted outside of hazardous area for cooler 230 V, 50/60 Hz
Motor protection switch mounted inside of hazardous area for cooler 230 V, 50/60 Hz
Condensate vessel GL 1; glass, 0,4 l
Condensate vessel GL 2; glass, 1 l
We reserve the right to amend specification
Sample Gas Cooler
EGK 2 Ex
Accurate measurements of gases require gas samples with
stable dew points even under harsh ambient conditions.
The EGK models provide a CFC-free, compressor-type
cooling system connected to a cooling block. The cooling
block evenly dissipates the heat thus supporting the highly
efficient heat exchangers. The temperature of the cooling
block is regulated by the Bühler Constant Regulating
System. This system allows smooth regulation and eliminates
the disadvantages of the traditional on-off operating mode.
§ ATEX certificate Zone 1 (Cat. 2G)
§ CFC-free
§ Nominal cooling capacity 583 Btu/hr
§ 1 or 2 heat exchangers can be
inserted: up to 4 gas paths
§ Self-checking with status output
The controller is self-checking. Significant deviation from the
preset is signaled by a status output. A bi-color LED on the
front shows 4 different operating conditions.
§ 4 operational conditions displayed
Condensate is removed either into condensate vessels or by
automatic condensate drainers which can be attached to the
heat exchangers within the cooler’s outer contour.
§ Easy to install
DA 45 0010
10/2014
Page 1/4
§ Simple operation and test
Buhler Technologies LLC
1030 West Hamlin Road, Rochester Hills, MI 48309
Phone: 248.652.1546
Fax: 248.652.1598
Internet: www.buhlertech.com
Technical Data
ATEX-class
Ready for operation
Cooling capacity (at 25°C)
Ambient temperature
Gas outlet dewpoint (preset)
Power supply
II 2 G Ex px e mb q [ia] IIC T4 Gb
after max. 20 minutes
> 583 Btu/hr
32-115 °F
approx. 40 °F
230 V, 50/60 Hz or
115 V, 50/60 Hz
Power consumption
250 VA (230 V)
300 VA (115 V)
Fuse
motor protection switch
Potential-free status outputs (fail-safe) 230 V / 3 A AC
24 V / 1 A DC
Protection classelectrically
IP 54
Housing material
stainless steel / polyester
Installation
upright or against wall
Dimensions (H x W x D) approx.
27.6 x 19.7 x 19.7 in.
Weight w/2 heat exchangers
approx. 82 lb.
Display
Status LED with 4 conditions:
Green:
Temperature in range
Green flashing: Temperature in range, compressor is running
Red:
Temperature off range, cooling operation
Red flashing: Cooler stooped or service required
Dimensions (Inch)
.4”
18
.5”
22.8”
15
16
.5”
A000114X
DA 45 0010
10/2014
Page 2/4
Heat Exchanger
The energy content of the sample gas and, as a result, the required cooling capacity of the gas cooler is determined by 3
parameters: gas temperature JG, dew point te (moisture content) and flow v. The outlet dew point rises with increasing
energy content (heat) of the gas. The required cooling capacity is determined by the maximum acceptable level of the outlet
dew point.
The following table shows cooler performance assuming the following conditions: te=120°F and JG=160°F. Indicated is the
vmax in lpm cooled air (i.e. after the moisture has condensed).If the actual values stay below the parameters te and JG, vmax
can be increased. For example (TG), instead of te= 120°F, JG = 160°F and v = 5.7 lpm the values te=105°F, JG=160°F a
maximum flow rate of v=7.1 lpm could be achieved.
Please contact one of Buhler’s application specialists for assistance and further information.
Heat exchanger
TS
TG
Flow rate vmax
8.8 lpm
Inlet dew point te,max 1)
175 °F
Gas inlet temperature JG,max 1) und 3) 355(275) °F
Max. cooling capacity Qmax
427 Btu/hr
Gas pressure pmax
2321 psig
Pressure drop Dp (v=150 l/h)
0.12 psig
Dead volume Vtot
4.2 cu. in.
Sample gas connections
G 1/4“ i 2)
Condensate outlet connections
G 3/8“ i 2)
4.7 lpm
175 °F
275 °F
218 Btu/hr
44 psig
0.12 psig
2.9 cu. in
GL 14
GL 25
1)
TV
DTS
DTG
DTV 4)
2.1 lpm
2*4.2 lpm
2*2.3 lpm
2*1.9 lpm
150 °F
175 °F
150 °F
150 °F
275 °F
355(275) °F
275 °F
275 °F
114 Btu/hr
427 Btu/hr
218 Btu/hr
175 Btu/hr
44 psig
363 psig
44 psig
29 psig
0.12 psig each 0.07 psig each 0.07 psig each 0.22 psig
7.9 cu. in. 1.7/1.5 cu. in. 1.5/1.5 cu. in. each 1.3 cu. in.
DN 4/6
tube 6 mm
GL 14
DN 4/6
G 3/8” i
tube 10 mm
Gl 184
DN 5/8
1)
With maximum heat transfer of the heat exchanger and max. cooling capacity of the cooler
2)
NPT-threads upon request
3)
Values in parentheses due to temperature class
4)
Automatic condensate drainers and glass vessels not available
Performance Data
700
2 x TS/DTS
kJ/h
2 x TG / DTG
600
2 x DTV
500
2 x TV
cooling capacity
400
300
200
100
0
0
5
10
15
20
25
30
35
40
0
41
50
59
68
77
86
95
104 °F 113
Ambient temperature
DA 45 0010
10/2014
Page 3/4
°C
45
Please indicate with order
Please extract the part number for the cooler fulfilling your requirements from the type code below.
Please note: Each gas path should be equipped with a peristaltic pump or an automatic condensate drain.
Part No. 4 5 9 0
1
2
0 0 0
1 1 0
1 2 0
1 3 0
2
2
2
2
2
2
1
2
3
6
7
8
0
0
0
0
0
0
3 1 0
3 2 0
3 3 0
4 6 0
4 7 0
4 8 0
1)
2)
0 0 0 EGK 2 Ex
Power Supply1)
115 V
230 V
Gas Path / Material / Version
Without heat exchanger
1 Gas Path / Material / Version
1 single path heat exchanger / stainless steel /TS
1 single path heat exchanger / glass / TG
1 single path heat exchanger / PVDF / TV-SS
2 single path heat exchangers / stainless steel / TS
2 single path heat exchangers / glass / TG
2 single path heat exchangers / PVDF / TV-SS
1 dual path heat exchanger / stainless steel / DTS
1 dual path heat exchanger / glass / DTG
2)
1 dual path heat exchanger / PVDF / DTV
1 single path + 1 dual path heat exchanger / stainless steel / TS+DTS
1 single path + 1 dual path heat exchanger / glass / TG+DTG
1 single path + 1 dual path heat exchanger / PVDF / TV-SS+DTV 2)
2 dual path heat exchangers / stainless steel / DTS
2 dual path heat exchangers / glass / TG
2)
2 dual path heat exchangers / PVDF / DTV
Condensate Discharge
Without condensate discharge
0
3
AK20 assembled
4
11 LD V38 assembled
Operating the cooler in the hazardous area is allowed only with sufficient motor protector switch.
Automatic condensate drains or condensate vessel cannot be connected.
Accessories
91 320 200 09
91 320 200 29
91 320 200 32
91 320 200 35
44 100 05
44 100 19
DA 45 0010
10/2014
Page 4/4
Condensate vessel GL 1; glass, 0,4 l
Condensate vessel GL 2; glass, 1 l
We reserve the right to amend specification
CERTIFICATION
1
EC TYPE-EXAMINATION CERTIFICATE
2
Component intended for use in Potentially Explosive Atmospheres Directive 94/9/EC
3
Certificate Number:
Sira 99ATEX3172U
4
Component:
BPG Range of Enclosures
5
Applicant:
ABTECH Limited
6
Address:
Sanderson Street
Lower Don Valley
Sheffield S9 2UA
UK
7
This component and any acceptable variation thereto are specified in the schedule to this certificate
and the documents therein referred to.
8
Sira Certification Service, notified body number 0518 in accordance with Article 9 of Directive 94/9/EC
of 23 March 1994, certifies that this component has been found to comply with the Essential Health and
Safety Requirements relating to the design and construction of a component intended for use in
potentially explosive atmospheres given in Annex II to the Directive.
Issue:
6
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 60079-0:2011
EN 60079-7:2007
EN 60079-11:2012
EN 60079-31:2009
This report may be issued against standards that do not appear on the UKAS Scope of Accreditation, but have been added
through Sira’s flexible scope of accreditation. Sira’s flexible scope is available on request.
10
The sign ‘U’ is placed after the certificate number to indicate that the product assessed is a component
and may be subject to further assessment when incorporated into equipment. Any special conditions
for safe use are listed in the schedule to this certificate.
11
This EC type-examination certificate relates only to the design and construction of the specified
component. If applicable, further requirements of this Directive apply to the manufacture and supply of
this component.
12
The marking of the component shall include the following:
II 2 G D
Ex e IIC Gb
Ex tb IIIC Db IP6X
Project Number
Or
25164
C Ellaby
Deputy Certification Manager
This certificate and its schedules may only be
reproduced in its entirety and without change.
Form 9401 Issue 1
II 2 G D
Ex ib IIC Gb
Ex tb IIIC Db IP6X
Sira Certification Service
Page 1 of 4
Rake Lane, Eccleston, Chester, CH4 9JN, England
Tel:
Fax:
Email:
Web:
+44 (0) 1244 670900
+44 (0) 1244 681330
[email protected]
www.siracertification.com
CERTIFICATION
SCHEDULE
13
Sira 99ATEX3172U
Issue 6
DESCRIPTION OF COMPONENT
The BPG range of enclosures are manufactured from polyester in the following sizes:
BPG
Reference
1
2
3
4
5
6
7
8
9
10
11
12
13
13.5
14
15
Length
(mm)
80
110
160
190
230
122
220
160
260
360
560
255
400
400
600
400
Width
(mm)
75
75
75
75
75
120
120
160
160
160
160
250
250
250
250
405
Height
(mm)
55
55
55
55
55
90
90
90
90
90
90
120
120
160
120
120
The enclosures may also be manufactured to sizes not specified in the table. This assumes that any
given dimension is not larger than the respective dimension of the largest enclosure or smaller than the
respective dimension of the smallest enclosure. The enclosure lids may be hinged or detachable 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.
Variation 1 (dated 10 March 2008) - This variation introduced the following changes:
i.
The BPG 13.5 enclosure was added to the range.
Variation 2 - This variation introduced the following changes:
i.
ii.
iii.
The option to fit slotted trunking inside the enclosures, this trunking may be sited as required.
The instructions were modified to recognise additional restrictions associated with this change and
a new Condition of Manufacture was introduced.
The recognition of minor drawing modifications including the introduction of a new company logo;
these amendments are administrative or involve changes to the design that do not affect the
aspects of the product that are relevant to explosion safety.
The materials used to construct these enclosures were clarified and are recorded below:
•
BPG is used for all colours except black
•
Anti-static BPGC is the black version
Form 9401 Issue1
Page 2 of 4
Tel:
Fax:
Email:
Web:
+44 (0) 1244 670900
+44 (0) 1244 681330
[email protected]
CERTIFICATION
SCHEDULE
Sira 99ATEX3172U
Issue 6
Variation 3 - This variation introduced the following changes:
i.
ii.
iii.
Following appropriate re-assessment to demonstrate compliance with the requirements of the
EN 60079 series of standards, the documents previously listed in section 9, EN 50014:1997,
EN 50019:1994 and EN 50281-1-1:1999, were replaced by those currently listed, the markings in
section 12 were updated accordingly. In addition, the enclosure was allowed to be used for
intrinsically safe applications and EN 60079-11:2012 was included in the list of supporting standards.
The Description of Component and Condition of Certification were amended to recognise that
closed cell polychloroprene gaskets are no longer used.
The Conditions of Certification and Special Condition for Safe Use were rationalised to bring them
into line with IECEx SIR 06.0086U which is also associated with this enclosure.
14
DESCRIPTIVE DOCUMENTS
14.1
Drawings
Refer to Certificate Annexe.
14.2
Associated Sira Reports and Certificate History
Issue
0
1
2
Date
19 January 2000
28 September 2001
23 July 2002
Report/File no.
R51X6055E
53V7936
R53A9009A
3
10 March 2008
R51A17881A
4
5
6
03 April 2012
11 June 2012
9 October 2012
R26585A/00
R26585A/01
R25164A/00
Comment
The release of prime certificate.
The introduction of Variation 1.
The prime certificate was re-issued to permit the following:
• The incorporation of variation 1.
• The lower ambient temperature range was confirmed as
–65°C.
• The introduction of the changes included in Sira report
number R53A9009A.
This Issue covers the following changes:
• All previously issued certification was rationalised into a
single certificate, Issue 3, Issues 0 to 2 referenced
above are only intended to reflect the history of the
previous certification and have not been issued as
documents in this format.
• The change of the Applicant’s name, first recognised
31 January 2007, was re-confirmed.
• The introduction of Variation 1.
Report R26585A/01 replaced report R26585A/00.
15
SPECIAL CONDITIONS FOR SAFE USE
15.1
The Enclosures shall not be used outside the temperature range -65°C to +90°C.
16
ESSENTIAL HEALTH AND SAFETY REQUIREMENTS OF ANNEX II (EHSRs)
The relevant EHSRs that are not addressed by the standards listed in this certificate have been
identified and individually assessed in the reports listed in Section 14.2.
Form 9401 Issue1
Page 3 of 4
Tel:
Fax:
Email:
Web:
+44 (0) 1244 670900
+44 (0) 1244 681330
[email protected]
CERTIFICATION
SCHEDULE
Sira 99ATEX3172U
Issue 6
17
CONDITIONS OF CERTIFICATION
17.1
The use of this certificate is subject to the Regulations Applicable to Holders of Sira Certificates.
17.2
Holders of EC type-examination certificates are required to comply with the production control
requirements defined in Article 8 of directive 94/9/EC.
17.3
If the Enclosures are supplied with blanking plugs, reducers, adapters and breather drains, then the
manufacturer shall ensure that:
•
•
•
17.4
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 fitted.
The manufacturer shall take all reasonable steps to ensure that the following items used in the
construction of the Enclosure are used within the minimum and maximum service temperature stated in
the condition for safe use, in addition, the manufacturer shall provide the user/installer with a copy of
the certificate associated with any blanking plugs, reducers, adapters and breather drains:
Item:
17.5
Solid silicone rubber gasket
Blanking plugs, reducers, adapters and breather drains
When trunking is fitted, it may be sited as required and the minimum creepage and clearance distances
shall still be met.
Form 9401 Issue1
Page 4 of 4
Tel:
Fax:
Email:
Web:
+44 (0) 1244 670900
+44 (0) 1244 681330
[email protected]
Certificate Annexe
Certificate Number:
Sira 99ATEX3172U
Component:
Applicant:
ABTECH Limited
CERTIFICATION
Issue 0 and 1: The drawings associated with these Issues were rationalised by those listed in Issue 2.
Issue 2
Number
ABT 10259
ABT 10305
ABT 10304
Sheet
1 of 1
1 of 1
1 of 1
Rev.
C
A
A
Date
25 Jun 02
16 Nov 99
16 Nov 99
Description
External Label (BPG)
BPG Enclosures
BPG Manufacturing Specification
Sheet
1 of 1
Rev.
B
Date (Sira stamp)
07 Mar 08
Description
BPG Enclosures
Sheets
1 of 1
1 of 1
Rev.
D
B
Date (Sira Stamp)
30 Mar 12
30 Mar 12
Description
BPG Nameplate – Empty Enclosures
BPG Manufacturing specification
Issue 3
Number
ABT 10305
Issue 4
Number
ABT 10259
ABT 10304
Issue 5 (No new drawings were introduced.)
Issue 6
Number
ABT 10259
ABT 10304
ABT 10305
Sheets
1 of 1
1 of 1
1 of 1
Rev.
E
C
C
Date (Sira Stamp)
30 Sept 12
30 Sept 12
30 Sept 12
Description
BPG Nameplate – Empty Enclosures
BPG Manufacturing specification
Form 9401 Issue 1
Page 1 of 1
Tel:
Fax:
Email:
Web:
+44 (0) 1244 670900
+44 (0) 1244 681330
[email protected]
ABTQ-29 rev 03
(Last review: 21 Jul 12)
INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR
ABTECH ‘BPG’ Range Enclosures – SIRA 99ATEX3172U
Marking
TYPE BPG
SERIAL No
Ex e IIC Gb
20
Ex tb IIIC Db
II 2 G D - IP6x
SIRA99ATEX3172U
WARNING !!!
STATIC HAZARD!
CLEAN ONLY WITH A DAMP CLOTH.
The marking shown is for a component certified
enclosure. The user must submit the completed unit
for type examination if it is to be used in a hazardous
area.
The Ex e marking may be replaced by Ex ia or Ex ib.
Enclosures marked Ex ia or Ex ib may only be used for
terminating intrinsically safe circuits.
When the box is black it is anti-static and the
‘STATIC HAZARD’ warning will be missing.
Static hazard
Glass reinforced polyester resin has a surface resistance greater than 10E9 Ohms. They can present a
hazard from static electricity. CLEAN ONLY WITH A DAMP CLOTH
Carbon loaded glass reinforced polyester, coloured black and identified by the suffix ‘C’, (e.g. BPGC9),
have a surface resistance between 10E6 and 10E9 Ohms. They do not present a hazard from static
electricity.
Installation
These instructions assume that the required cable entries have been pre-drilled. Cable entries may be
threaded. All cable entry devices must be appropriately certified to the latest standards and match the
certification of the box. i.e. ATEX certified devices are required for ATEX certified enclosures 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 out the positions for the mounting
holes on the surface where installation is required.
2) Drill the mounting holes for M4 fixing studs (for size BPG1 to BPG5) or for M6 fixing studs (for size
BPG6 to BPG15) as applicable.
3) Tap thread into mounting holes if required.
4) Place a mounting screw through one mounting hole in the box so that the thread of the screw
protrudes from the back of the box. Lift the enclosure into position using such assistance as may be
necessary to avoid injury and:-
a) If clearance mounting holes are used, insert the protruding thread through the appropriate
clearance hole and secure with a nut on the other side of the mounting surface.
Or
b) If threaded holes are used, locate the end of the mounting screw over the thread hole and, using
an appropriate screwdriver tighten the screw.
5) Rotate the box to line up the remaining mountings and repeat (4) above until all mounting screws
have been fitted.
6) Where slotted trunking has been supplied (solid trunking is not permitted) ensure that it is suitable for
the proposed T classification of the final certified product. Where the T6 is the proposed rating and no
windows are fitted any polymeric or metallic slotted trunking may be used. For other T classifications
1/2
A B Controls & Technology
Sanderson Street, Lower Don Valley, Sheffield S9 2UA
ABTQ-29 rev 03
(Last review: 21 Jul 12)
and where a window is fitted metallic slotted trunking must be used. Trunking may be mounted in any
orientation in the box, vertically, horizontally or diagonally.
7) Secure the lid by closing the lid and tightening the lid fixing screws.
Earthing/Grounding
The enclosure may be provided with an external earth/ground connection. If such a connection is provided
it must be connected to the appropriate earth bonding circuit before electrical power is connected to the
contents of the enclosure.
Operation
1. The lid must be secured using all of the lid screws provided in order to maintain the IP rating.
2. No attempt must be made to remove the enclosure lid whilst electrical power is connected to the
contents of the enclosure.
3. If the enclosure if fitted with an external earth/ground facility it must be connected to the earth bonding
circuit 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 that the lid seal is in place and not damaged
Each time the
enclosure is opened
Each time the
enclosure is closed
Annually
Annually
Annually
2 Check that all lid fixing screws are in place and secured
3 Check that the mounting bolts are tight and free of corrosion
4 Check the security of all cable glands
5 Check enclosure for damage
Chemical attack
The ABTECH BPG range of enclosures are manufactured using the following materials:glass reinforced polyester resin, (with or without carbon loading),
Polychloroprene or Silicone rubber,
316 stainless steel
Brass
Consideration should be given to the environment in which these enclosures are to be used to determine
the suitability of these materials to withstand any corrosive agents that may be present.
2/2
A B Controls & Technology
Sanderson Street, Lower Don Valley, Sheffield S9 2UA
RMA - Dekontaminierungserklärung
RMA - Decontamination Statement
DE/EN
Gültig ab / valid since: 2014/11/01
Revision / Revision 1
ersetzt Rev. / replaces Rev. 0
Um eine schnelle und reibungslose Bearbeitung Ihres Anliegens zu erreichen, füllen Sie bitte diesen Rücksendeschein
aus. Eine genaue Fehlerbeschreibung ist für die Ursachenanalyse nötig und hilft bei der schnellen Bearbeitung des
Vorgangs. Die Aussage „Defekt“ hilft bei der Fehlersuche
leider nicht.
Please complete this return form to ensure your claim is
processed quickly and efficiently. An accurate description of
the problem is necessary for cause analysis and will help
processing the claim quickly. Unfortunately, stating
“defective” will not help us troubleshoot the issue.
Die RMA-Nummer bekommen Sie von Ihrem
Ansprechpartner im Vertrieb oder Service.
You may obtain the RMA number from your sales or
service representative.
Zu diesem Rücksendeschein gehört eine Dekontaminierungserklärung. Die gesetzlichen Vorschriften schreiben vor, dass
Sie uns diese Dekontaminierungserklärung ausgefüllt und
unterschrieben zurücksenden müssen. Bitte füllen Sie auch
diese im Sinne der Gesundheit unserer Mitarbeiter
vollständig aus.
This return form includes a decontamination statement. The
law requires you to submit this completed and signed
decontamination statement to us. Please complete the entire
form, also in the interest of our employees’ health.
Bringen Sie den Rücksendeschein mit der
Dekontaminierungserklärung bitte zusammen mit den
Versandpapieren in einer Klarsichthülle außen an der
Verpackung an. Ansonsten ist eine Bearbeitung Ihres
Reparaturauftrages nicht möglich!
Attach the return form including decontamination
statement along with the shipping documentation to the
outside of the package, inside a clear pouch. Otherwise
we are unable to process your repair order!
Angaben zum Absender:
Sender information:
Firma / Company
Ansprechpartner /
Contact person
Anschrift / Address
Abteilung /
Department
E-Mai / E-Mail:
Tel. / Phone
Fax / Fax:
Artikelnummer /
Item number
Auftragsnummer /
Order number
Anzahl / Quantity
Rücksendegrund /
Return reason
RMA-Nr. /
RMA no.
Reparatur / Repair
Garantie / Warranty
Zur Prüfung / For inspection
Rückgabe / Return
Vorgangsnummer des Kunden /
Customer transaction number::
Fehlerbeschreibung / Description of the problem:
Ort, Datum /
Place, Date
Seite
Page
1/2
Unterschrift / Stempel /
Signature / Stamp:
Tel.: + 49 (0) 2102 / 4989-0 Fax: + 49 (0) 2102 / 4989-20
RMA - Dekontaminierungserklärung
RMA - Decontamination Statement
DE/EN
Gültig ab / valid since: 2014/11/01
Revision / Revision 1
ersetzt Rev. / replaces Rev. 0
Bitte füllen Sie diese Dekontaminierungserklärung für jedes
einzelne Gerät aus.
Gerät / Device
RMA-Nr /
RMA no:
Serien-Nr. / Serial no.
[
]
Please complete this decontamination statement for each
individual item
Ich bestätige hiermit, dass das oben spezifizierte
Gerät ordnungsgemäß gereinigt und dekontaminiert
wurde und keinerlei Gefahren im Umgang mit dem
Produkt bestehen.
I herewith declare that the device as specified above has been
properly cleaned and decontaminated and that there are no
risks present when dealing with the device.
Ansonsten ist die mögliche Gefährdung genauer zu
beschreiben:
In other cases, please describe the hazards in detail:
Aggregatzustand (bitte ankreuzen):
Aggregate state (please check):
Flüssig / Liquid
Fest / Solid
Folgende Warnhinweise sind zu beachten
(bitte ankreuzen):
Pulvrig / Powdery
Please note the following warnings (please check):
Explosiv
Explosive
Giftig / Tödlich
Toxic / lethal
Entzündliche Stoffe
Flammable substances
Komprimierte Gase
Compressed gasses
Gesundheitsgefährdend
Hazardous to health
Gesundheitsschädlich
Harmful to health
Bitte legen Sie ein aktuelles Datenblatt des
Gefahrenstoffes bei!
Ort, Datum /
Place, Date:
Seite
Page
2/2
Gasförmig / Gaseous
Brandfördernd
Oxidizing
Umweltgefährdend
Harmful to the environment
Please include an updated data sheet of the hazardous
substance!
Unterschrift / Stempel
Signature / Stamp:
Tel.: + 49 (0) 2102 / 4989-0 Fax: + 49 (0) 2102 / 4989-20

BE450008 EGK 2 Ex - buehler

Transcription

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