M&C TechGroup ECM-ExII Operator's manual

Operating Manual

Electric gas cooler series EC

®



Version ECM-ExII

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This Operating Manual does not claim completeness and may be
subject to technical modifications.
© 03/2002 M&C TechGroup Germany GmbH. Reproduction of this
document or its content is not allowed without permission from M&C.

ECM® is a registered trade mark.

4th Edition: 12/2004

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.

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Content

1 General information .................................................................................................................. 4

2 Declaration of conformity ......................................................................................................... 4

3 Electrical standards .................................................................................................................. 5

4 Safety instructions .................................................................................................................... 5

5 Information and safety instructions for using the cooler in hazardous areas .................... 6

6 Warranty..................................................................................................................................... 6

7 Used terms and signal indications .......................................................................................... 7

8 Introduction ............................................................................................................................... 8

8.1 Serial number ........................................................................................................................... 8

8.2 Patent references ..................................................................................................................... 8

9 Application ................................................................................................................................. 8

10 Technical Data ........................................................................................................................... 9

10.1 For basic cooler ECM-ExII without heat exchanger .................................................................. 9

10.2 Options for basic cooler ECM-ExII .......................................................................................... 10

11 Description .............................................................................................................................. 10

12 Function ................................................................................................................................... 11

13 Reception and storage ........................................................................................................... 12

14 Installation instructions .......................................................................................................... 13

15 Supply connections ................................................................................................................ 13

15.1 Hose connections ................................................................................................................... 13

15.2 Electrical connections ............................................................................................................. 15

16 Start-up .................................................................................................................................... 16

17 Closing down ........................................................................................................................... 17

18 Maintenance ............................................................................................................................ 17

18.1 Adding and replacing the heat exchangers ............................................................................ 17

18.2 Cleaning the fins of the condenser ......................................................................................... 18

18.3 Maintenance of the optional mounted peristaltic pump(s), type SR25.2 ................................ 19

18.3.1 Change of contact pulleys and springs ............................................................................ 20

18.3.2 Cleaning the pump head ................................................................................................. 20

19 Operating of the built-in electronic temperature controller ................................................ 21

19.1 Changing the set value ........................................................................................................... 21

19.2 Changing the temperature alarm window ............................................................................... 21

20 Trouble shooting ..................................................................................................................... 22

21 Spare parts list ........................................................................................................................ 23

22 Appendix .................................................................................................................................. 24

List of illustrations

Figure 1 Application example of the ECM-ExII .................................................................................. 8

Figure 2 ECM-2G ExII ..................................................................................................................... 10

Figure 3 Schematic diagram of the heat exchanger function .......................................................... 12

Figure 4 Position of the gas and condensate .................................................................................. 13

Figure 5 Electrical sockets alarm contact ........................................................................................ 16

Figure 6 Change of the pump tube .................................................................................................. 19

Figure 7 Front view of the temperature controller ............................................................................ 21

Figure 8 Sample outlet dew point depending on gas flow rate and sample inlet dew points of

60°C .................................................................................................................................. 24

Figure 9 Circuit diagram ECM-ExII .................................................................................................. 25

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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: [e-mail]

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:

ATEX-Directive

The product described in this manual is produced in accordance with the EC directive for devices and
protection systems for appropriate use in hazardous areas 94/9/EG appendix II.

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.

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3 ELECTRICAL STANDARDS

The electrical standard of electrical equipment corresponds to the safety regulations concerning the
EN61010; CAN/CSA-C22.2 No 61010.1-04 , UL Std. No 61010-1(2 Edition) EN 60079-15:2003.
According to NEC 500: Class I, Div. 2, Groups A/B/C/D, T4 CAN/CSA-C22.2 No 61010.1-4 and No.

213-M87M; for 115V Approval Standard Class No. 3611.

4 SAFETY INSTRUCTIONS

Please note the following basic safety procedures when using this equipment:

 Read these operating instructions carefully before start-up and use of the equipment! The

information and warnings given in these operating instructions must be heeded.

 Attention must be paid to the requirements of the certificate of conformity (see appendix): 02

ATEX 1040X.

 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 when setting high-power electrical

units with nominal voltages of up to 1000V, together with the associated standards and
stipulations.

 For use in hazardous area observe the relevant national and international instructions and

regulations.

 Check the details on the type plate to ensure that the equipment is connected up to the correct

mains voltage.

 Protection against touching dangerously high electrical voltages. Before opening the

equipment, it must be switched and hold no voltages. This also applies to any external control
circuits that are connected.

 The equipment is only to be set within the permitted range of temperatures and pressures.
 Check that the location is weather-protected. It should not be subjected to either direct rain or

moisture.

 Installation, maintenance, monitoring and any repairs may only be done by authorised

personnel with respect to the relevant stipulations.

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5 INFORMATION AND SAFETY INSTRUCTIONS FOR USING THE COOLER IN

HAZARDOUS AREAS

The compressor cooler ECM-ExII is suitable for using in hazardous area category 3G.
The explosion proof protection is:
230V / 115 : II 3 G EEx nAC [nL] IIC T4 (appr.-no.: 02 ATEX 1040X)
230V / 115V : Class I, Div. 2, Groups A/B/C/D, T4 / CAN/CSA-C22.2 No 61010.1-4; No. 213-M87
115V : Class I, Div. 2, Groups A/B/C/D, T4
FM Approval Standard Class No. 3611

The certification of the cooler was done by the Kema the authorized institute of electrical equipment in
the Netherlands. For detailed information and a copy of the certificate see appendix.

Installation and operating of the cooler has to be done corresponding to the conditions fixed in the Ex­certificate (see appendix). Only in this case the reliability of the operation in the hazardous area can
be guaranteed.

If necessary, please install the cooler corresponding to NEC article 501.4 (B)(2) (conduit installation).
All changes of the standard configuration with parts which are not specified or approved by M&C as

well as repair and service with not specified parts means a loss of the Excertificate.
In case of doubt please turn directly to M&C respectively to your M&C franchised dealer.

6 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.

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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 ARN IN 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.

CAR E!

Without the warning triangle means that a material damage may
occur in case the respective safety measures are not met.

ATT ENT ION !

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.

7 USED TERMS AND SIGNAL INDICATIONS

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



 



Sample gas inlet

+5°C

ECM-1











Alternative :
Collecting vessel

Test gas
IN

8 INTRODUCTION

The patented M&C ECM-ExII gas cooler unit is always to be installed in situations where there is
interference from moisture in the gas to be measured.
Reduction of the gas temperature inside the cooler to a stable and very low dew point effects a
condensing-out of the sample gas.

8.1 SERIAL NUMBER

The type plate with the serial number is located at the side panel of the cooler housing (wall mounting
version). Whenever you call M&C regarding questions or orders for the spares please give us the
serial number of your ECM-ExII.

8.2 PATENT REFERENCES

The M&C sample gas cooling device is patented under the following patent number:

• Germany 199 57 052

• USA 6.477.851

9 APPLICATION

Figure 1 shows a typical example of an application for installation of an ECM-ExII gas cooler unit.

Figure 1 Application example of the ECM-ExII

1 : Filter sample probe SP ...
2 : Heating sample line
3 : ECM cooler
4 : 3-way ball valve
5 : Peristaltic pump (option)
6 : Membrane pump
7 : Super fine filter FP ...
8 : Aerosol filter CLF-5
9 : Flow meter FM10
10 : Analyser

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Gas cooler series EC

version ECM-1 ExII

version ECM-2 ExII

Part No.

02K7600 (a)**

02K7610 (a)**

Number of heat exchanger
possibility

prepared for 1 stream

prepared for 2 streams
Sample outlet dewpoint

range of adjustment: +2 °C ..... +7 °C, factory setting: +5 °C

Dew point stability

at const. conditions: < ±0,1°C

Sample inlet temperature

***max. +180°C

Sample inlet dew point

***max. +80°C

Gas flow rate

***max. 250l/h

Ambient temperature

+10°C to +50°C

Storage temperature

-20 to +60°C

Total cooling capacity

40W at 10°C - 50°C ambient temperature

Ready for working

< 15 min

Power consumption

max. 200VA (start up current at 230V=2,5A; at 120V=4,5A)

Main power connection

230V/115V, 50Hz/60Hz (a):-15%/+10%

Electrical connections

terminals: 6-12mm , cable gland: 2xM20x1,5

Status alarm

1 free configurable status alarm with 2 potential free change-over
contacts, alarm point: < 2°C and > 8°C (adjusted at works)
contact rating 250VAC, 2A; 500 VA; 50W

Explosion proof protection

230V / 115V:
II 3 G EEx nAC [nL] IIC T4 02 ATEX 1040X

240V / 120V:
Class I, Div. 2, Groups A/B/C/D, T4
CAN/CSA-C22.2 No 61010.1-04 and No. 213-M87

120V:
Class I, Div. 2, Groups A/B/C/D, T4
FM Approval Standard Class No. 3611

Electrical safety

EN

EN 61010

CAN/CSA-C22.2 No.61010.1-04
UL Std. No. 61010-1(2 Edition)

Approval number

02 ATEX 1040X

System of protection

IP20 (EN 60529)

Case colour

RAL 9003

Method of mountingrt

wall mounting

Dimensions
Weight

270 x 270 x 316mm (BxHxT)
12kg/13,5kg (version: 230V/115V)

The gas to be measured is taken from the ECM-ExII gas cooler  by a gas sample probe  via a
heated sample line  and cooled down to a dew point of +5°C. 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 .

10 TECHNICAL DATA

10.1 FOR BASIC COOLER ECM-EXII WITHOUT HEAT EXCHANGER

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Heat exchanger type

ECM-1G

ECM-1PV

ECM-1SS

ECM-2G

ECM-2PV

ECM-2SS

Part No

93K0140

93K0170

93K0160

97K0100

97K0110

97K0115

Material of heat
exchanger

Borosilicate
glass

PVDF

st. steel
316Ti

Borosilicate
glass

PVDF

st. steel
316Ti

Max. gas flow rate

250Nl/h

250Nl/h

250Nl/h

150Nl/h

150Nl/h

150Nl/h

Sample gas pressure
abs.

max. 2bar
(3bar)

1

max. 3bar

max. 10bar

max. 2bar
(3bar)1

max. 3bar

max. 10bar

Sample gas connection

GL18
for Ø6mm
a.d. tube*

G1/4“i

G1/4“i

oder 1/4“

NPT**

GL18
for Ø6mm a.d.
tube*

Tube
Ø6mm*

Tube
Ø6mm*

Condensate connection

GL25 for
Ø12mm tube*
Ø8mm or
Ø10mm**

G3/8“i

G3/8“i o.
3/8“NPT**

GL25 for
Ø12mm tube*
Ø8mm or
Ø10mm**

G3/8“i

G3/8“i o.
3/8“NPT**

P at max. flow

1mbar

1mbar

1mbar

1mbar

1mbar

1mbar

Stagnant space approx.

100ml

100ml

100ml

40ml

25ml

30ml

Peristaltic pump SR25.2

1 pc. incorporated in the cooler, compl. installed, part no.: 01P9125; cooler weight
plus 0,6kg per pump

the sample gas pressure is limited to 2bar absolute

Min. side distance

100

100

EC

Cooler

220

240

30

208

270

204

270

46

11

6

84

50

ventilation

opening

Compressor

ventilation outlet

Dimensions in mm

10.2 OPTIONS FOR BASIC COOLER ECM-EXII

* Standard, other version on request
** Option
*** 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.

1

with GL connecting adapter

11 DESCRIPTION

Figure 2 shows the ECM-2G ExII cooler unit.

Figure 2 ECM-2G ExII

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WAR NIN G!

The cooler ECM-ExII corresponds to the system protection IP20 (EN

60529) and therefore suitable for use in clean and dry rooms. Solids
and water must be avoided to enter the cooler housing via the
ventilation outlet. For installation according to NEC article 501.4 (B)
(2) (conduit installation) the cable glands have to be changed with
the enclosed Conduit Hub.

The cooler ECM-ExII is equally suitable for wall installation. The depth of the housing of the cooler is
270mm (316mm with optional mounted peristaltic pumps ).

On the upper side of the cooler casing you will see the cutouts for 1 or 2 heat exchangers. Sample
gas enters and leaves the heat exchangers by the correspondingly connections on the upper part of
the heat exchangers (see 8. technical data).

The main power connector and the contact output for the status alarm can be connected at terminals
X1 respectively X3 located behind the removable front panel of the ECMExII housing.

At the bottom of the housing the following connections are provided as standard:

 standard condensate outlets from the heat exchangers,
 cable bushings 2 x M20 x 1,5

clamp range 6-12mm; With under- respectively ambient pressure the condensate removal happens
via the peristaltic pumps SR25.2 optionally implemented in the cooler housing or externally with

collecting vessels type TG.../TK... . With over-pressure an automatic liquid drainer type AD-... is

suitable.

12 FUNCTION

The M&C gas cooler type ECM-ExII is a compressor cooler with status alarm capability. This ensures
100% availability of the cooler.
Up to 2 Jet-stream heat exchangers made of Borosilicate glass, PVDF or stainless steel are located in
a heat-insulated cooling block. All the heat exchangers are easily accessible and are arranged in such
a way that they can be removed very simply.
Figure 3 shows a schematic diagram of the functioning of the heat exchanger: The compressor cooler
system has a heat-insulated cooling block at a constant temperature of +5°C. The novel construction
of the heat exchanger guarantees a very good pre-separation of condensate and for that reason an
optimal drying of sample gas.

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+5°C

Sample

OUT

Sample

IN

Condensate OUT

Cooling

block

NOTE!

The cooler must be stored in a weather protected frost-free area!
During transport and when in storage, the cooler must always be stood up
with the transport feet positioned underneath so that the oil in the closed
compressor circuit cannot run out of this compressor case.
If the cooler is transported on its back by mistake, it must stood in the
operating position for approx. 24 hours before it is switched on!

Figure 3 Schematic diagram of the heat exchanger function

13 RECEPTION AND STORAGE

The ECM-ExII gas cooler is a complete pre-installed unit.

 Carefully inspect the ECM-ExII and any special accessories included with it immediately on

arrival by removing them from the packing and checking for missing articles against the
packing list!

 Check the items for any damage in transit and, if required, inform the shipping insurance

company immediately of the damage found!

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