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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NOTE!

The cooler is only suitable for dry and clean rooms (IP20). The operating
position for this cooler is exclusively vertical. This is the only way to
ensure proper separation and removal of condensate in the heat
exchangers. During transport and installation, 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 the compressor case.
The cooler should be kept away from sources of heat and well ventilated
when installed, so that condensation from warmth will not occur and
interfere with operation.
The minimum installation dimensions (fig. 2) must be followed without
fail. If the unit is installed in the open, the cooler must be installed in a
housing that is frost-free in winter and adequately ventilated in summer.
Avoid locating the unit in direct sunlight.
Unheated gas sample lines must be provided with slope up to the cooler.
In that case pre-separation of the condensate is not required. Connect the
heated sample line with sufficient thermal decoupling of min. 20cm to the
cooler!

1

EC

Cooler

2

1 Gas inlet and outlet
2 Condensate outlet
3 Condensate outlet with optional

mounted peristaltic pump

3

14 INSTALLATION INSTRUCTIONS

The ECM-ExII cooler is suitable for wall mounting.

15 SUPPLY CONNECTIONS

15.1 HOSE CONNECTIONS

The connection for sample gas inlet and outlet happens on the upper part of the heat exchangers. For
possible connectors see technical data (10.).

Figure 4 Position of the gas and condensate

Correspondingly tube and hose connectors are optional available by M&C (see document 3-5.1.1).

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NOTE!

Do not mix up the hose connections; the inlet and outlet connections of
the heat exchangers are marked with arrows;
Ensure that the connections are sealed adequately;
To ensure free removal of the condensate, ensure that the listed
diameters for the condensate removal lines are not reduced!

NOTE!

When fixing the connectors in the PVDF respectively stainless steel heat
exchanger hold up with a wrench at the pane of the bolt head!

NOTE!

Stainless steel heat exchangers with G3/8” thread joint can be directly

fitted up with the float-type condensate trap AD-SS by means of a thread

adapter part number FF 11000 (1/2” NPT to G3/8”i). By this wall mounting

and tubing of the AD-SS unit isn’t necessary!

Ensure that the connections are sealed adequately by noting the following:

Borosilicate glass heat exchangers with connections GL18-6 respectively GL25-12 (standard)

 Before assembly, check the GL coupling rings to see if the PTFE/silicon locking rings have

been damaged.

 The sealing rings should be installed with the PTFE side facing the medium.

PVDF- resp. stainless steel heat exchangers with G1/4“I resp. G3/8“I

 The correspondingly dimensioned tube respectively hose couplings with threaded connections

have to be screwed in with PTFE thread sealing tape.

 To grant a functional and unproblematic mounting we recommend to use union pieces with

taper pipe thread type R according to DIN 2999/1 in connection with suitable sealing tape.

Option: stainless steel heat exchanger with NPT

 The heat exchangers with NPT threaded connectors are marked with circulated notches.
 The NPT thread must be screwed in with sealant or fixed with adhesive.

In the standard configuration, the tubes for removal of condensate are connected directly to the heat
exchangers. These protrude with the GL25-12 tube connectors (standard, Borosilicate glass heat
exchanger) respectively with G3/8” (standard) thread joint PVDF or stainless steel heat exchanger
above the base plate of the cooler casing (fig.2). Condensate removal is done by customer according
to the type of operation with:

 peristaltic pump(s) type SR25.2 implemented optionally in the cooler housing,
 external mounted condensate vessel(s) with manually emptying respectively,

 automatic float-type condensate traps type AD-... (only for over-pressure operation).

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15.2 ELECTRICAL CONNECTIONS

CARE!

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

W ARN IN G !

Do not work at alive parts unless the area is known to be non­hazardous.

NOTE!

Attention must be paid to the requirements of IEC 364 (DIN VDE

0100) when setting high-power electrical units with nominal
voltages of up to 1000V, together with the associated standards
and stipulations.
Because of the exchangeable fuse the cooler must be equipped
with a suitable external switch, which takes the cooler off the
mains.

W ARN IN G !

Cooler versions with 115V resp. 120V have a built-in transformer
to generate an internal current of 230V. That means, device internal
live parts have a current of 230V not 115V/120V.

15

Figure 5 shows the electrical connections at the plastic housing behind the front panel of the ECM­ExII housing (fig. 2).

Alarm warnings for over- and under-temperature are given as a collective status alarm via a relay
output with two potential-free changeover contacts. Alarm will be released if the current temperature
is out of a range of ±3°C referring to the set-temperature (+5°C) .

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NOTE!

Before starting up the gas cooler, it must be placed in its operating
position for at least two hours. The liquid inside the system may have
been redistributed, and this could cause problems in operating.

NOTE!

The status contacts must be connected to the external sample gas pump
or to 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
from the cooler!

Figure 5 Electrical sockets alarm contact

The connection of the mains respectively status alarm signals happens as follows:

 release the screws (7 pcs.) from the cooler top and remove it;
 put the cables (6-12mm) through one of the cable glands and connect them according to a.m.

wiring plan;

 the re-installation of the cooler top happens in the opposite way.

16 START-UP

The thermo-hydraulic controlled cooling system of the ECMExII permit automatic start-up of the
cooler.
The following description is valid for start-up of the gas cooler for an ambient temperature > 8°C.

The following steps should be carried out before initial start-up:

 Connect the cooler unit to the mains power supply; Check that the equipment is connected to

the correct mains voltage, 115V or 230V, as shown on the type plate.

 Lead the status contact for status alarm to the measuring station;

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17 CLOSING DOWN

NOTE!

The location for the cooler must remain frost-free, even when the unit
has been switched off!
If the cooler unit is putting out of action for a short time no particular
measures need to be taken.
We recommend sweeping the cooler with inert gas or ambient air
while the unit is putting out of action for a longer time.

CARE!

Aggressive condensate is possible.
Wear protective glasses and proper protective clothing!

NOTE!

Do not work at alive parts unless the area is known to be non­hazardous.
Change fuses after the cooler is taken off the mains or the area is
known to be non-hazardous.

DANGER!

Dangerous voltage!
It is necessary to take the gas cooler off the mains before any
assembly, maintenance and repair work is carried out!

NOTE!

For cleaning the contaminated cooler housing please use a
moistened cloth with a suitable cleaning agent.

18 MAINTENANCE

17

The safety instructions specific to the plant and process are to be consulted prior to any maintenance
work!

18.1 ADDING AND REPLACING THE HEAT EXCHANGERS

Removal of the heat exchangers may be necessary to carry out maintenance or repair work.
We recommend the following procedures and in this order for replacement of the heat exchangers:

 Release the upper gas connections and lower condensate connections;
 Pull the heat exchangers upwards with rotation out of the cooling block;

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NOTE!!

Do not mix up the hose connections; gas outlet and gas inlet are marked
with arrows!

NOTE!

Do not mix up the hose connections; the inlet and outlet connections
of the heat exchangers are marked with arrows.

Replace the heat exchangers as follows:

 Dry and clean the push-in opening in the aluminium cooling block with a cloth;
 Smear the push-in opening with a thin and equal layer of thermal conductivity paste (part no.

90K0115);

 Smear the heat exchangers with a thin and equal layer over the whole surface with thermal

conductivity paste (part no. 90K0115) to ensure good conduction of heat. It is best to close off
the condensate removal of the heat exchangers tube with adhesive tape to prevent any of the
thermal conductivity paste from getting into the heat exchanger;

 Lightly push the heat exchangers with rotation back into the push-in opening of the cooling

block and press to the upper block;

 Remove the adhesive tape and any surplus thermal conductivity paste;
 Reconnect the hoses.

Mounting the Borosilicate glass heat exchangers please notice:

 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!

 Do up the red GL coupling rings hand-tight by turning them to the right;

To ensure a safe connection of the sample gas respectively condensate tubes to the Borosilicate
glass heat exchanger(s) we recommend the use of GL-couplings.
We like to advise you.

18.2 CLEANING THE FINS OF THE CONDENSER

Dust on the fins of the condenser reduces the cooling capacity. Therefore it is necessary to clean the
fins from time to time. The following steps are recommended:

 Shut off the gasflow;
 Dismantle the tubing for gas in- and outlet;
 Unscrew the cooler hood and remove it carefully;
 Clean the fins carefully with compressed air;
 Re-install the cooler hood;
 Connect the tubing for gas in- and outlet.

.

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DANGER

Dangerous voltage!
It is necessary to take the pump off the mains before any assembly,
maintenance and repair work is carried out!

CARE!

Aggressive condensate is possible!
Wear protective glasses and proper protective clothing!

NOTE!

If you send back the peristaltic pump to the M&C service for repair,
please let us know what kind of condensate has been pumped. Before
sending the pump back clean all parts from dangerous or highly
aggressive contaminants.

1

2

3

4

18.3 MAINTENANCE OF THE OPTIONAL MOUNTED PERISTALTIC PUMP(S), TYPE
SR25.2

Before the maintenance work is carried out, it is necessary hat the specific safety procedures
pertaining to the system and operational process are observed!

Flexible tube, conveying belt, contact pulleys and contact springs are the only parts of the pump
subject to wear.
They are simple to change.

Figure 6 Change of the pump tube

 Take off the cooler of the mains;
 Open hose connectors at the pump;
 Press conveying belt  at the recessed grips and turn Sbolt 2 clockwise up to limit stop;

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NOTE!

Only the usage of the original hose set guarantees a perfect function.
Never lubricate the hose.
Before mounting the pump check all parts for impurity and clean if
necessary.

NOTE!

While mounting pay attention to the fit of ‘rotational axisdriver’.
Use genuine spare parts only!

CARE!

Aggressive sample is possible!
Wear protective glasses and proper protective clothing during
disassembly, repair or cleaning!

 Take away conveying belt  and remove the old hose set  from the guides by the hose

connectors;

 Press the two contact pulleys  and check whether the spring pressure is still sufficient, if not,

the contact springs have to be changed;

 Put the new hose set  with the hose connectors into the guides of the conveying belt  ;

 Put the conveying belt  with the new hose  into the dovetail guide of the pump body;
 Press conveying belt at the recessed grips and simultaneously turn the S-bolt  anticlockwise

until it snaps;

 Switch on pump.

18.3.1 CHANGE OF CONTACT PULLEYS AND SPRINGS

 Take off the cooler of the mains;
 Unscrew the nut of the pump head (span of the jaw 5,5);
 Draw the pump head out of the motor shaft;

Now the driver can picked out of the pump head and is ready for maintenance.

 The removal of the springs (4 pcs.) away from the driver is possible without the aid of any

tools. Therefore press together the spring and take it out of the groove in the driver
respectively out of the boring in the axle. Now the roller bearing axle can be dismounted and
the contact pullets are ready for change.

 Remounting happens in the opposite way.

18.3.2 CLEANING THE PUMP HEAD

 When changing flexible tube or other parts, inspect all parts for dirt before assembling the

pump head and clean them if necessary.

 As far as possible clean the parts with a dry cloth. Solvents should not be used as they can

attack the plastics and synthetic rubber parts. If a compressed air line is available, blow the
parts out with it.

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NOTE!

Only use temperature controller 01 B 8365.

19 OPERATING OF THE BUILT-IN ELECTRONIC TEMPERATURE CONTROLLER

In normal operation the display of the temperature controller shows the actual cooling temperature.
Figure 7 shows the front view of the temperature controller.

Figure 7 Front view of the temperature controller

19.1 CHANGING THE SET VALUE

To change the set value the P-key has to be pushed < 2 sec. The company fixed value of 5°C
appears. With the two arrow keys the value can be changed. This value should not be adjusted lower
than +1°C, because otherwise the heat exchanger will freeze up. Is the value adjusted higher than the
ambient temperature the cooler will not work.

19.2 CHANGING THE TEMPERATURE ALARM WINDOW

The exact description of changing the temperature alarm window can be found in the manual of the
temperature controller in the appendix.

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Error

Possible reason

Check/Repair

Condensate in the gas outlet

Ambient temperature < 5C
Cooler overloaded
Peristaltic pump doesn’t work
Tube of the peristaltic pump
defective
Cooling capacity too low
(cooler is not overloaded)

Motor protection switch released

Heat up the components downstream;
eheizen; Keep the operational data (10.);
Change peristaltic pump;
Change the tubing (18.3);

Clean the fins of the condenser (18.2);
Check the vent;
Check the safety distance to other
heated components;
Secure sufficient ventilation;
Thermal load caused by the sample gas
resp. ambient is too high;
Clean the fins of the condenser;
Keep the operational data (10.);
Let the cooler cool down before restarting
it;

Gas flow blocks up reading

Contamination of the sample gas
way

Optimize the dust pre-separation
upstream the cooler;
Clean the gas ways and the coolin
system;

Wrong temperature

Temperature sensor defective
Temperature controller defective
Circuit of cooling agent leaky

Check the PT100-sensor;
Check the temperature controller;
Send the cooler for repair;

Cooler break-down

Power supply interrupted

Check the power supply and reconnect;

Pay attention to the relevant
safety instructions!

Compressor does not work

Compressor defective;
Motor protection switch defective

Send the cooler for repair;

20 TROUBLE SHOOTING

The following table should give an overview of possible errors and an instruction to check and to
repair them (is not valid for the starting-up period of cooler).

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Electric gas cooler ECM-ExII

(C) Consumable parts
(R) Recommended spare parts
(S) Spare parts

Recommended quantity being in
operation [years]

Part No.

Indication

C/R/S

1 2 3

93 K 0140

ECP-3000 G Jet-Stream heat exchanger
material: Borosilicate glass
connections gas: GL18-6mm
condensate: GL 25-12mm

E

1 1 1

93 K 0160

ECP-3000 SS Jet-Stream heat exchanger
material: SS 316

connections gas: G 1/4“i
condensat:e: G 3/8“i

E 1 1

1

93 K 0170

ECP-3000 PV Jet-Stream heat exchanger
material: PVDF (Polyvinylidenfluorid)

connections gas: G 1/4“i
condensate: G 3/8“i

E1 1 1

1

97 K 0100

ECM-2G Jet-Stream heat exchanger
material: Borosilicate glass
connections gas: GL18-6mm
condensate: GL 25-12mm

E 1 1

1

97 K 0110

ECM-2PV Jet-Stream heat exchanger
material: PVDF (Polyvinylidenfluorid)
connections gas: 6mm tube
condensate: G 3/8“i

E 1 1

1

97 K 0115

ECM-2SS Jet-Stream heat exchanger
material: SS 316
connections gas: 6mm tube
condensate: G 3/8“i

E 1 1

1

90 K 0115

EC-thermal conductivity paste 50g (-40°C bis 140°C)

E 1 1

2

90 K 0035

Fan ECP 230V, 50Hz

V - -

1

93 K 0040X

PT-100 temperature sensor for ECM

V - -

1

90 K 7005

Cooling unit, complete with compressor, vaporiser
and condensor for ECM
cooling medium: R134A, power: 230V, 50Hz

E - -

-

97 K 0010

ECM transformer 115V/230V, ... 230VA

E - -

-

01 B 8365

Electronical PID temperature controller for ECM-Ex

T - -

1

Peristaltic pump SR25.2

(C) Consumable parts
(R) Recommended spare parts
(S) Spare parts

Recommended quantity being in
operation [years]

Part No.

Indication

V/E/T

1 2 3

90 P 1007

Hose set  SR25.1
with PVDF-tube connectors 4/6mm, standard

V 1 2

4
90 P 1020

Driver SR25, complete

T - 1 1 90 P 1010

1 set (4 pcs) contact springs SR25 for driver

E 1 2 2 90 P 1045

Contact pulleys SR25 PVDF  for driver

T 2 4

4

90 P 1050

Conveying belt SR25.1 

T - 1 2 90 P 1025

S-bolt  SR25.1

T - -

1

01 P 1300

Peristaltic pump SR25.2, complete 230V/115V, 50/60Hz

E - -

1

90 P 1031

Heat peristaltic pump SR25, complete without tube set, motor and
gears

T - -

1

21 SPARE PARTS LIST

Wear, tear and replacement part requirements depend on specific operating conditions.
The recommended quantities are based on experience and they are not binding.

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3

4

5

6

7

8

9

10

0 50 100 150 200 250

Outlet dew point in °C

Gas flow Nl/h

ECM-2G

ECM-1G

22 APPENDIX

 Sample output dew point depending on gas flow rate at sample inlet dew points of 60C
 Circuit diagram ECM-ExII Drawing No.: 2456-5.01.0
 Ex-certifikates: ATEX, CSA, FM

Further product documentation can be seen and downloaded from our home page:

www.mc-techgroup.com

 Threaded couplings for ”GL” glass connections

Document: 3-5.1.1

 Instruction manual peristaltic pump SR25.1

Document: 3-7.1ME

 Automatic liquid drain AD-SS

Document: 3-6.2.3

 Automatic liquid drain AD-P

Document: 3-6.2.1

 Condensate vessel TG, TK

Document: 3-6.3.1

Figure 8 Sample outlet dew point depending on gas flow rate and sample inlet dew points of 60°C

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Figure 9 Circuit diagram ECM-ExII

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