Instruction Manual
Electric Gas Cooler Series ECP
®
Version ECP 1000/2000/3000 (from model nos.: 95...)
Gas sampling and gas conditioning technology 3-1.1-ME
2
This Operating Manual does not claim completeness and may be
subject to technical modifications.
© 06/1998 M&C TechGroup Germany GmbH. Reproduction of this
document or its content is not allowed without permission from M&C.
ECP® is a registered trade mark.
4th Edition: 01/2009
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 3-1.1-ME
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List of Contents
1 General information ..................................................................................................................... 4
2 Declaration of conformity ........................................................................................................... 4
3 Safety instructions ....................................................................................................................... 5
4 Warranty ....................................................................................................................................... 5
5 Used terms and signal indications ............................................................................................. 6
6 Application ................................................................................................................................... 7
7 Function of the M&C Jet-stream heat exchanger ..................................................................... 8
8 Technical data .............................................................................................................................. 9
9 Description ................................................................................................................................. 10
10 Receipt of goods and storage .................................................................................................. 11
11 Installation instructions ............................................................................................................ 12
12 Supply connections ................................................................................................................... 12
12.1 Hose connections ................................................................................................................ 12
12.2 Electrical connections ......................................................................................................... 13
13 Starting ....................................................................................................................................... 14
13.1 Function sequence and LED function display ..................................................................... 15
14 Closing down ............................................................................................................................. 15
15 Maintanance ............................................................................................................................... 16
15.1 Adding and replacing the heat exchangers ......................................................................... 16
16 Trouble shooting........................................................................................................................ 18
17 Temperature setting and control the ECP cooler ................................................................... 19
18 Checking the temperature sensor ............................................................................................ 20
19 Spare parts list ........................................................................................................................... 21
20 Appendix .................................................................................................................................... 23
List of Figures
Figure 1 Application example ECP .000 ............................................................................................. 7
Figure 2 Functioning diagram of the heat exchanger ......................................................................... 8
Figure 3 Electric gas cooler ECP .000 .............................................................................................. 10
Figure 4 Terminals for mains supply and temperature alarm ........................................................... 14
Figure 5 Temperature adjustment .................................................................................................... 19
Figure 6 Voltage in relation to the temperature of the cooler ............................................................ 20
Figure 7 Resistance temperature characteristics of the PT100 temperature sensor ........................ 20
Figure 8 Sample output dew point (ambient temperature 20°C) depending on gas flow rate .......... 24
Figure 9 Dimensions of the cooler Type ECP 1000/2000/3000 ........................................................ 25
Figure 10 Set-up diagram ................................................................................................................... 26
Figure 11 Electronic board and main board up to 2006 ...................................................................... 27
Figure 12 Electronic board and main board from 2007 on ................................................................. 28
Figure 13 Circuit diagram up to 2006 ................................................................................................. 29
Figure 14 Circuit diagram from 2007 on ............................................................................................. 30
Gas sampling and gas conditioning technology 3-1.1-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 3-1.1-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 3-1.1-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 AR NIN 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.
ATT ENT IO 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
Gas sampling and gas conditioning technology 3-1.1-ME
7
NOTE!
For protection against liquid breakthrough and to increase the dependability
of the complete system we recommend the use of a fluid alarm sensor.
Sample Gas IN
+5°C
ECP .000
Alternative:
Condensate vessel
Test
Gas IN
6 APPLICATION
The Peltier Gas Sample Cooler Type ECP .000 is used in analyser sample system design to reduce
the dew point of wet gases to a level that is stable and low.
Sample gas cooling prevents subsequent condensation in the analyser. The stability of the dew point
is also extremely important at it helps to prevent water vapour cross sensitivity and volumetric error,
especially in infrared analysers.
The sample gas passes through a sampling probe to the Type ECP .000 Cooler where it is lowered to
a dew point of +5°C. Solids will have been trapped in the filter of the sample probe, (If provided in the
type used) or are trapped in a downstream fine filter.
The conditioned gas can now be passed to the analyser.
If the analyser has no gas flow control or indicator functions, these should be provided externally, just
as with a gas delivery pump for unpressurized gases.
The condensate is discharged externally. For operations under pressure, an automatic condensate
drain or collection vessel is used. For operations in partial vacuum (suction), a condensate vessel with
a manual drain or a peristaltic pump for automatic condensate removal is used.
The following figure shows the flow sheet of an typical application of the electric gas cooler ECP .000.
Gas sample probe SP… Diaphragm pump
heated sample line Universal filter FP..
3-way ball valve Liquid particles filter CLF..
Gas cooler ECP .000 Flowmeter FM..
Peristaltic pump (option) Analyser
Figure 1 Application example ECP .000
Gas sampling and gas conditioning technology 3-1.1-ME
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+5°C
Sample gas
out
Sample gas
in
Condensate
out
Coolingblock
7 FUNCTION OF THE M&C JET-STREAM HEAT EXCHANGER
The coolers ECP 1000/2000/3000 with special design for analysis technique are prepared for
maximum flow rates of 350l/h.
The Jet-Stream heat exchangers made of Duran glass, optional 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 2 shows a schematic diagram of the functioning of
the heat exchanger.
Figure 2 Functioning diagram of the heat exchanger
Gas sampling and gas conditioning technology 3-1.1-ME
8 TECHNICAL DATA
Electro Gas Cooler Version
ECP 1000
ECP 2000
ECP 3000
Sample outlet dew point
range of adjustment: +2 °C … +15 °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/heat exchanger***
150l/h
150l/h
350l/h
Number of heat exchangers
1 2 1
Material of heat exchangers
Duran glass, PVDF or stainless steel 1.4571
Ambient temperature***
+5°C to +45°C*
+5°C to +50°C**
+5°C to +50°C
Storage temperature
-20 to +60°C
Pressure
Duran glass : max. 3bar
PVDF : max. 3bar
Stainless steel: max. 10bar (other versions on request)
Total cooling power at +25°C ambient
50KJ/h
90KJ/h
Dead volume/heat exchanger
50cm3
2 x 50cm3
100cm3
P/heat exchanger
1mbar
at 150l/h
1mbar
at 150l/h
5mbar
at 350l/h
Sample gas connection
for Tube 6mm *
8mm or 10mm **
G1/4“i
G1/4“i*
NPT**
Condensate connection
for Tube12mm *
8mm or 10mm **
G3/8“i
G3/8“i*
NPT**
Ready for operation
10min.
Power consumption
100VA
110VA
Mains power supply
230V or 115V ± 10%, 50...60Hz
Electrical connections
Clamps 2,5mm2, cable gland 2 x PG11
Alarm contact
2 change-over contacts,
alarm point: T ± 3°C to T
setting value
Contact rating
250V AC, 2A, 500VA, 50W
Service-measuring point
0,1V/°C
Electrical protection
Fuse 2 x 1,6AT
Case protection
IP22 EN 61010
Housing colour
RAL 9005 (black)
Method of mounting
Wall mounting
Dimension
275mm x 220mm x
136mm
305mm x 220mm x 136mm
Weight
5,5kg
7kg
Electrical equipment standard
EN 61010
9
* Standard
** 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.
Gas sampling and gas conditioning technology 3-1.1-ME
9 DESCRIPTION
(305)
Figure 3 shows the ECP cooler unit.
10
Figure 3 Electric gas cooler ECP .000
The type ECP 1000 Peltier Gas Sample Cooler is supplied complete with an ECPJet-Stream heat
exchanger made either of Duran glass, stainless steel or PVDF for a maximum flow of 150l/h.
The ECP 2000 is supplied with two ECP 1000 ECPJet-Stream heat exchanger for cooling of two
channels a’ 150l/h.
The Type ECP 3000 Peltier Gas Sample Cooler is supplied complete with an ECP 3000 Jet-Stream
heat exchanger made either of Duran glass, stainless steel or PVDF for a maximum flow of 350l/h.
The exchanger is housed for ease of replacement in a thermally insulated cooling block on the right
hand side of the cooler. From serial nos.: 95... the temperature is measured with a PT100 temperature
sensor and regulated electronically by Peltier Elements on a constant temperature of +5°C.
There are proof-plugs for checking the refe-rence temperature and the current temperature, with an
output signal at 0,1 Volt/°C. (see Temperature Setting and Control).
The system ensures optimum cooling of the sample gas and condensate separation.
The heat energy emitted by the cooling system is dissipated via a generously sized cooling fin block
with forced ventilation.
The electronic control system with status indication and the power supply unit are housed in a
protective aluminium enclosure on the front panel of the cooler.
The ECP ..000 Cooler is equipped with a change-over switch on the electronic control card for
operation at 230V/50Hz or 115V/60Hz.
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NOTE!
The equipment should be stored in a protected, frost-free room!
There are three LED status indicators:
Upper red LED " > °C " = Temperature alarm (T> +8°C)
Central green LED "On", lights or pulsates = Cooler on
Lower red LED " < °C " = Temperature alarm (T< +2°C)
The green LED alone indicates that the specifications with regard to dew point temperature and dew
point stability are achieved. The red LED lights to indicates that the control system has deviated from
the setpoint by more than 3°C. The upper red LED " > °C " lights up to indicate an overload, i.e. more
cooling capacity is being called for than is available. The ECP ..000 Electric Gas Cooler is overloadprotected. In an overload condition the dew point temperature will rise pro-portional to the overload.
An over and under temperature alarm as a status group alarm is available for external indication, via a
relay output with a volt free relay changeover contact. The alarm thresholds are 3°C above and below
the control temperature.
The gas inlet and outlet is located on the top of the cooler and is indicated by arrows on the ECP JetStream heat exchangers. On standard models with Duran glass heat exchangers the gas connections
are provided with GL18-6 mm PTFE sealing rings and on stainless steel or PVDF exchangers with
G1/4" female threads (or 1/4" NPT as optional).
The condensate drain of the ECP Jet-Stream heat exchangers are located beneath the cooler and
have GL25-12 mm PTFE sealing rings as standard on the Duran glass heat exchangers. And on
stainless steel or PVDF exchangers with G3/8" female threads (or 3/8" NPT as optional).
The type of condensate discharge used will depend on the type of operation:
Peristaltic Pump Type SR25.1 for automatic condensate discharge in vacuum and pressurised
operations.
Automatic Float Condensate Discharge Type AD- .. for pressurised operation only.
Condensate Collection Vessel Type TG../TK.. with manual drain.
10 RECEIPT OF GOODS AND STORAGE
The ECP gas cooler is a complete pre-installed unit.
Please take the ECP gas cooler and possible special accessories carefully out of the packaging
material immediately after arrival, and compare the goods with the items listed on the delivery note!
Check the goods for any damage caused during delivery and, if necessary, notify your transport
insurance company without delay of any damage discovered
Gas sampling and gas conditioning technology 3-1.1-ME
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NOTE!
The Cooler is to be used in a vertical position only! The perfect functioning
of the separation and drainage procedures will only be guaranteed if the
equipment is used in a vertical position!
When in use, the ECP cooler should be placed in an area well away from any
heat emitting sources in order to prevent damage caused by an
accumulation of heat the air vents must be free at all times!
When the equipment is being used outside, ample protection against the
effects of direct sunlight and dampness must be provided. In winter, the
equipment must only be used in frost-free areas!
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 to the
cooler!
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 removsl lines are not reduced!
11 INSTALLATION INSTRUCTIONS
The ECP .000 Peltier Gas Cooler is designed for wall or panel mounting.
12 SUPPLY CONNECTIONS
12.1 HOSE CONNECTIONS
The gas inlet and outlet is located on the top of the cooler and is indicated by arrows on the ECP JetStream heat exchangers. For possible connectors see technical data.
Correspondingly tube or hose connectors are optional available by M&C.
Ensure that the connections are sealed adequately by noting the following:
Duran glass heat exchangers with connections GL 18-6 respectively GL 25-12
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 respectively stainless steel heat exchangers with G 1/4“i respectively G 3/8“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.
Gas sampling and gas conditioning technology 3-1.1-ME
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NOTE!
When fixing the connectors in the PVDF heat exchanger hold up with a
wrench at the pane of the bolt head!
NOTE!
Stainless steel heat exchangers with G 3/8“ 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 G
3/8“i). By this wall mounting of the AD-SS unit isn’t necessary!
W AR NIN G!
When connecting the equipment, please ensure that the supply
voltage is identical with the information provided on the model type
plate.
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 1000 V, together with the associated standards
and stipulations.
Set the voltage selector S1 to the correct mains voltage!
A main switch and matching fuse must be provided externally!
The main circuit is equipped with a fuse corresponding to the
nominal current (over current protection); for electrical details see
technical data.
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, with the standard GL 25-12 tube connectors (Duran glass heat exchanger) respectively
with the standard G 3/8“ thread joint (PVDF or stainless steel heat exchanger).
Condensate removal is done by customer according to the type of operation with:
- External peristaltic pump SR25.1;
- Automatic float type condensate traps AD-... only for over-pressure operation;
- Condensate collector container that is emptied manually;
12.2 ELECTRICAL CONNECTIONS
The main power supply terminals are located in the aluminium enclosure on the ECP .000 electronic
board:
Power On, Terminal X1: 1, 2, 3 / L, N, PE
Gas sampling and gas conditioning technology 3-1.1-ME
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1
L
2
N
4
PE
3
PE
5
L
6
N
1 2 3
4
X1
X2
Netz/Power
230V/115V
50Hz/60Hz
ECP 1000 100VA
ECP 2000/3000 110VA
Alarm
250V AC
2A
500VA
ECP 1000/2000/3000
Sicherung F1 1,6 AT
Fuse F2 1,6 AT
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!
Coolers from serial nos.: 95.. also have a mains selector (S1) on the basic board for either 230V 50Hz
or 115V 60Hz operation on the basic circuit board (see circuit diagram in appendix).
Before commissioning, use a screwdriver to turn the selector to the correct position 230/115
depending on your main power input supply.
The status alarm contact for indicating and isolating the gas supply must be incorporated into the
equipment control system.
The volt free contact outputs of the status group alarm is located on the ECP .000 control board:
Temp. Alarm Terminal X2: 1 and 3 normal opened, 2 and 4 normal closed.
The two PG11 cable glands are located on the underside of the cooler enclosure. For further details
refer to the electrical circuits and terminal drawing and cover plate.
Figure 4 Terminals for mains supply and temperature alarm
13 STARTING
Before using the equipment for the first time, check that the safety measures specific to the installation
and process are complied with!
The automatic control electronics of the ECP 1000/2000/3000 permit automatic start-up of the cooler.
The error diagnostics guarantee full monitoring and reporting of possible sources of error.
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;
Lead the status contacts for reporting of under- and over-temperature to the measuring station;
Gas sampling and gas conditioning technology 3-1.1-ME
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NOTE!
The area in which the cooler is situated when not in use must be
kept free of frost at all times!
W AR NIN G!
Aggressive condensate is possible.
Wear protective glasses and proper protective clothing!
°C >
ON
°C <
red
°C >
ON
°C <
green
13.1 FUNCTION SEQUENCE AND LED FUNCTION DISPLAY
Three function display LED’s are provided to give a visualisation of the function sequence during startup of the cooler. The top LED (red) indicates that the temperature set by the ECP automatic control
electronics has been exceeded or has not been reached. The central green LED shows that the cooler
is operating. The bottom red function display LED gives an alarm if the temperature falls too low.
Switching the cooler on
As soon as there is a mains voltage, the top red LED lights up. This
indicates that the temperature of the cooler is above +8°C.
Normal operation
After around 20 minutes the cooler has been cooled down to a
temperature below +8°C. The top red LED goes out.
The status collector alarm contacts are deactivated and control the
automatic external release for gas measurement.
The central green LED is alternately switched on and off by the ECP
automatic control electronics in a load-dependent cycle. The cooler is
ready to use.
14 CLOSING DOWN
If the cooler unit is putting out of action for a short time no particular measures need to be taken.
We recommended sweeping the cooler with inert gas or ambient air while the unit is putting out of
action for a longer time. Condensate has to be removed completely from the cooler.
Gas sampling and gas conditioning technology 3-1.1-ME
16
W AR NIN G!
It is necessary to take the ECP electric gas cooler off the mains
before any assembly, maintenance or repair work is carried out!
W AR NIN G!
Aggressive condensate is possible.
Wear protective glasses and proper protective clothing!
15 MAINTANANCE
Before the maintenance work is carried out, it is necessary that the specific safety procedures
pertaining to the system and operational process be observed!
The ECP ..000 Gas Cooler requires no particular routine maintenance. Depending on the quality of the
ambient air the cooling fin block should be blown out with compressed air from time to time.
15.1 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;
Replace the heat exchangers as follows:
Dry and clean the push-in opening in the aluminium cooling block with a cloth;
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.
Do not mix up the hose connections; gas outlet and gas inlet are marked with arrows!
Gas sampling and gas conditioning technology 3-1.1-ME
17
Mounting the Duran 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;
Gas sampling and gas conditioning technology 3-1.1-ME
18
Problem/Indication
Possible cause
Action/Check
ECP .000 is not
cooling
°C >
ON
°C <
°C >
ON
°C <
red
No mains supply
Ambient temperature
+2°C T +5°C
Temperature sensor faulty
Set point at Pot 3 out of
adjustment
Check for mains supply voltage at terminals
L&N, X1/1+2 against nameplate. If OK,
check fuses F1, F2.
Check ambient temperature.
Disconnect white wires from terminals
X5/3+4 and measure sensor resistance:
107,79 +0,4 Ohm at +20°C ambient; if there
is great deviation change the sensor.
Adjust the desired temperature with the
trimmer Potentiometer P3 (0,1V/°C) and
control the current temperature at terminals
(X7/3) with an extern voltmeter (see
Temperature Setting and Control).
ECP .000 cools
continuously
°C >
ON
°C <
red
Transistor BUZ11 faulty
Check voltage of the Peltier elements at
terminal X5, 1 and 3 respectively 2 and 4
(see circuit diagram):
> 12V DC = transistor faulty;
Fit the new transistor V1 on the basic circuit
board.
16 TROUBLE SHOOTING
The following table aims to point out possible operational problems and offer solutions to such
problems (not applicable during the starting procedure).
Gas sampling and gas conditioning technology 3-1.1-ME
19
red
yellow
blue
set-temperature
current temperature
red
green
red
NOTE!
To prevent the heat exchangers freezing up, the temperature should never
be set below +2°C.
17 TEMPERATURE SETTING AND CONTROL THE ECP COOLER
The gas cooler is set by manufacturer to a control temperature of +5°C.
This temperature can be adjusted with a trimmer Potentiometer P3 within a range of 0°C to +20°C.
This Potentiometer is located in the ECP ..000 case behind the front sheet metal.
Turning clockwise will increase the temperature and turning counter clock will decrease the
temperature respectively.
To set the temperature it is measured at the reference terminals yellow (X7/2) and blue (X7/3) using
an external DC-Voltmeter (0,1Volt/°C).
Figure 5 Temperature adjustment
The current temperature can be measured at red (X7/1) and blue terminal (X7/3).
Gas sampling and gas conditioning technology 3-1.1-ME
20
°C
Voltage
-3
-2
-1
0
1
2
3
4
-30 -20 -10 0 10 20 30 40
°C
Ohm
95
97
99
101
103
105
107
109
111
113
115
117
-10 0 10 20 30 40
18 CHECKING THE TEMPERATURE SENSOR
The ECP .000 cooler temperature sensor is a PT100 element as from serial numbers 95... . There
are two methods for checking the PT100 element, as follows:
1. Voltage method
In order to check the sensor for the cooler currently in operation, the actual voltage at the
corresponding measuring sockets must be measured (see ‘Temperature Setting and Control’). The
following figure shows the voltage characteristics in relation to temperature. If the measured voltage is
inside the shaded area, the sensor is defective and must be replaced.
Figure 6 Voltage in relation to the temperature of the cooler
2. Resistance method
In this case the sensor must be disconnected from pins X5/3+4 at the ECP automatic control board
and removed from the cooling block. When measuring the resistance of the PT100 element, this must
be proportional to the ambient temperature. The resistance-temperature characteristics are shown in
the figure below.
Figure 7 Resistance temperature characteristics of the PT100 temperature sensor
Gas sampling and gas conditioning technology 3-1.1-ME
21
Electric Gas Cooler ECP1000/2000/3000
(C) consumable parts, (R) recommended spare parts, (S) spare parts
recommended quantity
ECP... being in operation
[years]
C/R/S 1 2
3
93 K 0100
ECP-1000 G Jet-Stream Heat Exchanger
Material: Duran Glass
Connections: Gas GL18-6/6mm
Condensate : GL25-12mm
R 1 1
1
93 K 0130
ECP-1000 G 90° Jet-Stream Heat Exchanger with
90° angled gas connections
Material: Duran Glass
Connections: Gas GL18-6/6mm
Condensate: GL25-12mm
R 1 1
1
93 K 0110
ECP-1000 SS Jet-Stream Heat Exchanger
Material: SS 316
Connections: Gas G 1/4" i
Condensate: G 3/8" i
R 1 1
1
93 K 0120
ECP-1000 PV Jet-Stream Heat Exchanger
Material: PVDF
Connections: Gas G 1/4" i
Condensate: G 3/8" i
R 1 1
1
93 K 0140
ECP-3000 G Jet-Stream Heat Exchanger
Material: Duran Glass
Connections: Gas GL18-6/6mm
Condensate : GL25-12mm
R 1 1
1
93 K 0150
ECP-3000 G 90° Jet-Stream Heat Exchanger with
90° angled gas connections
Material: Duran Glass
Connections: Gas GL18-6/6mm
Condensate: GL18-8mm
R 1 1
1
93 K 0160
ECP-3000 SS Jet-Stream Heat Exchanger
Material: SS 316
Connections: Gas G 1/4" i
Condensate: G 3/8" i
R 1 1
1
93 K 0170
ECP-3000 PV Jet-Stream Heat Exchanger
Material: PVDF
Connections: Gas G 1/4" i
Condensate: G 3/8" i
R 1 1
1
90 K 0115
Heat sink compound 50g Type 80B522
R 1 1
2
93 K 0540
1.6A fine-wire fuse 5mm x 20mm (F1/2)
R 2 4
4
93 K 0010
ECP 1000 Fan DC for ECP 1000/2000/3000
C - 2
2
19 SPARE PARTS LIST
Wear, tear and replacement part requirements depend on specific operating conditions.
The recommended quantities are based on experience and are not binding.
Gas sampling and gas conditioning technology 3-1.1-ME
22
Electric Gas Cooler ECP1000/2000/3000
(C) consumable parts, (R) recommended spare parts, (S) spare parts
recommended quantity
ECP... being in operation
[years]
C/R/S 1 2
3
93 K 0020
ECP Electronic Board complete
from serial nos.: 95...
R - -
1
93 K 0530
ECP Mains Board complete
from serial nos.: 95...
R - -
1
90 K 2010
Rectifier for ECP2000/3000 and ECP1000 as from s.no.:95xx
R - 1
1
93 K 0040
PT100 sensor incl. screw and spring ECP 1000
for ECP1000/2000/3000
R - 1
1
90 K 2020
ECP Power Transistor BUZ11
R - 1
1
93 K 0047
ECP 1000 Peltier element 4/4
for ECP1000 as from s.no.:95xx
R - -
1
93 K 0048
ECP 1000 Peltier element for ambient temperature at 50°C for ECP1000 as from s.no.:95xx
R - -
1
93 K 0520
ECP 2000/3000 Peltier element 6/6 for ECP2000/3000
R - -
1
90 K 0145
ECP Alarm Relay DSP1for ECP1000/2000/3000
R - -
1
Gas sampling and gas conditioning technology 3-1.1-ME
23
20 APPENDIX
Sample output dew point (ambient temperature 20°C) depending on gas flow rate
Dimensions of the Cooler Type 1000/2000/3000
Set-up diagram
Components of main -and electronic board up to 2006 and from 2007 on
Circuit diagram ECP .000, up to 2006 and from 2007 on
Drawing number : 2413-5.01.1 and 2413-5.03.0
For additional manuals and data sheets please look on our home page
www.mc-techgroup.com
Instruction manual peristaltic pump SR 25.1,
Document : 3-7.1-MD;
Condensate vessel TG, TK
Document : 3-6.3.1
GL-connectors
Document : 3-5.1.1
Automatic liquid drain AD-SS
Document : 3-6.2.3
Automatic liquid drain AD-P
Document : 3-6.2.1
Gas sampling and gas conditioning technology 3-1.1-ME
24
Gasausgangs-Taupunkt
Sample outlet dewpoint
Glaswärmetauscher
ECP 1000
Heatexchanger out of glass
Heatexchanger out of PVDF
PVDF Wärmetauscher
Rostf. Stahl Wärmetauscher
Heatexchanger out of SS316
10 5 50
100
150
°C
N l/h
Messgas-Durchfluss
Gas flow rate
100
200
300
50
350
Gasausgangs-Taupunkt
Sample outlet dewpoint
Glaswärmetauscher
ECP 2000
Heatexchanger out of glass
Heatexchanger out of PVDF
PVDF Wärmetauscher
Rostf. Stahl Wärmetauscher
Heatexchanger out of SS316
10 5 50
100
150
°C
N l/h
Messgas-Durchfluss
Gas flow rate
Gasausgangs-Taupunkt
Sample outlet dewpoint
Glaswärmetauscher
ECP 3000
Heatexchanger out of glass
Heatexchanger out of PVDF
PVDF Wärmetauscher
Rostf. Stahl Wärmetauscher
Heatexchanger out of SS316
10
5
°C
N l/h
Messgas-Durchfluss
Gas flow rate
Sample inlet dew point 50°C
Figure 8 Sample output dew point (ambient temperature 20°C) depending on gas flow rate
Gas sampling and gas conditioning technology 3-1.1-ME
25
ECP
Cooler
>°C
ON
<°C
GL18
GL25
2xPG 11
180
200 6 11
63
137
215
220
30
275
25
55
26
220
GL18
GL25
68
136
17
25
2xPG
>°C
<°C
ON
ECP 2000
Cooler
305
ECP 1000
ECP 2000
ECP 3000
GL1
GL25
220
45
305
2xPG 11
>°C
<°C
O
ECP
Cooler
25
Figure 9 Dimensions of the cooler Type ECP 1000/2000/3000
Gas sampling and gas conditioning technology 3-1.1-ME
26
1
2
3
4
5
6
Pelt.-
Pelt.+
PT100
PT100
Fan -
Fan +
X5
Temperature sensor PT100
**install the sensor with
thermal conductivity
paste
Peltier element
**install with thermal
conductivity paste
Cooling block
Fan
Mains electronic board
Electronic housing
GL 25
Control electronic
board
GL 18
Figure 10 Set-up diagram
Gas sampling and gas conditioning technology 3-1.1-ME
Electronic board up to 2006
Main board up to 2006
27
Figure 11 Electronic board and main board up to 2006
Gas sampling and gas conditioning technology 3-1.1-ME
Electronic board from 2007 on
Main board from 2007 on
X5
28
Figure 12 Electronic board and main board from 2007 on
Gas sampling and gas conditioning technology 3-1.1-ME
29
Figure 13 Circuit diagram up to 2006
Gas sampling and gas conditioning technology 3-1.1-ME
30
Figure 14 Circuit diagram from 2007 on
Gas sampling and gas conditioning technology 3-1.1-ME
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