M&C TechGroup EC-30-FD Operator's manual
Operating Manual
Low-temperature electric gas cooler series EC®
version EC30 and EC-30/FD
Gas sampling and gas conditioning technology 3-4.20-ME
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Content
1 General information ................................................................................................................... 5
2 Declaration of conformity .......................................................................................................... 5
3 Safety instructions ..................................................................................................................... 6
4 Warranty ...................................................................................................................................... 6
5 Used terms and signal indications ........................................................................................... 7
6 Introduction ................................................................................................................................ 8
6.1 Serial number ........................................................................................................................... 8
7 Application .................................................................................................................................. 9
8 Technical data .......................................................................................................................... 10
9 Description................................................................................................................................ 10
9.1 Assembly ................................................................................................................................ 11
10 Function .................................................................................................................................... 12
11 Reception and storage ............................................................................................................. 14
12 Installation instructions ........................................................................................................... 15
13 Supply connections ................................................................................................................. 15
13.1 Hose connections ................................................................................................................... 15
13.2 Electrical connections ............................................................................................................. 16
14 Start-up ..................................................................................................................................... 18
14.1 Function sequence and LED function display ........................................................................ 18
15 Closing down ............................................................................................................................ 20
16 Maintenance.............................................................................................................................. 20
16.1 Maintenance of the peristaltic pumps type SR25.1 of the EC-30/FD ..................................... 21
16.1.1 Change of the pump tube ................................................................................................. 21
16.1.2 Change of contact pulleys and springs ............................................................................. 22
16.1.3 Cleaning the pump head ................................................................................................... 22
16.2 Replacing the heat exchangers .............................................................................................. 23
17 Trouble shooting ...................................................................................................................... 24
18 EC automatic control board .................................................................................................... 26
18.1 Connecting the cooling compressor ....................................................................................... 27
18.2 Temperature setting for the cooler ......................................................................................... 28
19 temperature sensors ................................................................................................................ 28
19.1 Checking the temperature sensor of the pre-cooling stage .................................................... 28
19.2 Checking the temperature sensor of the deep cooling stage ................................................. 29
20 EC control board ...................................................................................................................... 31
20.1 Function sequence of the EC30 control electronics ............................................................... 32
21 Spare parts list ......................................................................................................................... 34
22 Appendix ................................................................................................................................... 35
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List of Illustrations
Figure 1 Example of application of EC-30/FD .................................................................................. 9
Figure 2 EC-30 with options EC-F and EC-FD .............................................................................. 11
Figure 3 Schematic diagram of functioning of heat exchanger ...................................................... 12
Figure 4 Tubing of the heat exchangers ........................................................................................ 13
Figure 5 Timing schematic of the switching processes .................................................................. 13
Figure 6 Position of terminal X0 ..................................................................................................... 17
Figure 7 Electrical connections ...................................................................................................... 17
Figure 8 Change of the pump tube ................................................................................................ 21
Figure 9 EC automatic control board ............................................................................................. 26
Figure 10 Connection diagram for compressor ................................................................................ 27
Figure 11 Temperature adjustment .................................................................................................. 28
Figure 12 Voltage in relation to the temperature of the cooling stage ............................................. 29
Figure 13 Resistance-temperature characteristics of the PT100 temperature sensor ..................... 29
Figure 14 Sensor voltage as function of temperature ...................................................................... 30
Figure 15 EC30 control board .......................................................................................................... 31
Figure 17 Sample outlet dew point .................................................................................................. 36
Figure 18 Circuit diagram EC automatic control board .................................................................... 37
Figure 19 Circuit Diagram EC-30 ..................................................................................................... 38
Figure 20 Circuit diagram control electronic EC-30 ......................................................................... 39
Figure 21 Wiring plan automatic condensate removal unit EC-FD .................................................. 40
Gas sampling and gas conditioning technology 3-4.20-ME
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This Operating Manual does not claim completeness and may be
subject to technical modifications.
© 04/2000 M&C TechGroup Germany GmbH. Reproduction of this
document or its content is not allowed without permission from M&C.
3rd Edition: 11/2001
Dear customer,
we have made up this operating manual in such a way that all necessary information about the
product can be found and understood quickly and easily.
Should you still have any question, please do not hesitate to contact M&C directly or go through your
appointed dealer. Respective contact addresses are to be found in the annexe to this operating
manual.
Please also contact our homepage www.mc-techgroup.com for further information about our
products. There, you can read or download the data sheets and operating manuals of all M&C
products as well as further information in German, English and French.
Gas sampling and gas conditioning technology 3-4.20-ME
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Head Office
M&C TechGroup Germany GmbH Rehhecke 79 40885 Ratingen Germany
Telephone: 02102 / 935 - 0
Fax: 02102 / 935 - 111
E - mail: info@mc-techgroup.com
www.mc-techgroup.com
1 GENERAL INFORMATION
The product described in this operating manual has been examined before delivery and left our works
in perfect condition related to safety regulations. In order to keep this condition and to guarantee a
safe operation, it is important to heed the notes and prescriptions made in this operating manual.
Furthermore, attention must be paid to appropriate transportation, correct storage, as well as
professional installation and maintenance work.
All necessary information a skilled staff will need for appropriate use of this product are given in this
operating manual.
2 DECLARATION OF CONFORMITY
CE - Certification
The product described in this operating manual complies with the following EC directives:
EMV-Instruction
The requirements of the EC directive 2004/108/EC “Electromagnetic compatibility“ are met.
Low Voltage Directive
The requirement of the EC directive 2006/95/EC “Low Voltage Directive“ are met.
The compliance with this EC directive has been examined according to DIN EN 61010.
Declaration of conformity
The EU Declaration of conformity can be downloaded from the M&C homepage or directly requested
from M&C.
Gas sampling and gas conditioning technology 3-4.20-ME
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3 SAFETY INSTRUCTIONS
Please take care of the following basic safety procedures when mounting, starting up or
operating this equipment:
Read this operating manual before starting up and use of the equipment. The information and
warnings given in this operating manual must be heeded.
Any work on electrical equipment is only to be carried out by trained specialists as per the regulations
currently in force.
Attention must be paid to the requirements of VDE 0100 (IEC 364) when setting high-power electrical
units with nominal voltages of up to 1000 V, together with the associated standards and stipulations.
Check the details on the type plate to ensure that the equipment is connected to the correct mains
voltage.
Protection against touching dangerously high electrical voltages:
Before opening the equipment, it must be switched off and hold no voltages. This also applies to any
external control circuits that are connected.
The device is only to be used within the permitted range of temperatures and pressures.
Check that the location is weather-protected. It should not be subject to either direct rain or moisture.
The device must not be used in hazardous areas.
Installation, maintenance, monitoring and any repairs may only be done by authorized personnel with
respect to the relevant stipulations.
4 WARRANTY
If the equipment fails, please contact M&C directly or else go through your M&C authorised dealer.
We offer a one year warranty as of the day of delivery as per our normal terms and conditions of sale,
and assuming technically correct operation of the unit. Consumables are hereby excluded. The terms
of the warranty cover repair at the factory at no cost or the replacement at no cost of the equipment
free ex user location. Reshipments must be send in a sufficient and proper protective packaging.
Gas sampling and gas conditioning technology 3-4.20-ME
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DANGER!
This means that death, severe physical injuries and/or important
material damages will occur in case the respective safety measures
are not fulfilled.
W A R NI N G !
This means that death, severe physical injuries and/or important
material damages may occur in case the respective safety
measures are not fulfilled.
CARE!
This means that minor physical injuries may occur in case the
respective safety measures are not fulfilled.
CARE !
Without the warning triangle means that a material damage may
occur in case the respective safety measures are not met.
ATTE N T I O N !
This means that an unintentional situation or an unintentional status
may occur in case the respective note is not respected.
NOTE!
These are important information about the product or parts of the
operating manual which require user’s attention.
SKILLED STAFF
These are persons with necessary qualification who are familiar with
installation, use and maintenance of the product.
5 USED TERMS AND SIGNAL INDICATIONS
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6 INTRODUCTION
The patented M&C EC30 gas cooler with universal unit EC-F and EC-30/FD with unit EC-FD is always
to be installed in situations where there is interference from moisture in the gas to be measured, or if
the measured components exhibit very high sensitivity to water vapour or if long and expensive heated
sampling lines are to be avoided.
Reduction of the gas temperature inside the cooler to a stable and very low dew point effects a
condensing out of the sample gas. Dry gas leaves the gas cooler and passes into the analyser after
suitable filtration. When installing the EC30(/FD) gas cooler on site in a frost-free protective housing,
there is no need to use a heated sample line with a high energy consumption as long as the ambient
temperature does not fall below a value of -25C.
6.1 SERIAL NUMBER
The type plate with the serial number is located at the side panel of the cooler housing (19“ version).
Whenever you call M&C regarding questions or orders for the spares please give us the serial number
of your EC30.
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1
EC-
Sample gas IN
Sample
gas OUT
EC-30
Condensate
OUT
Test gas
IN
7 APPLICATION
The patented M&C ultra-low temperature cooler EC-30(/FD) finds its applications in the analytical field
for reducing the dew point of humid sample gases, providing a stable and very low dew point and
reducing aerosol formation in the analyser. By mounting the cooler near to the sample point, costly
energy consuming heated sample lines can be avoided. An extremely stable and low gas dew point
avoids water vapour cross-sensitivity and volumetric errors.
Figure 1 shows a typical example of an application for installation of an EC-30 gas cooler unit.
Filter sample probe SP... Universal unit EC-FD Membrane pump Analyser
Heated sample line 3-way-ball valve Flow meter FM
EC-30/FD cooler Super-fine filter FP... Aerosol filter CLF
Deep cooling stage 1 Deep cooling stage 2 Pre cooling stage
Figure 1 Example of application of EC-30/FD
The gas to be measured is taken from the EC-30/FD gas cooler by a gas sample probe and
cooled down to a dew point of -30°C. Via the universal unit EC-FD the condensate is removed. The
super-fine filter located afterwards removes solid particles. For increased operating safety of the
entire system we recommend installing a super-fine filter with a liquid alarm sensor. If required an
aerosol filter can be installed in front of the flow meter . The gas thus treated can now be passed
into the analyser . Via the 3-way-ball valve it is possible to feed test gas for calibration to the
analyser.
Gas sampling and gas conditioning technology 3-4.20-ME
8 TECHNICAL DATA
Cooler series EC®
Version EC-30
Version EC-30/FD
Part No.
02K6000 (a)**
02K6010 (a)**
With integrated universal unit:
EC-F to force the ventilation
EC-FD ventilation and
condensate removal
Gas connection
tube connector DN 4/6 i./o. d. mm
Condensate connections
3x tube connector GL25-12 mm
1x tube connector DN 4/6 i./o. d.
mm
Material of sample contacting parts
Duran glass, PTFE, PVDF
Duran glass, PTFE, PVDF,
Novoprene
Single stream, gas flow rate
90 Nl/hr-250 Nl/hr*
Gas pressure
max. 3 bar abs.
max. 2 bar abs.
Ambient temperature
+5 to +45 °C
Storage temperature
-20 to +60°C
Sample outlet dew point
-30 °C
Sample inlet temperature
max. 180 °C*
Sample inlet dew point
max. 80 °C*
Cooling capacity at 25 °C ambient
max. 860 kJ/hr*
Main power connection / Power
consumption
230V 50Hz 380VA or **Part No. ...-a = 115V 60 Hz 380VA
Start up time
< 60 min.
Stagnant space
approx.160 ml
Δ P at 250 Nl/hr flow rate
5 mbar
Electrical connection
2,5 mm2 terminals, 2x PG13,5 cable glands
Status alarm
2 changeover contacts, potential free contact rating 250V, 3A,
500VA, 50W
Case protection / Electrical equipment
standard
IP20 EN 60529 / EN 61010
Method of mounting / Case colour
19" rack or wall / case colour RAL 9003
Dimension / Weight
84 TE x 8 HE x 360 mm / 37 kg
84 TE x 10 HE x 360 mm / 42 kg
10
** Maximum values in technical datas must be rated in consideration of total cooling capacity at 25 °C ambient temperature and an outlet
dew point of 5 °C.
9 DESCRIPTION
The patented M&C gas cooler EC-30(/FD) is a two stage combination of compressor and Peltier
cooler with status alarm and automatic defrosting of the dual deep freezer unit for 100% sample
availability. The pre-cooler of the gas cooler EC- is fitted with a “Jet-Stream“ heat exchanger EC-G
which is cooled by a compressor cooling unit with electronic control at a constant temperature of +1°C.
Optimum cooling of sample gases and pre-elemination of a larger part of the condensate from the gas
is reliably achieved. No external pre-draining is normally needed. The deep freezer and is cooled
with two modified “Jet-Stream“ heat exchangers EC-30 fitted between two automatic cooling units for a
minimum temperature of -30 °C. The special design of the Jet-Stream heat exchanger guarantees
optimum dew point reduction to a low, stable value and secures condensate separation. The gas
outlets of the heat exchangers are connected to a 3/2 way solenoid valve. An electronic control system
EC-30 switches the solenoid valve for simultaneous changeover and automatic defrosting of the heat
exchangers EC-30. In order to guarantee the necessary and minimum operation of the gas cooler EC30, we provide this unit with an accessory module EC-F containing two fans for forced air ventilation
and cooling of the compressor unit. Alternative we deliver the cooler with the module EC-FD
containing additionally three peristaltic pumps SR-25.1 for automatic removal of condensate.
Gas sampling and gas conditioning technology 3-4.20-ME
9.1 ASSEMBLY
11
Figure 2 EC-30 with options EC-F and EC-FD
Gas sampling and gas conditioning technology 3-4.20-ME
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+5°C
Sample gas
out
Sample gas
in
Condensate out
Coolingblock
The EC30 is equally suitable for wall installation or mounting in a 19” rack. The versions differ in the
positioning of the LED function display . While for wall installation the LED function display can be
fitted into the corresponding cut-outs in the EC30 front panel, for 19” rack mounting this is done using
the cut-outs in the back panel of the casing. This positioning is done at the factory when stating the
type of installation of the EC30 gas cooler. It is relatively simple to subsequently reconfigure it on site
at the user location. The location for installation of the LED function display is marked
correspondingly.
On the upper side of the cooler casing you will see the cut-outs for the heat exchangers of the precooling stage and for the two low-temperature stages and . Sample gas enters the pre-cooling
stage at the 4/6 hose connection on the upper part of the heat exchanger. At the rear part of the
casing the condenser to remove heat given off in the compressor can be seen. The mains power
connector, EC automatic control board and EC30 control board with the contact outputs for the status
alarm are located in two plastic housings respectively behind the removable front panel of the EC30
casing.
On the underside of the casing the following connections are provided as standard: cable glands
PG13,5 to the plastic housings ; condensate outlets GL25/12 from the heat exchangers ,
and ; sample gas outlet DN4/6.
As standard, the condensate is removed externally with collecting vessels, peristaltic pumps, or by
”over-pressure operation”, with automatic float condensate traps, as e.g. type AD-... The heat energy
from the cooling system is drawn off by a forced-ventilation . The required fans and large air
suction filter elements are provided as standard in universal unit EC-f . This is arranged below the
EC30 casing and is absolutely essential for operation of the cooler unit. Optionally, the universal unit
EC-F can be replaced by an automatic condensate removal unit EC-FD , which is likewise located
below the casing of the cooler. Apart from the above-mentioned condenser forced ventilation, the ECFD unit has three peristaltic pumps of type SR25.1 for automatic condensate removal. This can also
be set in underpressure operation (suction operation).
The connections for the sample gas outlet and the condensate outlet are located in the front
panel of the EC-FD unit.
10 FUNCTION
The patented M&C EC30(/FD) gas cooler is a combined two stage compressor Peltier cooler with
status alarm capability. Automatic defrosting of the double-construction low temperature stage ensures
100% availability of the cooler. The pre-cooling stage (see fig. 1) of the cooler is equipped with a jet
stream EC heat exchanger made of Duran glass. Figure 3 shows a schematic diagram of the
functioning of the heat exchanger.
Figure 3 Schematic diagram of functioning of heat exchanger
Gas sampling and gas conditioning technology 3-4.20-ME
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