M&C TechGroup ECS Operator's manual
Operating Manual
Electric gas cooler series EC ®
Version EC/ECS (from model nos.: 95...)
Gas sampling and gas conditioning technology 3-4.1-ME
2
List of Contents
1 General information ................................................................................................................... 5
2 Declaration of conformity .......................................................................................................... 5
3 Safety instructions ..................................................................................................................... 6
4 Warranty ...................................................................................................................................... 6
5 Used terms and signal indications ........................................................................................... 7
6 Introduction ................................................................................................................................ 8
7 Application .................................................................................................................................. 8
8 Technical data ............................................................................................................................ 9
9 Description................................................................................................................................ 10
10 Function .................................................................................................................................... 12
11 Reception and storage ............................................................................................................. 13
12 Installation instructions ........................................................................................................... 13
13 Supply connections ................................................................................................................. 14
13.1 Hose connections ............................................................................................................. 14
13.2 Electrical connections ....................................................................................................... 15
14 Start-up ..................................................................................................................................... 17
14.1 Function sequence and LED function display ................................................................... 18
15 Closing down ............................................................................................................................ 19
16 Maintenance.............................................................................................................................. 19
16.1 Change of the filter element at option EC-F or EC-FD ..................................................... 19
16.2 Adding and replacing the heat exchangers ....................................................................... 20
16.3 Maintenance of the optional mounted peristaltic pump(s), type SR25 .............................. 20
16.3.1 Change of the pump tube ........................................................................................... 21
16.3.2 Change of contact pulleys and springs ....................................................................... 22
16.3.3 Cleaning the pump head ............................................................................................ 22
17 Trouble shooting ...................................................................................................................... 23
18 EC automatic control board .................................................................................................... 25
18.1 Connecting the cooling compressor .................................................................................. 26
18.2 Temperature setting for the EC/ECS cooler ..................................................................... 27
18.3 Connection of an external temperature reading with option second PT100 sensor
(part no. 02k9500) ............................................................................................................. 27
19 Checking the temperature sensor .......................................................................................... 28
20 Changing the cooler aggregate .............................................................................................. 29
21 Retrofitting a digital temperature indication .......................................................................... 31
21.1 Data for mounting ............................................................................................................. 31
21.2 Installation instructions ...................................................................................................... 31
21.3 Electrical connections ....................................................................................................... 32
22 Spare parts list ......................................................................................................................... 33
23 Appendix ................................................................................................................................... 34
Gas sampling and gas conditioning technology 3-4.1-ME
3
List of Illustrations
Figure 1 Example of application of EC/ECS .................................................................................... 8
Figure 2 EC/ECS with options EC-F and EC-FD ........................................................................... 10
Figure 3 Peristaltic pump SR25.2 mounted into the front panel .................................................... 11
Figure 4 Schematic diagram of functioning of heat exchanger ...................................................... 12
Figure 5 Electrical sockets ............................................................................................................. 16
Figure 6 Pin configuration from model nos. 96... ........................................................................... 16
Figure 7 Pin configuration for EC/ECS up to model nos. 95... ....................................................... 17
Figure 8 Change of the pump tube ................................................................................................ 21
Figure 9 EC automatic control board ............................................................................................. 25
Figure 10 Connection diagram for compressor ................................................................................ 26
Figure 11 Voltage in relation to the temperature of the cooling stage ............................................. 28
Figure 12 Resistance-temperature characteristics of the PT100 temperature sensor ..................... 28
Figure 13 EC cooler aggregate ........................................................................................................ 29
Figure 14 Locating distance of digital temperature indication .......................................................... 31
Figure 15 Sample outlet dew point .................................................................................................. 35
Figure 16 Circuit diagram EC automatic control board .................................................................... 36
Figure 17 Wiring plan automatic condensate removal unit EC-FD .................................................. 37
Gas sampling and gas conditioning technology 3-4.1-ME
4
This Operating Manual does not claim completeness and may be
subject to technical modifications.
© 05/2002 M&C TechGroup Germany GmbH. Reproduction of this
document or its content is not allowed without permission from M&C.
EC® is a registered trade mark.
2nd Edition: 08/2009
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 3-4.1-ME
5
Head Office
M&C TechGroup Germany GmbH Rehhecke 79 40885 Ratingen Germany
Telephone: 02102 / 935 - 0
Fax: 02102 / 935 - 111
E - mail: info@mc-techgroup.com
www.mc-techgroup.com
1 GENERAL INFORMATION
The product described in this operating manual has been examined before delivery and left our works
in perfect condition related to safety regulations. In order to keep this condition and to guarantee a
safe operation, it is important to heed the notes and prescriptions made in this operating manual.
Furthermore, attention must be paid to appropriate transportation, correct storage, as well as
professional installation and maintenance work.
All necessary information a skilled staff will need for appropriate use of this product are given in this
operating manual.
2 DECLARATION OF CONFORMITY
CE - Certification
The product described in this operating manual complies with the following EC directives:
EMV-Instruction
The requirements of the EC directive 2004/108/EC “Electromagnetic compatibility“ are met.
Low Voltage Directive
The requirement of the EC directive 2006/95/EC “Low Voltage Directive“ are met.
The compliance with this EC directive has been examined according to DIN EN 61010.
Declaration of conformity
The EU Declaration of conformity can be downloaded from the M&C homepage or directly requested
from M&C.
Gas sampling and gas conditioning technology 3-4.1-ME
6
3 SAFETY INSTRUCTIONS
Please take care of the following basic safety procedures when mounting, starting up or
operating this equipment:
Read this operating manual before starting up and use of the equipment. The information and
warnings given in this operating manual must be heeded.
Any work on electrical equipment is only to be carried out by trained specialists as per the regulations
currently in force.
Attention must be paid to the requirements of VDE 0100 (IEC 364) when setting high-power electrical
units with nominal voltages of up to 1000 V, together with the associated standards and stipulations.
Check the details on the type plate to ensure that the equipment is connected to the correct mains
voltage.
Protection against touching dangerously high electrical voltages:
Before opening the equipment, it must be switched off and hold no voltages. This also applies to any
external control circuits that are connected.
The device is only to be used within the permitted range of temperatures and pressures.
Check that the location is weather-protected. It should not be subject to either direct rain or moisture.
The device must not be used in hazardous areas.
Installation, maintenance, monitoring and any repairs may only be done by authorized personnel with
respect to the relevant stipulations.
4 WARRANTY
If the equipment fails, please contact M&C directly or else go through your M&C authorised dealer.
We offer a one year warranty as of the day of delivery as per our normal terms and conditions of sale,
and assuming technically correct operation of the unit. Consumables are hereby excluded. The terms
of the warranty cover repair at the factory at no cost or the replacement at no cost of the equipment
free ex user location. Reshipments must be send in a sufficient and proper protective packaging.
Gas sampling and gas conditioning technology 3-4.1-ME
7
DANGER!
This means that death, severe physical injuries and/or important
material damages will occur in case the respective safety measures
are not fulfilled.
WARNING!
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.
ATTENTION!
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 3-4.1-ME
8
Sample gas
in
+5°C
EC
Collecting vessel
Checkgas in
6 INTRODUCTION
The patented M&C EC/ECS 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.
7 APPLICATION
Figure 1 shows a typical example of an application for installation of an EC/ECS gas cooler unit.
Filter sample probe SP... 3-way ball valve Super-fine filter FP...
Heated sample line Peristaltic pump Aerosol filter CLF
EC/ECS cooler Membrane pump Flow meter FM 10
Analyser
Figure 1 Example of application of EC/ECS
The gas to be measured is extracted with a gas sample pump via a gas sample probe and a
heated sample line and cooled down in the gas cooler EC/ECS to a dew point of +5°C. The
emerging condensate is removed by a peristaltic pump or a collecting vessel . 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 . For calibration of the analyser a ball-valve is existing.
Gas sampling and gas conditioning technology 3-4.1-ME
8 TECHNICAL DATA
Sample outlet dew point
range of adjustment: +2 °C ..... +7 °C, factory setting: +5 °C
Dew point stability
at constant conditions 0,25 °C
Sample inlet temperature
**Max. + 180°C
Sample inlet dew point
**Max. +80°C
Gas flow rate per heat exchanger
**Max. 250l/h
Number of heat exchangers
1*, installation of max. 4 heat exchangers possible
Material of heat exchangers
Duran glass or PVDF or stainless steel 316
Ambient temperature
**+5 to +45°C
with option EC-F and EC-FD: +5°C to +50°C
Storage temperature
-20 to +60°C
Admissible gas pressure
with glass and PVDF: max. 3 bar
with stainless steel : 10 bar*
with option EC-FD : 1,2 bar
Total cooling power
Max. 520 KJ/h at +25°C
Dead volume per heat exchanger
70 ml
Sample gas connection glass:
PVDF:
stainless steel:
For tube 6mm*,
option: 8mm, 10mm or hose connector
G 1/4“i,
option: hose connector
G 1/4“i*,
option: NPT or hose connector
Condensate connection glass:
PVDF:
stainless steel:
For tube 12mm*,
option: 8mm, 10mm or hose connector
G 3/8“i,
option: hose connector
G 3/8“i*,
option: NPT or hose connector
Ready for operation
< 30 minutes
Power consumption
280VA, start up current at 230V = 7,9A
Mains power supply
230V 50Hz +/- 10% *, or: 115V 60Hz +/- 10%
Electrical connections
Terminal 2,5 mm²
Status alarm
2 changeover contacts, max. 250V 2A AC/DC 500VA, 50W
Protection for casing
IP 20 (EN 60529)
Casing colour
RAL 9003
Method of mounting
19“ rack or wall mounting
Casing dimensions
EC : 84 TE x 7 HE x 450mm, 32kg
ECS: 84TE x 7 HE x 360mm, 31 kg
Refrigerant
230V: R134A 100% CFC free
115V: R404A 100% CFC free
Electrical equipment standard
EN 61010
9
* standard
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 3-4.1-ME
10
EC-FD
Universal unit
Kondensat Aus
Condensate out
°C>
ON
°C<
View A
A
235
310
ECS 360
435
133
45
57
2 X cable glands
PG 13,5
max. 4 X condensate out
1
268
91012134
7
3
37,5
6,2
Option: EC-F
Option: EC-FD
EC/ECS
355
443
* necessary locating distance
240
70
85
88 * 2HE
100 *
100 *
3 HE
1 HE
7 HE
465
84 TE
SR 25
SR 25
SR 25
SR 25
EC 450
5
9 DESCRIPTION
Figure 2 shows the EC/ECS cooler unit with the optional universal units EC-F and EC-FD.
Figure 2 EC/ECS with options EC-F and EC-FD
Gas sampling and gas conditioning technology 3-4.1-ME
11
The EC/ECS is equally suitable for wall installation or mounting in a 19“-rack.
The versions differ in the positioning of the LED function display . While for wall installation the LED
function display can be fitted into the corresponding cut-outs in the EC/ECS front panel, for 19”
rack mounting this is done using the cut-outs in the back panel of the casing. This positioning can be
done at the factory when stating the type of installation of the EC/ECS gas cooler. It is relatively
simple to subsequently reconfigure it on site at the user location. The location for installation of the
LED function display will be marked correspondingly.
The casing depth of the EC-.. cooler is 450mm. The ECS cooler unit differs in its less casing depth of
360mm and thereby is appropriate for mounting in a gas analysis cabinet with swing frame.
On the upper side of the cooler casing you will see the cut-outs for maximum 4 heat exchangers.
Sample gas enters and leaves the heat exchangers by the correspondingly connections on the upper
part of the heat exchangers.
At the rear part of the casing the condenser to remove heat given off in the compressor can be
seen.
The EC automatic control board is located in the plastic housing behind the removable front panel
of the EC/ECS casing.
On the underside of the casing the following connections are provided as standard:
Standard condensate outlets from the heat exchangers respectively,
Cable glands PG 13,5;
As standard, the condensate is removed externally with collecting vessels, peristaltic pumps SR25.1,
or by “over-pressure operation”, with automatic drawing-off of condensate, as e.g. type AD-... .
The heat energy from the cooling system is drawn off by a forced-ventilation . The required fans
and large air suction filter elements are provided as standard in This is arranged below the EC/ECS
casing and is absolutely essential for operation of the cooler unit.
Optionally, the automatic condensate removal unit EC-FD (10) with maximum 4 peristaltic pumps
SR25.1 (13) can by mounted by factory below the casing of the EC/ECS cooler. The fans and large
air suction filter elements guarantee the above-mentioned condenser forced ventilation and make
operation at higher ambient temperatures up to +50°C possible. The connection for the common
condensate outlet (12) is located in the front panel of the EC-FD unit.
If no forced ventilation for the condenser is required, peristaltic pumps type SR25.2 can be build into
the front plate of the cooler (Part No. 01P9140).
Figure 3 Peristaltic pump SR25.2 mounted into the front panel
Instead of the unit EC-FD the universal unit EC-F optionally can be used for operation at higher
ambient temperatures up to +50°C without automatic condensate removal. The unit is mounted by
factory below the casing of the EC/ECS cooler and contains as well the above mentioned fans with
large air suction filter elements.
Gas sampling and gas conditioning technology 3-4.1-ME
12
+5°C
Sample gas
out
Sample gas
in
Condensate out
Coolingblock
10 FUNCTION
The M&C EC/ECS gas cooler is a compressor cooler with status alarm capability. This ensures 100%
availability of the cooler.
Up to 4 Jet-stream heat exchangers made of Duran 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..
Figure 4 Schematic diagram of functioning of heat exchanger
The compressor cooler system has a heat-insulated cooling block at a constant temperature of +5°C.
Control of the compressor for models as from serial numbers 95... is done contactless by the EC
automatic control electronics and is therefore not subject to wear.
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.
Alarm warnings for excess- and low-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) .
Gas sampling and gas conditioning technology 3-4.1-ME
Loading...