M&C EC-30C Instruction Manual

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EC®

Ultra Low Gas Cooler

EC-30C

Instruction Manual

Version 1.00.02

Software Version 1.00

Get help

For more information about using your M&C product, please contact M&C TechGroup. We will answer your questions about commissioning, handling and technical service. With our experience and know-how, we will get your M&C product running in no time - and with no charge.

Please contact our service center in Ratingen, Germany,

for US Service Ventura, California

For faster service, please have this information ready when you contact us:



Product model



Product serial number



M&C order or invoice number



Germany service center:

+49 2102 935 - 888 service-DE@mc-techgroup.com



US service:

+1 805-654-6970 info-usa@mc-techgroup.com

For online service and support information go to:



www.mc-techgroup.com

EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com 1

Table of Contents

1 About this instruction manual 6

2 Important safety information 7

2.1 Intended use 7

2.2 Personal safety 7

2.3 Warning signs and definitions 7

2.4 Safety instructions 8

2.5 Working on electrical and electronic devices 9

2.6 Not certified in hazardous areas 9

3 Introduction 10

4 Product overview 11

4.1 Application 11

4.2 Principle 12

5 Technical Data 14

5.1 Max. possible water vapor dew point input [°C] / [°F] 15

5.2 Dimensions 16

6 Receiving the EC-30C 17

6.1 Product label and serial number 17

7 Using the EC-30C 18

7.1 Graphical user interface (GUI) 18

7.2 LED color coding and possible color combinations 18

7.3 Self-monitoring after powering-on the unit 19

7.4 Self-monitoring during operation 20

7.4.1 Power consumption readjustment 20

7.4.2 Pre-warning messages 20

7.5 Display during start-up of the EC-30C 21

7.6 Overview screen 23

7.7 Alarm and warning history 24

7.7.1 Error codes 27

7.7.2 Warning symbols 27

7.7.3 Alarm symbols 29

7.8 Temperature diagrams 32

7.8.1 Diagram of the pre-cooler unit (PCU) 32

7.8.2 Diagram of the deep cooling units (DCU 1 and DCU 2) 33

7.9 Parameter menu 34

7.9.1 Parameter settings 36

7.10 Device information 37

7.11 Service-Reset (qualified personnel only) 39

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8 Installation instructions and mounting of the EC-30C 40

8.1 Installation instructions 40

8.2 Wall and rack mount 41

8.3 Mounting instructions for SR25.2 peristaltic pump (optional) 43

8.4 Tubing without heat exchanger purging (standard tubing) 44

8.4.1 Heat exchanger connections for tubing without purging 44

8.5 Tubing with heat exchanger purging for special requirements (optional) 46

8.5.1 Heat exchanger connections for tubing with purging 47

8.6 Duran-glass heat exchanger with GL-connections 48

8.7 PVDF- heat exchanger with PVDF-tube connectors 48

8.8 Electrical connections 49

8.8.1 mA-output 51

8.8.2 Liquid alarm sensor LA (optional) 51

8.8.3 Gas flow sensor FA 20 and gas flow meter FM 40 (optional) 52

9 Start-up 53

9.1 Preparation for start-up 53

9.2 Temperature chart of the start-up stages 54

10 Maintenance 58

10.1 Maintenance of the peristaltic pump type SR25.2 (optional) 58

10.1.1 Changing the pump tubing 59

10.1.2 Changing the contact pulley and springs 60

10.1.3 Cleaning the pump head 60

10.2 Changing the heat exchanger 61

10.3 Changing the 0-20 V-Module 62

10.4 Changing the buffer battery 63

10.5 Checking the temperature sensors 64

10.6 Changing the compressor unit 65

11 Decommissioning 66

12 Appendix 67

12.1 Overview of the EC-30C screens 67

12.2 How to configure the mA-output 68

12.2.1 How to calculate temperature based on measured mA-value 68

12.2.2 How to calculate mA-value based on measured temperature 69

12.3 Spare parts and consumables 70

12.4 Additional Information 71

12.5 Declaration of conformity 71

12.6 Certificates 72

12.7 Warranty 72

12.8 Liability and disclaimer 72

12.9 Storage 73

12.10 Shipping and handling 73

12.11 Proper disposal of the device 73

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13 About us 74

13.1 M&C‘s group of companies 74

13.2 The quality-oriented M&C catalog 75

13.3 Technical consulting services 76

13.3.1 Ideas, suggestions and feedback 76

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Table of Illustrations

Fig. 1: Application example of the EC-30C 11 Fig. 2: Jet-Stream heat exchanger 12 Fig. 3: Front view: dimensions including optional peristaltic pumps 16 Fig. 4: Side view: dimensions including optional peristaltic pumps 16 Fig. 5: Graphic user interface 18 Fig. 6: Smiley symbols during self-test 19 Fig. 7: The smileys on the display after self-testing 19 Fig. 8: ‘Service‘-monitor: Self-test failed 20 Fig. 9: Start-up phase: first cooling phase 21 Fig. 10: Start-up phase: TKS reaches and/or exceeds ‘0 °C / 32 °F’-limit 22 Fig. 11: Start-up phase: Target temperature reached 22 Fig. 12: That’s how you reach the overview screen 23 Fig. 13: Overview screen 23 Fig. 14: How to reach the alarm and warning history 24 Fig. 15: Alarm and warning history 25 Fig. 16: How to chose an alarm or warning message 25 Fig. 17: How to scroll through stored messages 26 Fig. 18: Detailed information for a selected message 26 Fig. 19: How to reach the graphical temperature diagrams 32 Fig. 20: Temperature diagram of the pre-cooling unit 32 Fig. 21: Temperature diagram of the deep-cooling units 33 Fig. 22: How to reach the parameter menu (screen 1) 34 Fig. 23: Parameter menu, screen 1 34 Fig. 24: Parameter menu, screen 2 35 Fig. 25: How to reach the parameter settings 36 Fig. 26: How to reach the device information 37 Fig. 27: Device information 38 Fig. 28: Activating Service Reset (Qualified personnel only) 39 Fig. 29: Reset screen (Qualified personnel only) 39 Fig. 30: Min. assembly dimensions (unit with optional peristaltic pumps) 41 Fig. 31: Mounting rail for wall or rack mounting 42 Fig. 32: SR25.2: Mounting distance between pump motor and front panel 43 Fig. 33: Standard tubing: DCU 1 active, solenoid valve triggered, no FA 44 Fig. 34: Heat exchanger connectors (device with four optional peristaltic pumps) 45 Fig. 35: Tubing with purging: DCU 1 activ, solenoid valves triggered, no FA 46 Fig. 36: Heat exchanger connections, tubing with purging 47 Fig. 37: Electrical connections 50 Fig. 38: Temperature chart of the start-up stages 55 Fig. 39: Changing the pump tubing 59 Fig. 40: Resistor - temperature characteristic of the PT100 64 Fig. 41: Compressor: electrical connections 65 Fig. 42: Overview: screens 67

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1 About this instruction manual

Welcome to the M&C product manual. The goal of this document is to give a broad overview of the main functions of the EC-30C. It will help you to get started with using the EC-3 0 C .

If you have any questions about this instruction manual, please contact M&C or one of our official distributors.

Document: Instruction Manual EN for EC-30C

Version: 1.00.02

Software Version: 1.00

Release date: 10.2019

Published by: M&C TechGroup Germany GmbH, Rehhecke 79

40885 Ratingen, Deutschland

This instruction manual does not claim to be complete and it may be subject to technical modifications. We appreciate any feedback you may have to this document .

Any copy of this document or of its content is not allowed without explicit approval of M&C.

With the release of this version all older manual versions will no longer be valid.

Registered trademarks

EC® is a registered trademark of M&C Techgroup Germany GmbH.

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2 Important safety information

Please read this important safety information carefully before installing the EC-30C. Follow these safety precautions during commissioning, start-up and regular operation.

2.1 Intended use

This product is designed to be used as an ultra-low cooler to reduce the dew-point of humid sample gas to provide a stable and very low dew point.

Do not use this product for any other purpose. Improper use and handling can create hazards and cause damage. For more information, please refer to the safety information in this instruction manual.

2.2 Personal safety

Please read this instruction manual carefully before commissioning and operating the device. If you have any questions regarding the product or the application, please don’t hesitate to contact M&C or an M&C authorized distributor.

Please follow all instructions and warnings closely.

The product described in this instruction manual has been built and tested in our production facility. All ultra-low cooler are packed to be shipped safely. To ensure the safe operation and to maintain the safe condition, all instructions and regulations stated in this manual need to be followed.

This instruction manual includes all information regarding proper transportation, storage, installation, operation and maintenance of this product by qualified personnel.

2.3 Warning signs and definitions

DANGER

WARNING

CAUTION

ATTENTION

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

ATTENTION is used to address practices not related to physical injury.

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High Voltage!

Caution, risk of electric shock!

High Pressure!

Hot Surface! Caution, hot surface! Do not touch!

Hazardous Gas!

Qualified personnel

Safety Gloves!

Pull Main Plug!

Note

Caution, system might be under pressure.

Caution, hazardous and toxic gas! Do not inhale!

‘Qualified personnel’ are experts who are familiar with the installation, mounting, commissioning and operation of these types of products.

Put on safety gloves for your protection.

Unplug power supply before opening!

‘Note’ indicates important information relating to the product or highlights parts of the documentation for special attention.

Do you need help?

Please contact M&C!

2.4 Safety instructions

Please follow these safety directions and instructions regarding installation, commissioning and operation of the EC-30C.

Qualified personnel

Install the device only in protected areas, sheltered from sun, rain and moisture.

Operate the device only in the permitted temperature and pressure ranges. See details on page 14 chapter ‘5 Technical Data’ .

Don‘t repair or maintain this product without M&C‘s specific maintenance- and service instructions.

Installation, commissioning, maintenance, inspections and any repairs of all M&C products and components must be carried out by qualified personnel in compliance with the current regulations.

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When replacing parts, use only original M&C spare parts.

Pull Main Plug!

If there is any indication that safe operation of the EC-30C is no longer possible, turn off the power and disconnect the device from the power supply immediately.

Then protect the defective device against accidental switch-on and mark it clearly as defective.

2.5 Working on electrical and electronic devices

Only qualified and authorized personnel are permitted to work on equipment which operates on 115 or 230 VAC supply voltage. Please be sure to observe the generally accepted engineering standards and all of your national and local regulations.

Note

High Voltage!

Before connecting the device, please make sure that the supply voltage matches the specified voltage on the product label.

Protect yourself and others against damages which might be caused by high voltages. Disconnect the power supply before opening the device for access. Make sure that all external power supplies are disconnected.

Please make sure to take appropriate precautions even by working on unplugged or low-voltage devices. Unplugged devices need to be properly grounded to prevent damage to internal electronics from electrostatic discharges (ESD).

2.6 Not certified in hazardous areas

This device is NOT certified to be installed or operated in hazardous areas.

Explosion hazard!

WARNING

For general purpose areas ONLY. Don’t use the EC-30C in hazardous areas.

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3 Introduction

Congratulations on your purchase of the EC-30C ultra-low cooler. We know from experience that you surely will enjoy this reliable and durable M&C product.

M&C is one of the premium and performance-driven companies in the business. With this in mind, our customers benefit from a number of significant advantages. We offer proven, durable and advanced products and solutions. We have listened to our customers needs, when designing our products, allowing M&C to provide premium products at a comparatively lower cost over the entire life cycle.

Our products and special systems are designed and tested in our own facilities by our highly skilled staff that are always quality-oriented. We carefully package our goods and send them to our customers worldwide.

With our 30-years of experience in customer specific solutions for almost 30 different industries and applications, it is our goal to supply you with an excellent product. Our products offer fast commissioning, safe and reliable day-to-day operation and low maintenance.

We expect that our products fully meet your expectations. If you have any question regarding the product or the application, please don’t hesitate to contact M&C or your M&C authorized distributor. Our service does not end with delivery of the products.

Thanks again for your purchase.

We appreciate your business.

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4 Product overview

4.1 Application

The M&C ultra-low cooler EC-30C is used in the gas analysis technique to reduce the dew point of humid sample gases and to provide a stable and very low dew point. This eliminates condensate built-up and aerosol formation in the analyzer.

Due to the extremely stable and low gas dew point, there are no water vapor cross-sensitivity and volumetric errors.

Sample gas IN

Condensate OUT

Test gas IN

Fig. 1: Application example of the EC-30C

1 Gas sample probe SP2000-H 2 Electrically heated sample line 4M4/6 3 Ultra-low cooler EC-30C 4 3-way ball valve 3L/PV-1 5 Filter 6 Bellows pump MP-F 7 Aerosol filter CLF -5/W optional depend-

ing on application

8 Analyzer, e.g. PMA1000

9 Flow meter FM40, 25-250 Nl/h 10 Option: 4.peristaltic pump with solenoid valve

(heat exchanger purging)

11 O ption: three SR25.2 peristaltic pumps

(condensate removal)

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4.2 Principle

The M&C gas cooler EC-30C is a two stage combination of compressor and Peltier cooler. The automatic defrost function of the dual deep freezer unit ensures 100 % availability during operation.

The micro processor-controlled electronics of the EC-30C in combination with the graphical display, offers a high degree of functionality, convenience in use, and safe operation.

The EC-30C is built for 24/7 hours of operating time. The cooling capacity of 130 kJ/h is constant, even under maximum allowed ambient temperature.

A capacity reserve compensates parts of the natural aging process and maximizes the service life of the EC-30C.

The pre-cooler unit is equipped with a Jet-Stream heat exchanger. The heat exchanger is cooled down to the constant temperature of +2 °C (35.6 °F) by a separate, microprocessor controlled, compressor cooling unit.

Sample gas - OUT

M&C Jet-Stream heat exchanger

Cooling block

Condensate - OUT

Sample gas - IN

Fig. 2: Jet-Stream heat exchanger

The Jet-Stream heat exchanger in the pre-cooler unit removes a large amount of condensate, this ensures a safe and reliable pre-drying of the sample gas. An additional external vessel to separate the condensate is under normal conditions not necessary. The cooling unit of the pre-cooler dissipates the heat of the Peltier elements.

The dual deep freezer unit is equipped with two modified Jet-Stream heat exchangers. Two separate pairs of Peltier elements are cooling the heat exchangers down to a constant temperature between -20 °C (~-4 °F) and -30 °C (~-22 °F). The factory setting is -30°C (~-22 °F).

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The EC-30C switches automatically every 3 hours between the two deep freezer units. The deep freezer which is currently not in use, will be defrosted to prevent freezing of the heat exchanger and clogging of the gas lines. Upon special request, this cycle of 3 hours can be reduced directly at your facility by M&C personnel.

The new graphical user interface is icon-based for easy and intuitive navigation. The messages are displayed in form of easy-to-understand icons. Features like time stamps for the alarm message history, periodically self-monitoring and pre-warning messages to inform about upcoming maintenance work ensure a maximum degree of comfort, ease-of-use and safety of operation of the EC-30C.

The smart periodically self-monitoring of the EC-30C, helps to plan upcoming maintenance and service work to prevent unnecessary down time.

A configurable mA-output is part of the EC-30C standard version.

Three optional peristaltic pumps SR-25.2 for automatic condensate removal can be installed into the unit.

An internal flow meter including an optical flow sensor can be installed into the unit as an option. Another option would be an external flow meter including an optical flow sensor or an external humidity sensor.

A fourth optional peristaltic pump can be installed in combination with a second solenoid valve to provide permanently fresh test gas to the inactive cooling unit. This makes sure that even in systems, where water vapor cross sensitivity exists, there are no visible peaks at switching of the dual deep freezer unit. This also prevents short peaks in the sample gas concentration due to stagnant gas.

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5 Technical Data

Series EC Part No.: 02 K 6100 (a)*

Gas connection DN 4/6 tube connector Condensate connections 3x tube connector GL25-12 mm Material of sample contacting

parts Single stream, gas flow rate 90 Nl/h – 250 Nl/h Gas pressure max. 3 bar abs.

Ambient temperature +5 °C to +45 °C (+41 °F to +113 °F) Storage temperature -20 °C to +60 °C (~-4 °F to +140 °F) Sample outlet dew point -20 °C to -30 °C (default -30 °C) (~-4 °F to ~-22 °F, default

Sample inlet temperature max. 180 °C (+356 °F) Water vapor dew point input max. 70 °C (+158 °F) Cooling capacity max. 130 kJ/h** (at given input conditions) Main power connection /

Power consumption Start up time < 60 min Dead space approx. 160 ml (5.41 fl. oz) ∆P at 250 Nl/h flow rate 5 mbar Electrical connection 2.5 mm2 (0.0039 in2) terminals, cable glands PG (1 x 12

mA-output 0 - 20 mA / 4 - 20 mA, max. 500 Ohm load (including

Relay output alarm 1 changeover contact: 230 V AC 3 A, 24 V DC 3 A

Relay output warning 1 NO contact, 24 V (AC/DC), 0.5 A

Relay output freezer units I and II1 NO contact, 24 V (AC/DC), 0.5 A

Case protection IP20, EN 60529 Electrical equipment standard EN 61010 Method of mounting 19" rack or wall mount Case color RAL 9003 Dimension (w x h x d) 84 HP x 8U (with connections) x 360 mm (14.17“) Weight 39.34 kg (86.73 lbs)

Version EC-30C

Duran Glass, PTFE, PVDF

~-22 °F)

230 V, 50 Hz, 380 VA or* Part-No. …-a=115 V, 60 Hz, 380 VA

mm, 2 x 16 mm, 2 x 20 mm)

cable resistance),

alarm: COM & NC closed No alarm: COM & NO closed

warning: open

unit I on: closed unit II on: open

* (a)Addition to the part number for EC-30C with 115 V

** For the given input conditions, please have a look at the table on page 15 chapter ‘5.1 Max. possible water vapor dew point input [°C] / [°F]’ .

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Options

Part-No.: 01 P 9145 Peristaltic pump SR25.2, to mount into the EC-30C (See

spare parts for SR25.2 on page 70 chapter ‘12.3 Spare parts and consumables’ )

Part-No.: 03 F 3000 Aerosol-Filter CLF-5: External mounting in the outlet of

an ultra low gas cooler EC-30C when sample tends to form aerosols. Technical data see data sheet 7.7 Fluid particle filter CLF-5

Part-No.: 02 K 9700 (a)* Heat-exchanger purging: 4. peristaltic pump with

solenoid valve

Part-No.: 03 E 1001 LA 1S humidity sensor, 4 m (13.12 ft) cable with cable

breakage detection Part-No.: 03 E 3500 FA 20 (Flow sensor with 0.45 m [1.48 ft] cable) Part-No.: 02 K 9710 FM 40 (Flow meter, 25-250 Nl/h)

* (a)Addition to the part number for EC-30C with 115 V

5.1 Max. possible water vapor dew point input [°C] / [°F]

This table shows the max. possible water vapor dew point input (°C) / (°F) depending on the incoming gas temperature and the flow rate.

These values correspond to the maximum cooling capacity of 130 kJ/h. The maximum possible water vapor dew point input (°C) / (°F) indicated must not be exceeded.

Incoming gas temperature in °C (°F)

Gas flow [l/h] 70

(158 °F)

90 70

(158 °F)

110 68

(154.4 ° F )

130 65

(149 °F)

150 62

(143.6 °F)

170 59

(138.2 °F)

190 57

(134.6 °F)

210 55

(131 ° F)

230 53

(127. 4 ° F)

250 52

(125.6 ° F)

90 (194 °F)

70 (158 °F)

67 (152. 6 °F)

64 (147.2 ° F )

61 (141. 8 °F)

58 (136.4 ° F )

56 (132. 8 ° F )

54 (129. 2 ° F )

52 (125.6 ° F)

50 (122 °F)

120 (248 °F)

69 (156.2 °F)

66 (150.8 ° F )

63 (145.4 °F)

59 (138.2 °F)

56 (132. 8 ° F )

54 (129. 2 ° F )

52 (125.6 ° F)

49 (120.2 °F)

47 (116.6 °F)

150 (302 °F)

68 (154.4 ° F )

65 (149 °F)

61 (141. 8 °F)

58 (136.4 ° F )

55 (131 ° F)

52 (125.6 ° F)

49 (120.2 °F)

47 (116.6 °F)

44 (111. 2 ° F)

180 (356 °F)

67 (152. 6 °F)

63 (145.4 °F)

59 (138.2 °F)

56 (132. 8 ° F )

53 (127. 4 ° F)

50 (122 °F)

46 (114 . 8 ° F)

43 (109.4 °F)

41 (105.8 °F)

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5.2 Dimensions

Dimensions in mm [Inch]

Fig. 3: Front view: dimensions including optional peristaltic pumps

Dimensions in mm [Inch]

Note

You will find mounting directions on page 40 chapter ‘8 Installation instructions and mounting of the EC-30C’ .

Fig. 4: Side view: dimensions including optional peristaltic pumps

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6 Receiving the EC-30C

Heavy device!

CAUTION

Note

The ultra-low cooler EC-30C is a complete pre-installed unit.

Please remove the cooler carefully from the packaging. Check the scope of the delivery specified on the delivery note. Please make sure that you have received all items stated on the delivery note.

Please check the unit for any transport damages after receipt and report any complaints to the transport company immediately.

For transport reasons, the heat exchangers are not mounted inside of the cooler. They are included in the packaging, but wrapped separately. Connect the heat exchangers properly before commissioning.

Risk of injury when handling heavy equipment. Do not lift, move or carry the device without help. A second person is required to lift, move or carry the device.

The cooler should always be transported and stored in an upright position, with the equipment feet facing downwards to ensure that the oil in the closed compressor circuit cannot run out of the compressor case. If the device is transported on its back, it needs to be standing in an upright position for at least 2 hours before turning on.

Follow the instructions to connect the tubing to the heat exchangers

Note

on page 40 chapter ‘8 Installation instructions and mounting of the EC-3 0 C’

6.1 Product label and serial number

There are two product labels on the EC-30C. One of them is located on the right side of the cooler and the second one is inside the cooler housing on the bottom plate. Please refer to this serial number if you have any questions about the device or if you need to order spare parts or consumables.

Note

The EC-30C features two serial numbers. One serial number is for the device and the other one for the display controller.

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7 Using the EC-30C

PRG

ESC

7.1 Graphical user interface (GUI)

The EC-30C has a graphical, icon-based intuitive menu navigation. The graphic user interface includes three LED indicators, the display and the operating buttons. The figure below shows the screen, where the deep cooling unit has reached its target temperature of

-30 °C (~-22 °F), and describes the components of the user interface.

1 2 3

Fig. 5: Graphic user interface

1 Red LED (alarm message) 2 Yellow LED (warning message) 3 Green LED is on (OK) 4 Snow-flake-symbol with ‘1’ in its center (Tempera-

ture ≤ 0 °C and DCU 1 is active)

5 UP button (upwards pointing arrow) 6 PROGRAM button (PRG) 7 Temperature indication 8 DOWN button (downwards pointing arrow) 9 ESCAPE button (ESC)

Note

With the ESC button you will return to the start screen from any other screen.

7.2 LED color coding and possible color combinations

Red Yellow Green Description



 

Everything is OK

One or more warning messages

One or more alarm messages

A combination of one or more alarm messages and warning messages

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7.3 Self-monitoring after powering-on the unit

PRG

ESC

1 2 3

4 5 6

The EC-30C automatically monitors and controls its correct functioning and the wear out of its components. The self-test includes six different tests, each of them being symbolized by a smiley icon.

Fig. 6: Smiley symbols during self-test

1 ‘Test passed’-symbol 2 ‘Test failed’-symbol

Please switch on the EC-30C. After powering-on the unit starts the self-testing. After successful self-testing the display shows the following picture.

Fig. 7: The smileys on the display after self-testing

1 Internal low voltages 2 Power supply voltage 3 D/A converter 4 0-20 V-Module 5 Peltier elements 6 decoupling capacitor/ rectifier

If the self-test has succeeded, the unit enters the start-up phase and starts cooling.

If the display shows a ‘Test failed’-symbol, this means that an error has been detected which prevents the correct operation of the unit.

In case of a failed self-test the display alternates between the monitor with smiley symbols and the service monitor. These monitors will be shown on the display until the fault is cleared.

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Please contact the M&C Service in case of self-test failures. The M&C Service will recom-

PRG

ESC

mend suitable measures to repair the unit.

Fig. 8: ‘Service‘-monitor: Self-test failed

In some cases it is helpful to switch off the unit and to switch it on

Note

again after approx. one hour. If a ‘Test failed’-symbol is shown again after that, please contact the M&C Service!

7.4 Self-monitoring during operation

Note During its regular operation the unit runs automatic self-tests.

7.4.1 Power consumption readjustment

Over time the signs of aging of the Peltier elements increase gradually the value of the internal resistance. As a consequence the power necessary to keep the target temperature constant can not be supplied anymore. The projected capacity reserve compensates this unavoidable aging effect and maximizes the service life of the EC-30C.

7.4.2 Pre-warning messages

If the capacity reserve has been exhausted up to a critical value, the unit will show a warning message about the upcoming failure. An exact definition of the remaining time, until the breakdown of the unit, is not possible.

Please plan servicing the unit ahead of time. The remaining service

Note

life of the unit after the failure warning can not be determined exactly.

If the reserve capacity is exhausted, an alarm message will occur. The unit still keeps on cooling, but the target temperature will not be reached any more. The longer the unit will be kept in this modus, the less it will be able to cool. The possible cooling temperature will constantly rise.

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If the operation process allows it, it is possible to set the target temperature a little bit

PRG

ESC

2 3

higher, e.g. to -25 °C or -20 °C (~-13°F or ~-4°F). This will delay the alarm message until the capacity reserve will be exhausted even for this higher target temperature.

7.5 Display during start-up of the EC-30C

The start screen will always show the temperature of the active deep-cooling unit (DCU). At the beginning of the start-up phase the temperature will decrease

Note

very slowly, given that the active DCU is cooled only via the passive pre-cooler unit (PCU). After the PCU reaches +2°C (35.6 °F), the active cooling phase of the DCU starts. From this point on, the temperature will decrease considerably faster.

Fig. 9: Start-up phase: first cooling phase

1 ’Falling’ thermometer 2 Red LED is on (alarm) 3 Temperature of the active DCU

Directly after the successful self-test, the EC-30C will start cooling the pre-cooling unit (PCU) to +2°C (35.6 °F) (target temperature of the pre-cooling unit). Depending on the load, the compressor of the pre-cooling unit will switch between 12 to 120 times per hour, in order to reach this target temperature.

The ‘falling’ thermometer is the symbol for this first cooling phase. At this point the initial dew point of the sample gas is still higher than 0 °C (32 °F), which means that the target temperature has not been reached yet, and the EC-30C is still in alarm modus.

Note

The red LED shows the status of the alarm relay. Operation mode of the relay (safety first): alarm active = red LED

EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com 21

PRG

ESC

2 3

PRG

ESC

2 3

Fig. 10: Start-up phase: TKS reaches and/or exceeds ‘0 °C / 32 °F’-limit

1 Snowflake-symbol with a clock in its center 2 Red LED is on (alarm) 3 Temperature of the active DCU

As soon as the first DCU reaches the 0 °C (32 °F) temperature limit, the thermometer-symbol changes to a snowflake-symbol. The clock in its center stands for the start-up phase of the active DCU. The EC-30C is still in alarm modus (red LED is on), because the DCU has not reached its target temperature yet.

Fig. 11: Start-up phase: Target temperature reached

1 Snowflake-symbol with ‘1’ for DCU 1 2 Green LED is on (ready for operation) 3 Temperature of the active DCU (here DCU 1)

Note

The ‘1’ in the center of the snowflake stands for the active deep-cooling unit DCU 1.

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As soon as the EC-30C reaches the target temperature of DCU 1, including the alarm hys-

PRG

ESC

PRG

ESC

3 7

teresis of 5 °C (41 °F), it changes from alarm modus to OK modus. The red LED goes out and the green LED turns on.

7.6 Overview screen

The overview screen shows detailed information about the pre-cooling unit PCU and the two deep-cooling units DCU 1 and DCU 2. You can change from the start display to the overview display by pressing the DOWN button.

Fig. 12: That’s how you reach the overview screen

The icons on the overview screen inform you about the current conditions of the three cooling units.

Fig. 13: Overview screen

1 2

1 Column: target-temperatures 2 Column: current temperatures 3 DCU 1 temperature displayed on start screen 4 ‘M‘-symbol: PCU (not active) 5 DCU 1-symbol: cooling (active) 6 DCU 2-symbol: heating (active) 7 Smiley icon: PCU target temperature reached 8 Smiley icon: DCU 1 target temperature

reached

9 Clock icon: DCU 2 target temperature not

reached

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The following table shows the icons occurring on the display and their descriptions:

PRG

ESC

Symbol Description

Pre-cooling unit is cooling

Pre-cooling unit is not cooling

Deep-cooling unit I and/or II is cooling

Deep-cooling unit I and/or II is not cooling

Deep-cooling I or II is heating

Status display: The unit has reached its target temperature.

Status display: A warning or an alarm has occurred

Status display: The unit has not reached its target temperature yet

7.7 Alarm and warning history

The alarm and warning history shows in detail all warnings and alarms occurred.

The EC-30C is able to record 768 messages. In case of more than 768 messages the oldest messages will be deleted and replaced automatically.

You can reach the alarm and warning history from the overview screen by pressing the DOWN button.

Fig. 14: How to reach the alarm and warning history

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PRG

ESC

41 2 3

PRG

ESC

Fig. 15: Alarm and warning history

1 Column: date or time 2 Column: alarm or warning icon 3 Column: component Icons 4 Column: error code

Please press the PRG button to see the messages in detail.

Fig. 16: How to chose an alarm or warning message

1 Line, which is highlighted in Fig. 17 and Fig. 18

After pressing the PRG button the last line of the alarm and warning history screen will be displayed inverted (highlighted).

With the UP and DOWN buttons you can scroll through the stored messages. You will reach the highlighted message in Fig. 17 by pressing the UP button two-times.

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PRG

ESC

Fig. 17: How to scroll through stored messages

PRG

ESC

The highlighted line will show the time instead of the date of the selected alarm or warning message. The column for component icons will display the component of the device, the warning or alarm refers to.

In the selected line shown above the DCU 2-icon has changed into the temperature icon, which means that the warning refers to the temperature of the second deep-cooling unit.

Note

A slider on the right side of the display indicates the current position in the alarm and warning history.

Fig. 18: Detailed information for a selected message

1 Time of the selected message 2 Slider 3 Temperature icon

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7.7.1 Error codes

The error code in an alarm and warning history consists of two digits. The first digit in the error code refers to the component:

First digit Description

0 Pre-cooling unit

1 Deep-cooling unit I

2 Deep-cooling II

3 General device error

The second digit of the error code offers detailed information about alarm or warning messages.

The following chapters describe the error codes for warning and alarm messages in detail.

7.7.2 Warning symbols

In the alarm and warning history there are two different warning symbols:

Warning symbol Description

Warning

Canceled warning (warning triangle with check mark)

The warning triangle stands for a warning. A canceled warning is symbolized by a warning triangle with check mark.

When a warning has been canceled, the alarm and warning history will show a line displaying a warning triangle with check mark including date and hour of cancellation.

If you want to contact our service department to report a warning or

Note

alarm message, please keep ready the following information:

• Is the message an ‚alarm‘ or a ‚warning‘ message?

• Which error code is being displayed on the screen?

The following table shows the symbols that can occur in case of a warning and explains their meaning.

EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com 27

Components

Pre-cooling unit

Deep-cooling unit I

Deep-cooling unit II

Warning type

Symbol Code Description Comments

Temperature

Peltierelement(s)

0 - 20 V Module 1

12 Loss of power U

Temperature 14

Temperature

PeltierElement(s)

0 - 20 V Module 2

22 Loss of power U

Temperature 24

Temperature too low

PCU takes too long to cool down

Cooling temperature too low

Heating temperature too low

0 - 20 V Module deteriorated

Heating/ cooling takes too long

Cooling temperature too low

Heating temperaturetoo low

0 - 20 V Module deteriorated

Heating/ cooling takes too long

T1 ≤ 0 °C (32 °F)

> 45 min.

T2 < T2 °F)

T2 < T2 °F) after heating

-3 °C (26.6

set

-5 °C (23

set

cycle

≥ 19 V

PE1

OUT

≤ U

OUT, set

-0.5 V

or U

OUT

≥ U

OUT, set

+0.5 V

> 45 min. Thermal load maybe too high or ambient temperature too high

T3 < T3 °F)

T3 < T3

-3 °C (26.6

set

-5 °C

set

(23 °F) after heating cycle

≥ 19 V

PE2

OUT

≤ U

OUT, set

-0.5 V

or U

OUT

≥ U

OUT, set

+0.5 V

> 45 min. Thermal load maybe too high or ambient temperature too high

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Components

General device

Warning type

Service

Device temperature

Gas flow alarm

Back-up battery

Decoupling capacitor or rectifier

Symbol Code Description Comments

Service due in 20 days

Service expired

Service-remaining time ≤ 20 days

Service-remaining time ≤ 0 days

Device

temperature too high

≥ +70°C (158°F)

device

Device

temperature to low

≤ +5 °C (41 °F)

device

Heat exchanger

34 No gas flow

maybe frozen or gas line defect

Back-up battery empty

Power supply needs to be checked

≤ 2.3 V

Decoupling capacitor deteriorated or rectifier defect

7.7.3 Alarm symbols

In the alarm and warning history there are two different alarm symbols:

Alarm symbol Description

Alarm

Canceled alarm (alarm symbol with check mark)

The bell stands for an alarm. A canceled alarm is symbolized by a bell with check mark.

When an alarm has been canceled, the alarm and warning history will show a line displaying a bell with a check mark including the date and hour of cancellation.

If you want to contact our service department to report a warning or

Note

alarm message, please keep ready the following information:

• Is the message an ‚Alarm‘ or a ‚Warning‘ message?

• Which error code is being displayed on the screen?

The following table shows the symbols that can occur in case of an alarm, and explains their meaning.

EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com 29

Components Alarm type Symbol Code Description Comments

Pre-cooling unit

Deep-cooling unit I

Deep-cooling unit II

Temperature

Peltierelement(s)

0 - 20 V Module 1

Temperature

Peltierelement(s)

0 - 20 V Module 2

12 Loss of power U

13 defect

14 defect

22 Loss of power U

23 defect

24 defect

Temperature too high

Temperature too low

Cooling temperature too high

Heating temperature too high

Cooling temperature too high

Heating temperature too high

T1 ≥ +5 °C (41 °F)

T1 ≤ -1 °C (30.2 °F)

T2 ≥ T2 °F)

+3 °C (37.4

set

T2 ≥ +30 °C (86 °F)

≥ 19.7 V

PE1

No cooling despite the FET, relay etc. OK

≤ U

OUT

OUT, set

or U

≥ U

OUT

OUT, set

T3 ≥ T3 °F)

+3 °C (37.4

set

T3 ≥ +30 °C (86 °F)

≥ 19.7 V

PE2

No cooling despite the FET, relay etc. OK

≤ U

OUT

OUT, set

or U

≥ U

OUT

OUT, set

-1 V

+1 V

-1 V

+1 V

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Components Alarm type Symbol Code Description Comments

Liquid alarm 1

Liquid

Liquid alarm

alarm 2 (only for M&C service personnel)

Device

Device temperature

temperature too high

Device temperature too low

≥ +80 °C (176 °F)

Gerät

≤ +2 °C (35.6 °F)

Gerät

Couplings

Voltage error 34

capacitor or bridge rectifier defect

General device

I2C communication doesn‘t work

One IC doesn‘t answer; probably IC defect

All IC‘s don‘t answer (probably power cord defect or removed)

One internal Only for M&C Service Personnel

voltage supply

(5 V or 12 V) is

incorrect

5 V voltage < 4.5 V 12 V Voltage < 9 V

Cools down, but

H/K Relay unit

1 defect

does not heat up, or heats up, but does not cool down

Cools down, but

H/K Relay unit

2 defect

does not heat up, or heats up, but does not cool down

EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com 31

7.8 Temperature diagrams

PRG

ESC

PRG

ESC

The EC-30C shows the temperature diagrams of the pre-cooling unit and the two deep-cooling units. The temperature diagrams display a time period of 6 hours.

You can reach the temperature diagrams from the alarm and warning history screen by pressing the DOWN button.

Fig. 19: How to reach the graphical temperature diagrams

With the UP and DOWN buttons you can switch between the

Note

graphical temperature diagrams of the pre-cooling unit and the two deep-cooling units.

7.8 .1 Diagram of the pre-cooler unit (PCU)

You can reach the temperature diagram of the pre-cooler unit (PCU) from the alarm and warning history screen by pressing the DOWN button.

Fig. 20: Temperature diagram of the pre-cooling unit

After the commissioning of the EC-30C, the temperature diagram starts adding measurement readings from right to left. Every three minutes the characteristic line is updated with a new temperature value. The diagram always shows the measured temperature of the last 6 hours. Temperature values older than 6 hours will be deleted.

The y-axis of the PCU temperature diagram shows a temperature range from -35 °C to +25 °C (~-31 °F to +77 °F). Measured values exceeding or going below this temperature range will not be displayed.

32 EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com

7.8 . 2 Diagram of the deep cooling units (DCU 1 and DCU 2)

PRG

ESC

Starting from the pre-cooling unit (PCU) temperature diagram screen, please press the DOWN button to reach the temperature diagram of the two deep-cooling units. Here both deep-cooling units are displayed in one diagram.

The fine line shows the temperature characteristic of DCU 1 and the thicker line shows the characteristic of DCU 2.

1 2

Fig. 21: Temperature diagram of the deep-cooling units

1 Diagram of DCU 1 2 Diagram of DCU 2

The temperature range of the y-axis is limited from -35 °C to +25 °C (~-31 °F to +77 °F). Measured values exceeding or going below this temperature range will not be displayed.

Broken temperature lines are caused by switching the unit off and on again.

Note

When the EC-30C is turned off, and for excample after 2 hours turned on again, the temperature of the deep-cooling units will have changed. This leads to a broken line in the diagram.

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7.9 Parameter menu

PRG

ESC

PRG

ESC

The parameter menu is used for setting the individual parameters e.g. service interval or deep-cooling temperature. The parameter menu has two screens. You can switch between these screens by using the UP and DOWN buttons.

You can reach the parameter menu from the temperature diagram of the deep-cooling units by pressing the DOWN button.

Fig. 22: How to reach the parameter menu (screen 1)

The first parameter screen shows the following information:



Operating time of the EC-30C



Requested service interval



Settings for the mA-output

Fig. 23: Parameter menu, screen 1

1 Line 1: operating time 2 Line 2: Service interval in days 3 Line 3: mA-output

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In the second part of the parameter menu, there are the following parameters:

PRG

ESC



Required deep-cooling temperature



Current date



Current time

Fig. 24: Parameter menu, screen 2

1 Line 1: Deep-cooling temperature 2 Line 2: Current date 3 Line 3: Current time

Note

You will find the permitted parameter ranges on page 36 chapter ‘7.9.1 Parameter settings’ .

Here are the definitions of the symbols used in the parameter menu:

Symbol Definition

Information about the time period the unit has already been running

Setting of the required service interval

Setting of the mA-output and of the correlated temperature interval

Setting the required deep-cooling temperature

Information: current date

Information: current time

EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com 35

7.9.1 Parameter settings

PRG

ESC

The parameters displayed on the screens can be adjusted within a defined parameter range.

You can set the following parameters:

Parameter Parameter range Default value

Service interval

mA-output (power range)

Off (0 days), 1-1095 Tage

0-20 mA, 4-20 mA

365 days

4-20 mA

Min.: -40 °C to -10 °C mA-output (correlated temperature range)

(Min: ~-40 °F to 14 °F)

Max.: +10 °C to +60 °C

-30 °C to +30 °C (~-22 °F to +86 °F)

(Max: +50 °F to 140 °F)

Required deep-cooling temperature

Date [Day, Month, Year]

Time [Hour, Minute, Second]

-20 °C to -30 °C

(~-4 to °F to ~-22 °F)

Day: 01 to 31

Month: 01 to 12

Year: 15 to 99

Hour: 00 to 23

Minute: 00 to 59

Second: 00 to 59

-30 °C (~-22 °F)

01.01.16

12:00:00

To reach the program level for setting the parameters please start from the corresponding parameter screen and press the PRG button.

Fig. 25: How to reach the parameter settings

36 EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com

The screens of the parameter menu are independent screen pages.

PRG

ESC

You can change only the parameters of the screen that is currently

Note

displayed. If you want to change parameters from a different parameter screen, you have to leave the current setting level first by pressing the ESC button.

The first parameter of the parameter menu will be highlighted. You can switch between the parameters of this screen page with the PRG button.

First you have to invert the parameter you want to change. Then you use the UP and DOWN button to switch between the different parameter ranges.

You can exit this screen without changing any parameter by pressing the ESC button.

To accept the value shown on the display, please press the PRG button for about 3 seconds. The parameter will change from highlighted to not highlighted. This means that the value has been set to the new parameter. You can also change more than one parameter on the screen, and accept all of them by pressing the PRG button for 3 seconds.

You can exit this program level by pressing the ESC button.

Note

Please find more details about the program levels on page 67 chapter ‘12.1 Overview of the EC-30C screens’ .

7.10 Device information

Please start from the parameter menu (screen 2) and press the DOWN button to change to the device information screen.

Fig. 26: How to reach the device information

EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com 37

PRG

ESC

Fig. 27: Device information

1 Line 1: Device temperature 2 Line 2: Serial number of the display controller 3 Line 3: Days left until servicing 4 Line 4: Software version number

This screen displays the following device information:



Device temperature



Serial number of the device controller



Days left until servicing



Software version number

The symbols used on the device information screen are as follows:

Symbol Description

Device temperature

Serial number of the display controller

Days left until service

Software version number

38 EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com

7.11 Service-Reset (qualified personnel only)

PRG

ESC

Press for 3 seconds simultaneously

PRG

ESC

Loss of data caused by service reset!

Note

The service reset can be activated from the start screen by pressing simultaneously the UP, DOWN and ESC button for three seconds.

Fig. 28: Activating Service Reset (Qualified personnel only)

There is no security query, whether you really want to carry out the service reset or not. Service reset has to be carried out only by qualified personnel!

After activating service reset all messages from the error memory will be deleted. The service time will also be reseted.

Fig. 29: Reset screen (Qualified personnel only)

EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com 39

8 Installation instructions and mounting of the EC-30C

Heavy device!

CAUTION

The cooler EC-30C is suitable for both: wall and 19“ rack mounting.

8.1 Installation instructions

Follow these installation instructions:



The operating position of the cooler is exclusively upright. The operation in vertical position ensures the faultless separation and removal of the condensate in the heat exchanger.



Mount the cooler in a ventilated place away from heat sources. This way you avoid disturbing heat accumulations.



When mounted outdoors, the cooler has to be installed into a protective case. Make sure that the place of operation is frost-free in winter and sufficiently ventilated in summer. Avoid direct sunlight.

Risk of injury when handling heavy equipment. Do not lift, move or carry the device without help. A second person is required to lift, move or carry the device.



Take into consideration the required minimum assembly dimensions.



For optimum measurement results we recommend to use an electrically heated gas sample line.



Heated sample gas lines need to end at least 20 cm (7.874“) before the gas line reaches the cooler to make sure that the heated sample line and the cooler is thermally decoupled. That means, the last 20 cm (7.874“) of the gas lines are not isolated.



Un-heated sample gas lines need to be installed with a declining angle towards the cooler. In this case, any built-up condensate in the gas lines can flow towards the cooler and will be removed by the heat exchanger in the pre-cooler unit.

40 EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com

8.2 Wall and rack mount

The tubes for condensate removal will be directly connected to the

Note

DN10/12 mm connectors at the bottom of the heat exchangers. These condensate removal connectors stick out of the bottom plate of the cooler housing.

Abmessungen in mm [Inch]

Fig. 30: Min. assembly dimensions (unit with optional peristaltic pumps)

1 Min. distance between isolation and

attachment point of the unit

3 Min. installation space below the

EC-30C

Please follow these instructions for mounting of the EC-30C (numbers correspond to Fig. 30 on page 41):

1 For heated gas sample lines, the insulated part of the line must end at least 200 mm

(7.87“) before the line reaches the device.

2 Please provide a minimum of 180 mm (7.09“) installation space above the unit for the

tubing. Make sure that outgoing air can exit from the upper side of the device.

3 Provide a min. of 50 mm (1.97“) installation space below the unit for tubing, air intake

and maintenance access. Our recommendation: min. 100 mm (3.94“).

2 Min. installation space above the EC-30C

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2 3

Fig. 31: Mounting rail for wall or rack mounting

Abmessungen in mm [Inch]

1 Back-mounting rail for wall mounting: min.

4 mm (0.16“) wall distance

2 Back-mounting rail for wall mounting: max.

19 mm (0.75”) wall distance

3 Front-mounting rail for 19” rack: housing

front aligned to or 15 mm (0.6“) behind the front of the mounting bracket

To mount the EC-30C with the provided mounting rails, please follow these instructions (numbers correspond to Fig. 31 on page 42):

1 The mounting rails can be attached to the side panels close to the rear of the housing.

The minimum distance between the wall and the housing will be in this case 4 mm (0,16“).

2 The mounting rails can be attached to the side panels close to the rear of the housing.

The maximum distance between the wall and the housing will be in this case 19 mm (0.75“).

3 The mounting rails can be attached to the side panels close to the front of the housing

(19“ rack mount). In this case the front of the housing can either be aligned with or 15 mm (0.6“) behind the front of the mounting bracket.

42 EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com

8.3 Mounting instructions for SR25.2 peristaltic pump (optional)

Make sure to mount the pump to the front of the cooler with a minimum distance of 3.5 mm (0.138”) and a maximum distance of 5.5 mm (0.216”) between the pump motor and the front panel.

The minimum distance avoids damages to the pump motor and the maximum distance prevents the motor shaft from getting loose.

Fig. 32: SR25.2: Mounting distance between pump motor and front panel

1 Pump head (outside the EC-30C housing) 2 Front panel of the EC-30C 3 Recommended mounting distance 4 Pump motor (inside the EC-30C housing)

Note

For more mounting instructions, see the SR25.2 instruction manual. The manual is available on our website www.mc-techgroup.com.

EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com 43

8.4 Tubing without heat exchanger purging (standard tubing)

Do not mix up the tube connectors for sample gas inlet and outlet. The inlet and outlet connectors of the heat exchanger are marked with arrows.

Note

Make sure that all the connections are sealed adequately. To ensure free removal of the condensate, the stated diameters for the condensate removal lines can not be decreased!

The standard version of the EC-30C is equipped with tubing without heat exchanger purging. This standard tubing includes one solenoid valve (valve 1), to switch between the two deep-cooling units.

The standard tubing of the EC-30C is shown in the following figure.

Fig. 33: Standard tubing: DCU 1 active, solenoid valve triggered, no FA

1 Heat exchanger pre-cooling unit (PCU) 2 Heat exchanger DCU 1 (on the right, here:

active)

3 Heat exchanger DCU 2 (on the left, here:

not active)

Gas IN is the connector of the PCU heat exchanger. The sample gas enters the cooler at this connection. Gas OUT is the connector at the solenoid valve 1, which sticks out of the bottom plate of the cooler on the left-hand side. The sample gas leaves the cooler at this connection.

8.4.1 Heat exchanger connections for tubing without purging

4 Solenoid valve 1

The EC-30C provides six connectors for three heat exchangers, which protrude through the top panel of the device on the left hand-side. The sample gas enters the cooler at the sample gas inlet of the PCU heat exchanger.

The sample gas outlet DN 4/6 protrudes through the bottom plate of the cooler close to the front plate on the left-hand side.

44 EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com

2 3

Fig. 34: Heat exchanger connectors (device with four optional peristaltic pumps)

1 Heat exchanger pre-cooling unit 2 Heat exchanger DCU 1 (on the right) 3 Heat exchanger DCU 2 (on the left) 4 Flow alarm sensor FA (optional)

The PCU heat exchanger has two connectors which are marked with arrows as gas inlet and gas outlet. The connectors of the DCU heat exchangers are also marked with arrows.

Connect the gas inlet connectors of the DCU heat exchangers with a tee connector to the outlet of the pre-cooling heat exchanger.

Route the gas outlets of the DCU heat exchangers through the top panel of the EC-30C to the inside of the housing. Inside of the device connect the gas outlets of the DCU to the inlet connectors of the solenoid valve 1. Connect DCU 1OUT to the front and DCU 2OUT to the back connector of solenoid valve 1.

If you are using an internal flow alarm sensor FA: Connect the outlet of the solenoid valve 1 on the right hand-side to the gas inlet of the flow meter FM 40. Connect the outlet of the flow meter FM 40 to the gas outlet which protrudes through the bottom plate of the cooler close to the front panel on the left-hand side.

If you are using three optional peristaltic pumps: Connect the heat exchanger outlets to the peristaltic pumps. Each heat exchanger outlet will be connected to one peristaltic pump at the front panel of the cooler.

Keep the tubing of the heat exchanger condensate outlets as short and structured as possible. The tubing does not need to be connected in order.

EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com 45

8.5 Tubing with heat exchanger purging for special requirements (optional)

Do not mix up the tube connectors for sample gas inlet and outlet. The inlet and outlet connectors of the heat exchanger are marked with arrows.

Note

Make sure that all the connections are sealed adequately. To ensure free removal of the condensate, the stated diameters for the condensate removal lines can not be decreased!

A fourth optional peristaltic pump can be installed in combination with a second solenoid valve 2 to provide permanently and slowly (0.3 l/h) fresh sample gas to the inactive cooling unit. This prevents short peaks of the sample gas concentration due to stagnant gas during switching between the two deep cooling units.

The tubing with heat exchanger purging for special requirements is shown in Fig. 35:

90 - 250 l/h

0.3 l/h

Fig. 35: Tubing with purging: DCU 1 activ, solenoid valves triggered, no FA

1 PCU heat exchanger 2 DCU 1 heat exchanger (right, here: active) 3 Heat exchanger DCU 2 (left) 4 Solenoid valve 1 (right) 5 Solenoid valve 2 (left, optional for heat

exchanger purging)

Gas IN is the connector of the PCU heat exchanger. The sample gas enters the cooler at this connection. Gas OUT is the connector at the solenoid valve 1, which sticks out of the bottom plate of the cooler on the left-hand side. OUT2 is the optional connection to the fourth peristaltic pump, the gas outlet for the heat exchanger purging.

6 Fourth peristaltic pump, optional for heat

exchanger purging

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8.5.1 Heat exchanger connections for tubing with purging

The EC-30C provides six connectors for three heat exchangers, which protrude through the top panel of the device. The sample gas enters the cooler at the sample gas inlet of the PCU heat exchanger.

The sample gas outlet DN 4/6 protrudes through the bottom plate of the cooler close to the front plate on the left-hand side.

2 3

Fig. 36: Heat exchanger connections, tubing with purging

1 Heat exchanger pre-cooling unit 2 Heat exchanger DCU 2 (on the left) 3 Heat exchanger DCU 1 (on the right) 4 Heat exchanger purging: 4. peristaltic pump

(here: on the right)

The PCU heat exchanger has two connectors which are marked with arrows as gas inlet and gas outlet. The connectors of the DCU heat exchangers are also marked with arrows.

Connect the gas inlet connectors of the DCU heat exchangers with a tee connector to the outlet of the PCU heat exchanger.

The outlet connector of solenoid valve 2 sticks out of the bottom plate of the cooler located in the middle, close to the front plate. Connect the gas outlet of solenoid valve 2 to the fourth peristaltic pump.

Route the gas outlet of DCU 1 (on the right) through the top panel of the EC-30C to the inside of the housing. Inside of the device connect the gas outlet of DCU 1 to the forward-facing connectors of solenoid valve 1 and 2 with a tee.

Route the gas outlet of DCU 2 (on the left) through the top panel of the EC-30C to the inside of the housing. Inside of the device connect the gas outlet of DCU 2 to the backward-facing connectors of solenoid valve 1 and 2 with a tee.

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Connect the gas outlet of solenoid valve 1 on the right hand-side to the gas inlet of the flow meter FM 40. Connect the outlet of the flow meter FM 40 to the gas outlet which protrudes through the bottom plate of the cooler close to the front panel on the left-hand side.

Connect the outlet of solenoid valve 2 (left) which protrudes through the bottom plate of the cooler, in the middle, close to the front plate, to the fourth peristaltic pump.

Keep the tubing of the condensate outlets as short and structured as possible. The tubing does not need to be connected in order.

8.6 Duran-glass heat exchanger with GL-connections

On mounting the glass heat exchangers, please follow these instructions:



Before mounting the GL connections, please check the PTFE/Silicone locking rings for damages.



Mount the locking rings with the PTFE side facing the medium.

After assembly please check the leak tightness of the GL connections at the Duran glass heat exchangers.

8.7 PVDF- heat exchanger with PVDF-tube connectors

Compared to Duran glass heat exchangers, the PVDF heat exchang-

Note

On mounting the PVDF heat exchangers with PVDF compression fittings, please follow these instructions:



Carefully remove the nut from the screw-connection. Pay attention to the loose ferrule inside the nut.



Push the union nut onto the 4/6 mm tubing.



Push the ferrule with the thick bulb facing the nut onto the tubing.



Push the tubing onto the support nipple in the screw-connection.



Tighten the union nut hand-tight.

ers have a lower heat conductivity. If you are using PVDF heat exchangers, please keep in mind, that the cooling capacity of these heat exchangers are lower.

48 EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com

Note

To tighten the connectors onto the PVDF heat exchanger, hold a wrench against the spanner flats of the bushing!

After assembling all lines check the leak tightness of the PVDF tube connectors.

8.8 Electrical connections

Wrong supply voltage can destroy your cooler!

ATTENTION

There are two EC-30C versions available: 115 V and 230 V. Make sure to operate each version with the appropriate supply voltage stated on the model type plate.

Note

There are five cable fittings at the bottom of the EC-30C, where all electrical connections can be lead through.

When connecting the equipment, make sure that the supply voltage is identical with the information provided on the model type plate!

The installation and commissioning of the device must conform to the requirements of VDE 0100 (IEC 364) ‘Regulations on the Installation of Power Circuits with Nominal Voltages below 1000 V’ and must be in compliance with all relevant regulations and standards.

You can open the front of the EC-30C by loosening the four front screws. The front of the cooler is hooked into the bottom plate with a guide rail and can be tilted to up to 90° forwards. The power supply electronics are inside the housing on the right. All necessary connections can be plugged in here without removing the shielding plate.

Fig. 37 shows all available electrical connections.

EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com 49

Transformer out

Fan out

Solenoid valve 1

Solenoid valve 2

Aggregate out

Relay Relay Relay

Relay Warning Relay Warning Relay Relay

Fig. 37: Electrical connections

1 X37 2 X38 3 X39 4 X40 5 X41

The pins from Fig. 37 are marked as follows:

Pin No. Definition PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7

X37 Power IN PE L N --- --- --- ---

X38 Alarm Relais NO COM NC --- --- --- ---

X39 Warn+Ak.St. W:COM W:NO A.St:COM A.St:NO --- --- ---

X40 mA+LA+FA mA:+ mA:- LA:In LA:GND FA:+5V FA:IN FA:GND

X41 M&C BUS x x x x x x x

x: M&C BUS configuration, only for M&C service personnel.

50 EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com

Note

It is important that the load of the relay contact meets the requirements stated on page 14 chapter ‘5 Technical Data’ .

8.8.1 mA-output

By default, the EC-30C has a configurable mA-output. The mA-output value always corresponds to the temperature of the active deep-cooling unit and represents the current outlet dew point.

You can assign the mA-output value range (0-20mA or 4-20 mA) to a temperature range ∆T. In this case the lower temperature limit T mA or 4 mA, and the upper temperature limit T

corresponds to the mA-output signal of 0

min

corresponds to the mA-output signal of

max

20 mA.

This correlation makes it possible to influence the resolution of the mA signal and e.g. to achieve an improved measuring accuracy for a smaller temperature range.

The measuring error based on the display of the controller is ±2 % of the measuring range limit.

The maximum load of the mA output including the supply line is 500 Ohm.

You will find information on how to calculate the correlation between

Note

the mA output signal range and the temperature range in the annex of this manual on page 68 chapter ‘12.2 How to configure the mA-output’ .

8.8.2 Liquid alarm sensor LA (optional)

It is possible to connect an external liquid alarm sensor LA to monitor the EX30-C, in order to protect any downstream analyzing equipment. The LA will detect a condensate leakage caused by a possible cooler defect or overload.

The EC-30C connected to the LA gives an alarm signal which will be registered in the alarm and warning history. The cooler switches the alarm relay to stop the gas supply by either turning off the sample gas pump or triggering a solenoid shut off valve.

The M&C liquid sensors are based on the principle of electric conduc-

Note

tivity starting from a conductive value of 50 μS/cm. Learn more about the M&C liquid sensors on our website www. mc-techgroup.com.

The connecting cable between cooler and external liquid sensor can not exceed a length of 3 m (19.84 ft.).

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The EC-30C can be connected to a liquid sensor with or without cable breakage detection. The default configuration of the EC-30C is for a sensor with cable breakage detection.

Sensors without cable breakage detection can be connected only to devices with a specific configuration.

Note

When ordering the EC-30C, please let us know whether you are going to use a sensor with or without cable breakage detection. We will configure your EC-30C individually for the required sensor.

Do you need help?

Do you need further information about liquid sensors? Please contact the M&C Service!

8.8.3 Gas flow sensor FA 20 and gas flow meter FM 40 (optional)

The M&C gas flow alarm sensor FA 20 is used for monitoring of sample gas or test gas failures in analyzing devices or analyzing systems. The EC-30C offers the option to process data coming from the mono-stable gas flow alarm sensor. The gas flow sensor allows both internal and external mounting.

In case of internal mounting of the FA20, it is necessary to mount into the EC-30C an additional flow meter FM40 with a scale of 0 to 250 l/h.

The flow meter FM40 will be added at the end of the internal tubing. When the flow meter is triggered, the EC-30C gives a warning message which will be recorded in the alarm and warning history. This allows to recognize a possible freezing up or leakage in the system at an early stage.

The connecting cable of an external flow meter must not exceed a length of 3m (19.84 ft.).

Do you need help?

Do you need further information about gas flow sensors or flow meters? Please contact the M&C Service!

52 EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com

9 Start-up

Wrong supply voltage can destroy your cooler!

ATTENTION

When the EC-30C is started, one of the gas lines through the deep-cooler is always open. The outlet status contact must be connected to an external sample gas pump or a valve in the sample gas line to protect the entire analysis system by immediately cutting off the gas supply in the event of error messages of the cooler.

Note

When connecting the equipment, make sure that the supply voltage is identical with the information provided on the model type plate!

Damages of the downstream analyzers can occur! Observe the alarm contacts! Do not extract gas when the EC-30C is turned off or when the LED light is red!

Disruption in operation possible! Before starting up the gas cooler make sure that it has been placed in its operating position for at least two hours! Transport or mounting can lead to the redistribution of the cooling liquid within the system and this can cause operating trouble when the cooler is turned on to early.

Note

The start-up ambient temperature has to be +5 °C to +45 °C (+41 °F to +113 °F).

9.1 Preparation for start-up

Please take into consideration all equipment and process specific security measures before initial start-up.

Before initial start-up, follow these steps:



Open the front panel of the EC-30C and connect all cable connections required (power, relay, mA etc.).



Connect all outputs required and - where necessary - connect them to the measuring station.



Close and secure the device again.



Apply the correct supply voltage 115 V / 60 Hz o 230 V / 50 Hz according to the specification plate.



Connect the cooler to the power supply.

The control electronics of the EC-30C permits automatic start up of the cooler, which ensures safe operation regardless of external influences such as a power failure. The error diagnostic will report possible error sources.

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9.2 Temperature chart of the start-up stages

When started up, the EC-30C carries out a self-test to check the main components of the unit.

The self-test consists of six testing steps. Each of the test steps is symbolized by a smiley icon. After successful self-testing the unit enters the starting phase and starts cooling.

When the display shows a ‘Test failed’-icon, the unit has detected an error. The cooler will not enter the start-up phase.

If the self-test has failed, the display alternates between the screen with the smileys and the service screen. These screens will remain on the display until the problem has been solved.

Generally in a cases like this the unit has to be sent to M&C for check-up and/or repair. Please contact our service department by phone before sending the unit.

Note

Please find more details about the self-test on page 19 chapter ‘7.3 Self-monitoring after powering-on the unit’ .

After successful testing, the unit starts the cooling process. It is carried out in several different stages, shown in the following phase diagram.

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t [h]

Fig. 38: Temperature chart of the start-up stages

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Description of the start-up stages:



1 EC-30C is turned off.



2 EC-30C is turned on. The pre-cooling unit PCU is cooling down to the target

temperature +2 °C (+35.6 °F). Deep-cooling unit DCU 1 (green line) and deep-cooling unit DCU2 (purple line) are cooled passively by the pre-cooling unit. The temperatures of DCU 1 and DCU 2 are decreasing.



3 Pre-cooling unit PCU reaches the target temperature of +2 °C (+35.6 °F). The

DCU with the lower temperature (here DCU 1) is cooling down until it reaches its target temperature of -30 °C (~-22 °F). Second deep-cooling unit (here: DCU

2) is still passively cooled.



4 DCU 1 reaches the target temperature of -30 °C (~-22 °F). DCU 2 heats and

starts defrosting to reach the target temperature of +20 °C (68 °F).



5 DCU 2 reaches target temperature of +20 °C (68 °F). DCU 2 keeps the target

temperature of +20 °C (68 °F) constant for 20 minutes in order to assure a successful defrost process. DCU 1 keeps a constant target temperature of -30 °C (~-22 °F).



6 DCU 2 will be turned off. DCU 1 still at target temperature -30 °C (~-22 °F).

Only after a restart of the unit this stage takes a shorter periode of time. This way the unit can switch very quickly to the dewed DCU and avoid a freeze up.

During operations the length of this stage follows the requirements of the 6 hours‘ cycle time. Because in any case the cooling DCU has to keep the re-

quired target temperature constant for three hours. (see stage 11).



7 DCU 2 cools down to target temperature -30 °C (~-22 °F). DCU 1 keeps

constant the target temperature of -30 °C (~-22 °F).



8 DCU 2 reaches the target temperature of -30 °C (~-22 °F). EC-30C switches the

gas flow to DCU 2. DCU 1 switches off for 20 minutes.



9 DCU 1 heats to the target temperature of +20 °C (68 °F). DCU 2 stays at target

temperature of -30 °C (~-22 °F).



10 DCU 1 reaches target temperature of +20 °C (68 °F). DCU 1 keeps the target

temperature of +20 °C (68 °F) constant for 20 minutes in order to assure a succesful defrost process. DCU 2 stays at target temperature of -30 °C (~-22 °F).

56 EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com



11 DCU 1 is turned off. DCU 2 stays at target temperature of -30 °C (~-22 °F).

Now the unit „knows“ how long it takes to cool DCU 1 down to the target temperature of -30 °C (~-22 °F) with the current load. DCU 1 remains off until the cooling process starts.

It depends on the required cooling process how long DCU 1 remains off. The goal is to alternate the deep-cooling units every 3 hours, in order to avoid freeze up of the unit.



12 DCU 1 cools down until the target temperature of -30 °C (~-22 °F) is

reached. DCU 2 stays at target temperature of -30 °C (~-22 °F).

From this moment on DCU 1 starts cooling, to reach the target temperature of

-30 °C (~-22 °F) in due time and to keep the required 6 hours`s cycle time.



13 DCU 1 reaches the target temperature of -30 °C (~-22 °F). EC-30C switches

the gas flow to DCU 1. DCU 2 turns off for 20 minutes.

From this point on the cooling stages of the EC-30C keep on repeating themselves starting with stage 4. Unlike the restart phase, stage 6 will take a longer time period during the

operation process.

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10 Maintenance

Dangerous voltage! Risk of death by electric shock!

DANGER

Before starting any maintenance work, please make sure that any work done on the device is in compliance with all relevant regulations and standards.

Depending on the degree of pollution of the ambient air, the cooling fins of the condenser need to be cleaned with pressure air periodically.

The intervals between servicing are dependent on the process and system conditions in your facility. The facility QA/QC plan should address the frequency for maintenance and should be updated based on your operations.

10.1 Maintenance of the peristaltic pump type SR25.2 (optional)

DANGER

Do not open the deep-cooler! Disconnect power supply before opening the device for access. Make sure that all external power supplies are disconnected.

Dangerous voltage! Risk of death by electric shock! Do not open the device! Disconnect power supply before opening the device for access. Make sure that all external power supplies, including all alarm and control circuits, are disconnected.

Flexible tube, conveying belt, contact pulleys and contact springs are the only consumables of the pump. Depending on the operating conditions, the flexible tubing needs to be checked and, if necessary, changed every three to six months.

The service interval of the EC-30C can be set according to the re-

Note

quired maintenance interval of the peristaltic pump. You can find the details about setting the service interval on page 36 chapter ‘7.9.1 Parameter settings’ .

Before starting any maintenance work, please make sure that any work done on the device is in compliance with all relevant regulations and standards.

Note

Please find details to spare parts for the SR25.2 peristaltic pump on page 70 chapter ‘12.3 Spare parts and consumables’ .

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10.1.1 Changing the pump tubing

Aggressive condensate possible!

WARNING

Note

Media residues in tubing! Chemical burns caused by aggressive media possible! Wear protective clothing and glasses!

When sending the peristaltic pump to M&C customer service for repair, please indicate the type of medium pumped. Before shipping the pump, please remove hazardous or aggressive contaminations from all parts of the pump!

Fig. 39: Changing the pump tubing

1 conveying belt 2 S-bolt 3 tubing 4 contact pulley

For changing the pump tubing please proceed as follows:



Unplug the cooler from the mains voltage. The device needs to be voltage free.



Open tube connections at the pump; press conveying belt 1 at the recessed grips and turn S-bolt 2 clockwise up to limit stop;



Remove conveying belt 1 and pull the old tubing 3 at the tube bushings out of the guides;



Press the two contact pulleys 4 and check whether the spring pressure is still sufficient, if not, the contact springs have to be changed (see chapter 7.4.1 on page 20).



Put the new tubing 3 with the tube bushing into the guides of the conveying belt 1 ;

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Use only the original M&C spare parts! Only the use of the original tubing set guarantees a perfect operation!

Note

Never lubricate tubing! Before mounting the pump, check all parts for contaminations and clean if necessary.



Put the conveying belt 1 with the new tubing 3 into the dovetail guide of the pump body;



Press conveying belt at the recessed grips and simultaneously turn the S-bolt 2 anticlockwise until it snaps;



Switch on the EC-30C.

10.1.2 Changing the contact pulley and springs

While mounting, make sure that the center of rotation and the driver

Note

are aligned. Use genuine spare parts only!

Follow these instructions to change the contact pulley and springs:



Disconnect the cooler from the power supply.



Unscrew the nut of the pump head (wrench size 5.5).



Remove the pump head from the motor shaft. Now the driver can be removed from the pump head and is ready for maintenance.



The removal of the springs (4 pcs.) away from the driver is possible without any tools. Therefore press together the spring and pull it out of the groove in the driver, respectively out of the boring of the roll shaft. Now the roll shaft can be dismounted and the contact pulleys can be replaced.



Assemble the pump in reversed order.

10.1.3 Cleaning the pump head

Aggressive condensate possible!

WARNING

Media residues in tubing! Chemical burns caused by aggressive media possible! Wear protective clothing and glasses!

We recommend to clean the parts with a dry cloth. Solvent should not be used, because it can damage the plastics and synthetic rubber parts. Use oil-free compressed air to clean the parts if available.

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10.2 Changing the heat exchanger

Removal of the heat exchangers may be necessary to carry out any maintenance or repair work. The PCU heat exchanger can be disassembled without switching off the cooler.

The DCU 1 and DCU 2 heat exchangers need to be defrosted before disassembly. At operation temperatures of -30 °C (~-22 °F) the deep-freezer heat exchangers can not be disassembled because of freezing. Only after a defrost period of about one hour, the DCU heat exchangers can be removed.

We recommend the following procedure to replace the heat exchangers:



Purge the heat exchanger to remove any possible residue of aggressive media.



Release the upper gas connections and lower condensate connections by turning the green GL-connectors to the left.



Pull the heat exchanger upwards and slightly rotate it out of the cooling block.



Dry and clean the opening of the aluminum cooling block with a cloth.



Apply a thin and equal layer of thermal conductivity paste over the whole surface of the heat exchanger to ensure good conduction of heat.



Lightly push and slightly rotate the heat exchanger back into the opening of the cooling block and press it to the upper block.



Remove any surplus thermal conductivity paste.



Reconnect the tubing following the instruction in chapter 8.4 on page 44 or chapter 8.5 on page 46.

Note

Do not use force to remove frozen DCU heat exchangers! Glass heat exchangers might break!

Note Do not mix up DCU and PCU heat exchangers!

Note

Do not mix up tubing! The outlet tube of the DCU 1 has a red mark.

Special instruction for Duran glass heat exchanger assembly:



Check the PTFE/Silicon locking rings for damage. In assembly, the locking rings must have the PTFE side facing the medium, otherwise the required degree of sealing cannot be guaranteed!



Fasten the green GL-connection hand-tight by turning them to the right.

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10.3 Changing the 0-20 V-Module

Dangerous voltage! Risk of death by electric shock!

DANGER

If the self-test during start-up of the EC-30C fails and the fourth icon shown on the screen is a ‘Test failed’-icon, or if an alarm signal with the codes 14 or 24 is issued during operation, the 0-20 V-Module has to be changed. If a warning message with the codes 13 or 23 is shown, changing the module is not yet necessary, but recommended, to avoid breakdown of the unit.

Follow these steps to change the 0-20 V-Module:



Disconnect the cooler from the power supply.



Unscrew and open the front panel, but keep it hinged to the rail at the bottom plate.



Disconnect the electrical connectors X12, X13, X16, X17 and X18.



Unscrew the electronics cover from the front panel and remove it.

Do not open the device! Disconnect power supply before opening the device for access. Make sure that all external power supplies, including all alarm and control circuits, are disconnected.



Carefully unplug the connector between main board and 0-20 V-Module electronics.



Open the two screws which are holding the 0-20 V-Module. Replace the module.



Carefully plug in the connector between main board and the 0-20 V-Module electronics.



Fasten the electronics cover back to the front panel again.



Connect the plugs X12, X13, X16, X17 and X18 again.



Close and secure the front panel.



Turn on the device and check the result.

62 EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com

10.4 Changing the buffer battery

The EC-30C uses a type CR2032 buffer battery. To change the buffer battery please carry out the steps indicated below:



Disconnect the EC-30C from the power supply.



Unscrew and open the front panel, but keep it hinged to the rail at the bottom plate.



Unplug the connectors X12, X13.



Unscrew the electronics cover from the front panel and remove it.



Now you can change the battery.



Fasten the electronics cover back to the front panel.



Plug in the connectors X12, X13.



Close and secure the front panel.



Turn on the unit.



Set date and time.

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10.5 Checking the temperature sensors

All temperature sensors of the PCU, DCU 1 and DCU 2 are PT100 sensors.

The diagram below shows the resistance - temperature characteristics of the temperature sensor PT100.

Fig. 40: Resistor - temperature characteristic of the PT100

If there are any problems during temperature measurements, please follow these steps to check the PT100:



Disconnect the unit from the power supply.



Unscrew and open the front panel, but keep it hinged to the rail at the bottom plate.



Unscrew the faulty temperature sensor.



When the EC-30C has been in operating mode before, please wait until the temperature of the PT100 has adapted to the ambient temperature.



Check the resistance of the PT100 with an ohmmeter.

Compare the measured value with the value of the resistance at ambient temperature shown in the resistance- temperature diagram. If the measured value corresponds to the diagram value with good approximation the PT100 is in working conditions. A large deviation means either that the temperature of the sensor is not yet adapted to the ambient temperature or that it is defective.

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10.6 Changing the compressor unit

The compressor unit is connected to the electrical connections shown in Fig. 37 on page

50. The following figure shows the electrical connections of the compressor.

Fig. 41: Compressor: electrical connections

1 Compressor 2 Terminal area inside the compressor terminal box 3 Starting capacitor of the compressor 4 Controller cable from the main electronics 5 Connection wires 6 Flat connector

The four wires of the compressor unit are marked with the numbers ‘1’‚ ‘2’, ‘3’ and the letter combination PE. These characters are printed on the power supply board belonging to terminal X35. Connect the wires to the corresponding numbers and letters.

Connect wires in the correct order!

ATTENTION

Make sure to pay attention to the order of the printed numbers and letters!

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11 Decommissioning

Aggressive condensate possible!

WARNING

ATTENTION

When the EC-30C is out of operation, one of the gas lines through the deep-cooler will always remain open. If a sample gas pump is in-line before or after the EC-30C, downstream analyzing units can be damaged.

Turn off the sample gas pump before decommissioning the EC-30C.

It is recommended to connect the status contact output with an external sample gas pump or a solenoid valve in the gas line. In case of an alarm message this can protect the whole analyzing system by immediate interruption of the gas supply.

The alarm relay of the EC-30C can be used to interrupt the gas supply either by turning off the sample gas pump or by triggering the shut-off solenoid valve.

Media residues in tubing! Chemical burns caused by aggressive media possible! Wear protective clothing and glasses!

Damages of the downstream analyzing units possible! Turn off up- or downstream sample gas pumps before decommissioning!

Note

Please find further details about the alarm relay on page 51 chapter ‘8.8.2 Liquid alarm sensor LA (optional)’ .

In case of a short-term decommissioning of the cooler no special measures are required.

In case of a long-term decommissioning of the coolers we recommend to purge the cooler with inert gas or air.

Remove residual condensate entirely from the cooler.

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12 Appendix

12.1 Overview of the EC-30C screens

Level 1

(Main menus)

Level 2

(Parameter)

Level 3

(Values)

Using the UP and DOWN button to scroll through the alarm and warning messages

Fig. 42: Overview: screens

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Choose: ‚service interval‘ or ‚mA-output‘

(the choice will be highlighted)

Choose:

‘, ‚Date‘ and ‚Time‘

‚T

SET

(the choice will be highlighted)

Set service interval Set mA-output (0-20 mA or 4-20 mA) Assign a temperature range to the mA-output

Set T

SET

Set date Set time

12.2 How to configure the mA-output

      

(

mess

− I

offset

)

∗ ∆T

∆I

+ ∆T

min



m , wenn

− 20

 − 20m



m



20 − 20

− 20

The mA-output value always corresponds to the temperature of the active deep-cooling unit. That means, that it always represents the current ouptut dew point. T temperature limit set in the parameter menu. T

is either assigned to 0 mA or 4 mA. T

min

is the upper temperature limit and is assigned to 20 mA.

By changing the temperature limits, the user can adapt the mA signal to the required temperature range ∆T. This way the resolution of the signal can be influenced.

is the lower

min

max

Depending on the temperature limits set by the user, either ∆T

min

or ∆T

needs to be de-

max

terment first.

12.2.1 How to calculate temperature based on measured mA-value

The temperature of the deep-cooling unit can be determent by using the measured mA-output values. To calculate the temperature, please use the following formulas:

For T

≤ 0 °C (32 °F):

min

display

For T

min

With the following values for I

> 0 °C (32 °F):

offset

= (

and ∆I:

display

offset

∆I =

when

, wenn

when

, wenn

when

, wenn

when

)

m m

68 EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com

12.2.2 How to calculate mA-value based on measured temperature

mess

      

+∆T

m 

∗ ∆I

∆T

+ I

offset

mess

      

-∆T

m 

∗ ∆I

∆T

+ I

offset



m , wenn

− 20

 − 20m



m



20 − 20

− 20

when

Based on the displayed deep-cooling temperature, the value of the mA-output can be determent. For this calculation you can use the following formulas:

For T

With the following values for I

≤ 0 °C (32 °F):

min

(

display

(

> 0 °C (32 °F):

min

(

display

(

and ∆I:

offset

∆I =



Increments and resolution of the mA-output

, wenn

when

, wenn

when

, wenn

when

)

m m

The mA-output with the 0-20 mA setting has 400 increments per range. For the range of 4-20 mA the increments are proportionally reduced to 320.

Depending on the temperature range (see how to set the temperature range on page 34 chapter ‘7.9 Parameter menu’ ), the resolution or accuracy of the mA-output can be calculated as follows:

- T

max

) / 400 for 0-20 mA

min

or:

- T

max

) / 320 for 4-20 mA

min

Example:

Set: 4-20 mA for -30 °C to +30 °C (~-22 °F to 86 °F)

The resolution of the mA-output is:

[30 °C - (-30 °C)] / 320 = 0.1875 °C (0.34 °F)

EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com 69

12.3 Spare parts and consumables

The replacement interval for spare parts and consumables depends on the specific operating condition of the analyzer. The quantities recommended in the following table are based on experience. Your replacement intervals will be based on your operating conditions.

The product label with the serial number is located on the back of the EC-30C.

Type and name of the product

Part-No. Name C/R/S 1 2 3

90 K 6215 0-20 V Module R - - -

90 K 6210 Main electronics (Var 1) R - - -

90 K 6200 Power supply electronics (Var 1) R - - -

90 K 6205 Rectifier electronics (Var 1) R - - -

90 K 6220 Main adapter R - - -

EE 02710005 Rectifier capacitor R - - -

90 K 6265 Converter R - - -

90 K 6225 Fuse set* EC-30C 230 V R - - -

90 K 6225a Fuse set* EC-30C 115 V R - - -

90 K 1002 Temperature sensor pre-cooling unit PCU R - - -

90 K 0040x Temperature sensor deep-cooling unit DCU R - - -

93 K 0047 Peltier element R - - -

90 K 6245 O-ring set** Silicone EC-30C R - - -

90 K 1014 Cooling aggregate 230 V R - - -

90 K 1014a Cooling aggregate 115 V R - - -

90 K 1055 Starting capacitor: compressor 230 V: 80 µF R - 1 1

90 K 1060 Starting capacitor: compressor 115 V: 160 µF R - 1 1

90 K 6001 Heat exchanger glass DCU R 1 1 1

02 K 9105 Heat exchanger glass PCU R 1 1 1

90 K 6003 Heat exchanger PVDF DCU R 1 1 1

02 K 9300 Heat exchanger PVDF PCU R 1 1 1

90 K 0115 Heat conductivity paste (50 g)***

90 K 6040 Solenoid valve 230 V R - - -

90 K 6041 Solenoid valve 115 V R - - -

90 K 0042 Fan 230 V R - - -

90 K 0042a Fan 115 V R - - -

EZ 0024 Display controller TCU R - - -

91 B 8600 Key-pad R - - -

recommended amount based on number of years of operation [years]

70 EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com

Type and name of the product

recommended amount based on number of years of operation [years]

Part-No. Name C/R/S 1 2 3

90 P 1007 SR25.2: Tubing set

C 1 2 4

with PVDF-tube connectors 4/6mm, standard

90 P 1020 SR25.2: Driver, complete S - 1 1

90 P 1050 SR25.2: Conveying belt S - 1 2

90 P 1045 SR25.2: Contact pulley SR25 PVDF for driver S 2 4 4

90 P 1010 SR25.2: 1 set (4 pcs) contact springs SR25 for

R 1 2 2

driver

* Fuse set EC-30C includes fuses for main, power supply and rectifier electronics.

** The O-ring set Silicone EC-30C for the deep-cooling units DCU 1 and DCU 2 includes 2 x Ø 60 mm and 3 x Ø 16 mm O-rings. If you disassemble a deep-cooling unit, you always have to replace all five O-rings.

*** Each heat exchanger delivery includes 5 g (0.011 lb) heat conductivity paste. You will need additional heat conducting paste, if you insert the heat exchanger after cleaning.

12.4 Additional Information

More information about the EC-30C can be found on our website:

www.mc-techgroup.com

12.5 Declaration of conformity

CE - Certification

The EC-30C complies with the following EU directives:

EMC directives

The EC-30C complies with the EC directive 2014/30/EU ‘Electromagnetic compatibility’.

Low Voltage Directive

The EC-30C meets the requirements of the Low Voltage Directive 2014/35/EU.

To ensure the compliance with this EC directive, the EC-30C conforms to the DIN EN 61010 standard.

Declaration of conformity

The EU Declaration of conformity can be downloaded from the M&C website or directly requested from M&C.

EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com 71

12.6 Certificates

Certificates are available on our website:

www.mc-techgroup.com

12.7 Warranty

In case of a device failure, please contact M&C immediately or your authorized M&C distributor.

We have a warranty period of 12 months from the delivery date. The warranty covers only appropriately used products and does not cover the consumable parts. Please find the complete warranty conditions in our terms and conditions.

The warranty includes a free-of-charge repair at a M&C facility or the free replacement of the device. If you return a device to M&C, please be sure that it is properly packaged and shipped with protective packaging. The repaired or replaced device will be shipped free of delivery charges to the point of use.

For more information about shipping and handling of returned devices, please see on page 73 chapter ‘12.10 Shipping and handling’ .

12.8 Liability and disclaimer

This instruction manual is an original M&C document. It does not claim to be complete and it may be subject to technical modifications. We are not responsible for any printing errors or errors in the content of the manual. Please be assured that precautions have been taken to prevent errors in our product documentation to provide you with the best possible and accurate information.

Liabilities for indirect and direct damages that are related to the delivery or the usage of this instruction manual are excluded.

We are not liable for the content of translations from sources which are not authorized by M&C.

Copy of this document or of its content is not allowed without explicit approval of M&C.

With the release of this version all older instruction manual versions will no longer be valid.

72 EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com

12.9 Storage

If you plan to store your M&C product before installing and operating, please follow these storage recommendations. Make sure that the device is stored in a protected, dry and well ventilated area. Please cover the device with an appropriate cover to protect it from dirt and liquids.

If you have any questions about proper storage of your M&C products, please feel free to contact us.

12.10 Shipping and handling

If you need to ship your M&C product to another department inside your company or back to M&C, please follow these shipping and handling recommendations.

Please ship the device in its original packaging. This is the best way to protect the device. If the original packaging is not available any more, please use a sturdy cardboard box with enough packaging material to protect the device from damages during shipping.

If you send your M&C product in for maintenance work at our M&C facility, please send the properly packaged device to the M&C TechGroup address in the USA or Germany as needed.

12 .11 Proper disposal of the device

At the end of the life cycle of our products, it is important to take care of the appropriate disposal of obsolete electrical and non-electrical devices. To help protect our environment, please follow the rules and regulations of your country regarding recycling and waste management.

EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com 73

13 About us

13.1 M&C‘s group of companies

The M&C group of companies with its German headquarter and world wide market activities, has earned the reputation as one of the well-known and strongest partners in the market.

Our company, our products, special systems and overall performances are well established in the market. We continuously belong to the best of the best of our industry. This makes us very proud. Our core competences are to find qualified solutions for even the most complex and demanding measuring tasks. We are developing answers to solve the technical demands of the future. With our focus on premium services, we are reliable, innovative and an overall cost effective market partner worldwide.

To learn more about M&C, please visit our website:

www.mc-techgroup.com

For even quicker access, please use our QR-code:

74 EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com

13.2 The quality-oriented M&C catalog

M&C offers national and international services, project planning and construction of special systems with a wide range of products. Our catalog covers a large variety of high quality products with in-depth knowledge of various customer applications. Our product excellence and innovative solutions continues to make M&C a world class company.

You can find the following product groups in our catalog. The combination of products from these groups offers a complete solution for most industrial needs. We develop, manufacture and test our products in accordance with a wide range of national and international standards.

Probes Cooler Filter

Comprehensive range of probes with a large spectrum of available options for an almost unlimited range of applications. Different materials available (Hastelloy, Titan, PTFE etc.)

Optimised gas and condensate separation, low maintenance and self monitoring. Compact design for wall mounting or 19” rack.

Suitable for all processes, due to the modular and user-specific configuration possibilities of the filter components. Filter enclosures available in glass, stainless steel, PVDF, PTFE or in different metal combinations.

Portable components Compact systems Oxygen analyzer

Developed for high quality gas analysis at different locations.

Compact standard systems designed for a 19” enclosure or a plate structure.

A broad variety of products with high measuring accuracy. Direct measuring is based on paramagnetic measuring principle (dumbbell-type).

EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com 75

13.3 Technical consulting services

M&C has earned a reputation as one of the most capable and experienced companies in the world, especially when it comes to difficult or complex measurement projects. We are proud that our customers have confidence in our products and continue to experience repeat business.

We also offer technical consulting for our components, devices and complete systems. We support our customers in finding individual solutions for their specific measuring tasks.

These individual solutions lead to new concepts of designing and building custom-made devices or complete systems. The dedication and commitment to finding solutions to the most complex and challenging tasks for our customers sets us apart from our competitors.

We have custom-made application experiences in many different fields worldwide. With this experience we are able to support our customers by seeking and finding errors, trouble shooting during day-to-day operation or identifying hard to find interferences.

13.3.1 Ideas, suggestions and feedback

All our activities are designed to meet and exceed the demands of the market and the specific interests of our customers. That‘s why M&C is very interested in developing products, processes and services which are in demand and up to date.

This means that your feedback, ideas and suggestions are very important to us.

Please let us know what kind of new improvements and innovations you would like to see at M&C. Tell us, what you like about M&C and what needs improvement.

Please send us an email or feel free to just call us ...

We appreciate your comment.

76 EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com

Your contact to M&C in Germany and the USA

M&C TechGroup Germany GmbH

Rehhecke 79, 40885 Ratingen



Service phone:



Service e-mail:

M&C TechGroup North America

6019 Olivas Park Drive, Suite G

+49 2102 935 - 888

service-DE@mc-techgroup.com

Ventura CA 93003



Phone:



E-mail:

+1 805 654 6970

info-usa@mc-techgroup.com

Your M&C contacts world-wide

http://www.mc-techgroup.com/en/Locations-and-regions/

EC-30C | 1.00.02 +49 2102 935 888 www.mc-techgroup.com 77

M&C EC-30C Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual