Buhler EGK 10 Installation And Operation Instructions Manual
Installation and Operation Instructions
Sample gas cooler
EGK 10
BE450005 ◦ 05/2015
Original instructions
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20
Internet: www.buehler-technologies.com
E-Mail: analyse@buehler-technologies.com
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. ....................................BE450005
Version .................................................. 05/2015
Installation and Operation Instructions
Sample gas cooler EGK 10
Contents
Contents
1 Introduction.......................................................................................................................................................... 2
1.1 Intended Use .................................................................................................................................................2
1.2 Types .............................................................................................................................................................2
1.3 Scope of delivery ...........................................................................................................................................2
2 Safety instructions ..............................................................................................................................................3
2.1 Important advice ............................................................................................................................................3
2.2 General hazard warnings...............................................................................................................................4
3 Transport and storage ........................................................................................................................................5
4 Installation and connection ................................................................................................................................ 6
4.1 Installation site requirements .........................................................................................................................6
4.2 Installation......................................................................................................................................................6
4.3 Electrical connections ....................................................................................................................................7
5 Operation and control ......................................................................................................................................... 8
5.1 Operation of the menu functions....................................................................................................................8
5.1.1 Overview of the menu items .............................................................................................................. 9
5.1.2 Detailed description of the operational principle ................................................................................9
5.2 Description of the menu functions ...............................................................................................................10
5.2.1 Main menu .......................................................................................................................................10
5.2.2 Submenu.......................................................................................................................................... 10
6 Maintenance.......................................................................................................................................................11
7 Service und repair .............................................................................................................................................12
7.1 Troubleshooting ...........................................................................................................................................12
7.2 Safety instructions .......................................................................................................................................13
7.3 Opening the housing....................................................................................................................................13
7.4 Replacing the fuse of the cooler ..................................................................................................................15
7.5 Replacing the fan.........................................................................................................................................15
7.6 Replacing the power supply board ..............................................................................................................16
7.7 Replacing the controller board MCP1..........................................................................................................17
7.8 Replacing the display...................................................................................................................................17
7.9 Cleaning and removal of the heat exchanger ..............................................................................................17
7.10 Replacing the fuse of the peristaltic pump (option - only housing version)..................................................18
7.11 Replacing the hoses of the peristaltic pump (option)...................................................................................18
7.12 Spare parts and accessories .......................................................................................................................18
8 Disposal.............................................................................................................................................................. 19
9 Attached documents ......................................................................................................................................... 20
DE450007 EGK10...............................................................................................................................................21
KX450001_EGK1_EGK1-2_EGK4S_EGK10.....................................................................................................25
Declaration of Contamination status...............................................................................................................26
iBE45000505/2015
Installation and Operation Instructions
Sample gas cooler EGK 10
Introduction
1 Introduction
1.1 Intended Use
This unit is intended for industrial use in gas analysis systems. It's an essential component for
conditioning the sample gas to protect the analysis instrument from residual moisture in the
sample gas.
Please note the specifications in the data sheets on the specific intended use, existing material
combinations, as well as pressure- and temperature limits.
1.2 Types
The device is delivered with different configurations. The part number given on the type plate informs you about the specific configuration of your device.
1.3 Scope of delivery
– Cooler
– Product documentation (brief instruction + CD)
– Connection-/mounting accessories (optional)
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Safety instructions
2 Safety instructions
2.1 Important advice
Operation of the device is only valid if:
– the product is used under the conditions described in the installation- and operation instruc-
tion, the intended application according to the type plate and the intended use. In case of unauthorized modifications done by the user Bühler Technologies GmbH can not be held re-
sponsible for any damage,
– when complying with the specifications and markings on the nameplates.
– the performance limits given in the datasheets and in the installation- and operation instruc-
tion are obeyed,
– monitoring devices and safety devices are installed properly,
– service and repair is carried out by Bühler Technologies GmbH,
– only original spare parts are used.
This manual is part of the equipment. The manufacturer keeps the right to modify specifications
without advanced notice. Keep this manual for later use.
Signal words for warnings
DANGER
Signal word for an imminent danger with high risk, resulting in severe injuries
or death if not avoided.
WARNING
Signal word for a hazardous situation with medium risk, possibly resulting in
severe injuries or death if not avoided.
CAUTION
Signal word for a hazardous situation with low risk, resulting in damaged to
the device or the property or minor or medium injuries if not avoided.
NOTICE
Signal word for important information to the product.
Warning signs
These instructions use the following warning signs:
Warns of a general hazard General notice
Warns of voltage Unplug from mains
Warns not to inhale toxic gasses Wear respiratory equipment
Warns of corrosive liquids Wear a safety mask
Warns of explosive areas Wear gloves
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Safety instructions
2.2 General hazard warnings
Installation of the device shall be performed by trained staff only, familiar with the safety 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 unintention-
ally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
DANGER Toxic and corrosive gases / condensate
Sample gas / condensate can be hazardous.
a) Take care that the gas is exhausted in a place where no persons are in
danger.
b) Before maintenance turn off the gas supply and make sure that it cannot be
turned on unintentionally.
c) Protect yourself during maintenance against toxic / corrosive gases / con-
densate. Use gloves, respirator and face protector under certain circumstances.
DANGER Potentially explosive atmosphere
Explosion hazard if used in hazardous areas.
The device is not suitable for operation in hazardous areas with potentially explosive atmospheres.
Do not expose the device to combustible or explosive gas mixtures.
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Transport and storage
3 Transport and storage
The device should be only transported in the original case or in appropriate packing.
If the device is not used for some time, protect it against heat and humidity. Store the device in
a roofed, dry, and dust free room. Temperature should be between -20 °C and 60 °C (-4 °F and
140 °F).
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Installation and connection
4 Installation and connection
4.1 Installation site requirements
The unit is intended for wall-mounted or table-top use in enclosed areas. Adequate protection
from the weather must be provided when used outdoors.
Install the unit leaving enough room below the cooler to discharge the condensate. Leave room
above for the gas supply.
Be sure to maintain the approved ambient temperature. Do not obstruct the convection of the
cooler. The vents must have enough room to the next obstacle. The distance must especially be
a minimum of 10 cm on the air outlet side.
Ensure adequate ventilation when installing in enclosed housings, e.g. analyser cabinets. If the
convection is inadequate, we recommend aerating the cabinet or installing a fan to lower the inside temperature.
4.2 Installation
Run the gas supply to the cooler with a downward slope. The gas inputs are marked in red and
additionally labelled “IN”.
If a large amount of condensate accumulates, we recommend using a condensate pre-separator before the cooler. Our fluid separators with automatic condensate drain, 11LD spec.,
AK20V or model 165 SS, are suitable.
Glass vessels and automatic condensate drains are available for draining condensate for external mounting below the unit. When using automatic condensate drains, the gas pump must
be installed ahead of the cooler to ensure proper function of the condensate drain.
If the sample gas pump is located at the cooler outlet (suction operation), we recommend using
glass condensate traps or peristaltic pumps.
Connecting the condensate drains
Depending on the material, build a connecting line with fittings and tubing or hose between the
heat exchanger and condensate drain. For stainless steel the condensate drain can be suspended directly to the connecting tube, for hoses the condensate drain must be secured separately
using a clamp.
The condensate drain can be mounted directly to the heat exchanger.
Condensate lines must always be installed with a slope and a minimum inside diameter of DN
8/10 (5/16”).
Peristaltic pump (optional)
A peristaltic pump may also be installed a little away from the cooler. The bottom of the cooler
has two rivet M4 nuts designated for installing the pump directly below the cooler.
NOTICE
Installing peristaltic pumps limits the maximum approved operating pressure
in the system!
Operating pressure ≤ 0.5 bar
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Installation and connection
4.3 Electrical connections
WARNING Hazardous electrical voltage
The device must be installed by trained staff only.
CAUTION Wrong mains voltage
Wrong mains voltage may damage the device.
Regard the correct mains voltage as given on the type plate.
WARNING High voltage
Damage to the device in case of insulation testing
Do not proceed insulation tests with high voltage to the device as a whole!
Insulation test
The device is equipped with extensive EMC protection. If insulation tests are carried out the
electronic filter devices will be damaged. All necessary tests have been carried out for all concerned groups of components at the factory (test voltage 1 kV or 1.5 kV respectively, depending
on the device).
If you wish to carry out the insulation test by yourself, please test only separate groups of components.
Disconnect the compressor, the fan, the heating or the peristaltic pumps, respectively, and then
carry out the insulation tests.
Connection via plug
The device is equipped with connectors according to DIN 43650 for mains and status output. If
the cables are mounted properly, they cannot be interchanged. Please make sure that the connectors are remounted correctly after connecting the cable. The following figures show the pin
assignment with respect to the numbers printed on the connector.
power supply
status outputpin assignment
function ok
alarm
Fig.2: A05-100002 Cooler electric supply
The mains supply must be protected with 16 A. The clamping area has a diameter of 8-10 mm.
If the unit features a peristaltic pump, it must be connected to a power source separately.
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Operation and control
5 Operation and control
NOTICE
The device must not be operated beyond its specifications.
After turning on the power supply the display shows the actual temperature of the cooling block.
The display blinks until the (set) temperature range with respect to the pre-set output dew point
is reached. The status contact is switched to "Alarm".
If the temperature range is reached, the actual temperature is shown constantly and status contact switches back.
If the display starts blinking during operation or if an error message is displayed see chapter
"Troubleshooting".
For performance limits see datasheet.
5.1 Operation of the menu functions
Overview of the operational principal:
Use this short description if you have experience with the device.
Operation is carried out by only the keys with the following functions:
Key Function
– Switch from measurement display to main menu
– Selection of the display menu item
– Accepting the changed value or selection
– Switch to the upper menu item
– Increase of the value of switching the selection
– Temporary display of the alternative measurement display (if option is in-
stalled)
– Switch to lower menu item
– Decrease of the value of switching the selection
– Temporary display of the alternative measurement display (if option is in-
stalled)
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