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Gas Analysis
Sample gas cooler
EGK 2A Ex
Installation and Operation Instructions
Original instructions
BE450020
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
01/2020
Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20
E-Mail: analyse@buehler-technologies.com
Internet: www.buehler-technologies.com
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Summary of Contents for Bühler technologies EGK 2A Ex
- Page 1 Gas Analysis Sample gas cooler EGK 2A Ex Installation and Operation Instructions Original instructions BE450020 Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen 01/2020 Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20 E-Mail: analyse@buehler-technologies.com...
- Page 2 Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20 Internet: www.buehler-technologies.com E-Mail: analyse@buehler-technologies.com Read this instruction carefully prior to installation and/or use. Pay at- tention particularly to all advises and safety instructions to prevent in- juries.
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Page 3: Table Of Contents
EGK 2A Ex Contents Introduction............................................. 3 Intended use ......................................... 3 Design types.......................................... 3 Type plate .......................................... 3 Scope of delivery ........................................ 3 Ordering instructions ...................................... 4 Safety instructions......................................... 6 Important notices........................................ 6 General hazard warnings .................................... 7 Product description ........................................ 9 General description ...................................... 9 Functional principle of the cooler .................................. 9... - Page 4 EGK 2A Ex 12.1 Technical Data........................................ 31 12.2 Dimensions ......................................... 32 12.3 Heat exchanger........................................ 32 12.3.1 Heat exchanger description ................................ 32 12.3.2 Heat exchanger overview................................. 33 12.4 Performance data...................................... 33 13 Attached documents ........................................ 34 Bühler Technologies GmbH BE450020 ◦ 01/2020...
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Page 5: Introduction
1.3 Type plate Example: Notified body identification number Manufacturer and address 0158 Model designation EGK 2A Ex, 230V 50/60Hz Temperature range -20 °C ≤ Ta ≤ 45 °C Serial no., year of manufacture [serial number] [MM/YYYY] ATEX certificate no. BVS 03 ATEX E 301 X... -
Page 6: Ordering Instructions
EGK 2A Ex 1.5 Ordering instructions The item number is a code for the configuration of your unit. Please use the following model key: Please note: Every individual gas path must be equipped with condensate drain. 4590 X X X X X X X... - Page 7 EGK 2A Ex 4590 X X X X X X X 1 Product characteristics (US connections) Voltage 115 V 230 V Gas path/material/version 0 0 0 without heat exchanger 1 gas path/material/version 1x single heat exchanger/stainless steel/TS-I 1x single heat exchanger/glass/TG-I...
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Page 8: Safety Instructions
EGK 2A Ex 2 Safety instructions 2.1 Important notices NOTICE The device is suitable for hazardous areas. This unit may only be used if: – The product is being used under the conditions described in the operating- and installation instructions, used according to the nameplate and for applications for which it is intended. -
Page 9: General Hazard Warnings
EGK 2A Ex 2.2 General hazard warnings The equipment must be installed by a professional familiar with the safety requirements and risks. Be sure to observe the safety regulations and generally applicable rules of technology relevant for the installation site. Prevent malfunctions and avoid personal injuries and property damage. - Page 10 EGK 2A Ex DANGER Toxic, corrosive gas/condensate Sample gas/condensate may be hazardous to health. a) If necessary, ensure a safe gas/condensate discharge. b) Always disconnect the gas supply when performing maintenance or repairs. c) Protect yourself from toxic/corrosive gasses/condensate when performing mainten- ance.
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Page 11: Product Description
EGK 2A Ex 3 Product description 3.1 General description A sample gas cooler is used to lower the moisture content, thus the dew point of a sample gas. This is intended to on one hand lower measurement accuracies through volume influence, on the other to avoid for moisture to condense further along the measuring path and cause damage, particularly to the delicate measuring cell of the analyser. -
Page 12: Transport And Storage
EGK 2A Ex 4 Transport and storage The sample gas cooler must be transported in the original packaging or a suitable alternative. It must be transported upright. Never place it on its side during transport, as oil could otherwise leak from the compressor and enter the cooling circuit. This can result in cooler start-up problems or failure. -
Page 13: Installation And Connection
EGK 2A Ex 5 Installation and connection 5.1 Installation site requirements The unit is intended for use in enclosed areas. Adequate protection from the weather must be provided when used outdoors. The approved environmental conditions for explosive areas according to the enclosed data sheet must be met. -
Page 14: Peristaltic Pump Connector (Optional)
EGK 2A Ex When using automatic condensate drains, the gas pump must be installed ahead of the cooler to ensure proper function of the condensate drain. If the sample gas pump is located at the cooler outlet (suction operation), we recommend using glass condensate collectors or peristaltic pumps. - Page 15 EGK 2A Ex The sample gas cooler may only be operated with a suitable protective motor switch as overload protection. A suitable approved version of the protective motor switch protected against explosion is required when installing in an explosive area. A selection...
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Page 16: Testing Insulation Resistance
EGK 2A Ex 5.5 Testing insulation resistance CAUTION High voltage Insulation test will damage the device Do not test the electric strength if the entire unit is under high voltage! If you wish to check the electric strength again yourself, only do so on the following individual components using 500 VDC. -
Page 17: Operation And Controls
EGK 2A Ex 6 Operation and controls NOTICE The device must not be operated beyond its specifications. CAUTION Hot surface Risk of burns Depending on the operating parameters, the air heat exchanger at the back of the cooler can reach a temperature of up to 80 °C during operation. -
Page 18: Use Of Menu Functions
EGK 2A Ex 6.2 Use of menu functions Overview of the operational principal: Use this short description if you have experience with the device. Operation is carried out by only the keys with the following functions: Function – Switch from measurement display to main menu –... -
Page 19: Detailed Description Of The Operational Principle
EGK 2A Ex 6.2.2 Detailed description of the operational principle The detailed description will guide you through the menu step by step. Connect the unit to the power supply and wait for the startup procedure to complete. At first the software version im- plemented on the unit will be displayed for a brief period. -
Page 20: Submenu
EGK 2A Ex 6.3.2 Submenu Cooler -> nominal temperature (temperature) This setting determines the nominal temperature for the cooler temperature. The value can be set to a range from 2 °C (35.6 °F) to 20 °C (68 °F). Note: The standard value at delivery is 5 °C (41 °F) (unless otherwise agreed). If the temperature is changed the indicator may blink, until the new operating range has been reached. -
Page 21: Maintenance
EGK 2A Ex 7 Maintenance During maintenance, remember: – The equipment must be maintained by a professional familiar with the safety requirements and risks. – Only perform maintenance work described in these operating and installation instructions. – When performing maintenance of any type, observe the respective safety and operation regulations. -
Page 22: Maintenance Schedule
EGK 2A Ex 7.1 Maintenance Schedule Component Interval* Work to be performed To be performed by Pressure switch every 8,000 h or 1 year Test per chapter Testing the pressure monitoring cir- Customer cuit [> page 20] Starting capacitor every 8,000 h or 1 year... -
Page 23: Cleaning The Condenser (Air Heat Exchanger)
EGK 2A Ex 7.2.2 Cleaning the condenser (air heat exchanger) Looking from the top, at the back of the sample gas cooler you will see the ribs of the condenser, protected by a cover. These should be clean to ensure heat is removed adequately. They only need to be cleaned if large amounts of dust or deposits are vis- ible. -
Page 24: Replacing The Electronics
EGK 2A Ex – Close the terminal box observing the following items: No foreign objects, contaminants or moisture may be inside it. Tighten the terminal box at a tightening torque of 4 Nm, dust- and waterproof (be sure not to crush any cables!). -
Page 25: Replacing The Display
EGK 2A Ex – Close the terminal box observing the following items: No foreign objects, contaminants or moisture may be inside it. Tighten the terminal box at a tightening torque of 4 Nm, dust- and waterproof (be sure not to crush any cables!). -
Page 26: Service And Repair
EGK 2A Ex 8 Service and repair This chapter contains information on troubleshooting and correction should an error occur during operation. Repairs to the unit must be performed by Bühler authorised personnel. Please contact our Service Department with any questions: Tel.: +49-(0)2102-498955 or your agent... -
Page 27: Safety Instructions
EGK 2A Ex Problem / Malfunction Possible cause Action Reduced gas flow rate – Gas circuit clogged – Remove and clean or replace heat ex- changer per chapter Replacing the starting capacitor – Heat exchanger iced over – Remove and send in cooler Protective device is –... -
Page 28: Checking/Resetting Pressure Monitoring Switches
EGK 2A Ex 8.3 Checking/Resetting Pressure Monitoring Switches – Observe the warnings under Maintenance. – Switch off the cooler power supply and secure against restarting. – Remove the cover for the pressure controls, between the cooling block and electronics hous- ing. -
Page 29: Spare Parts And Accessories
EGK 2A Ex 8.6 Spare parts and accessories Please also specify the model and serial number when ordering parts. Upgrade and expansion parts can be found in our catalog. Available spare parts: Item no. Description 45 90 999 6 Pt100... -
Page 30: Disposal
EGK 2A Ex 9 Disposal The refrigerant circuit of the cooler contains R134a refrigerant. In EU member states, as per Directive 2012/19/EU, device with electrical components must be recycled separately. Dispose of parts so as not to endanger the health or environment. Follow the laws in the country of use for disposing of elec- tronic components and devices as well as hazardous materials during disposal. -
Page 31: Durability List
EGK 2A Ex 10 Durability list Heat exchanger: TS, DTS TG, DTG TV, DTV Formula Medium Concentration Glass (Teflon PVDF coated seal) COCH Acetone Benzol Chlorine 10 % wet Chlorine 97 % Ethane Ethanol 50 % Ethylene Ethyne Ethylbenzene Hydrofluoric acid... -
Page 32: User Book (Please Make Copies)
EGK 2A Ex 11 User book (Please make copies) Maintained on Unit no. Operating hours Remarks Signature 30 Bühler Technologies GmbH BE450020 ◦ 01/2020... -
Page 33: Appendices
EGK 2A Ex 12 Appendices 12.1 Technical Data Gas Cooler Technical Data ATEX approval II 2 G Ex pxb eb mb q [ia] IIC T4 Gb IECEx approval Ex pxb eb mb q [ia] IIC T4 Gb Ready for operation after max. -
Page 34: Dimensions
EGK 2A Ex 12.2 Dimensions Mounting holes 445 x 420 x Ø10 (wide x high x diameter) 12.3 Heat exchanger 12.3.1 Heat exchanger description The energy content of the sample gas and the required cooling capacity of the gas cooler is determined by three parameters: gas temperature ϑ... -
Page 35: Heat Exchanger Overview
EGK 2A Ex 12.3.2 Heat exchanger overview Heat exchanger TV-SS DTS (DTS-6 2) 3) TS-I TV-SS-I DTS-I (DTS-6-I DTV-I Version/Material Stainless steel Glass PVDF Stainless steel Glass PVDF Flow v 530 L/h 280 L/h 125 L/h 2 x 250 L/h... -
Page 36: Attached Documents
EGK 2A Ex 13 Attached documents – Wiring diagram: 47/170-10-3 – Declaration of Conformity KX450007 – Gas Cooler Examination Certificate – Examination Certificate for Components – RMA - Decontamination Statement Bühler Technologies GmbH BE450020 ◦ 01/2020... - Page 37 PE-Sammelschiene...
- Page 53 C E R T I F I C A T I O N EC TYPE-EXAMINATION CERTIFICATE Component intended for use in Potentially Explosive Atmospheres Directive 94/9/EC Certificate Number: Sira 99ATEX3172U Issue: Component: BPG Range of Enclosures Applicant: ABTECH Limited Address: Sanderson Street Lower Don Valley Sheffield S9 2UA...
- Page 54 C E R T I F I C A T I O N SCHEDULE EC TYPE-EXAMINATION CERTIFICATE Sira 99ATEX3172U Issue 6 DESCRIPTION OF COMPONENT The BPG range of enclosures are manufactured from polyester in the following sizes: Length Width Height Reference (mm) (mm)
- Page 55 C E R T I F I C A T I O N SCHEDULE EC TYPE-EXAMINATION CERTIFICATE Sira 99ATEX3172U Issue 6 Variation 3 - This variation introduced the following changes: Following appropriate re-assessment to demonstrate compliance with the requirements of the EN 60079 series of standards, the documents previously listed in section 9, EN 50014:1997, EN 50019:1994 and EN 50281-1-1:1999, were replaced by those currently listed, the markings in section 12 were updated accordingly.
- Page 56 C E R T I F I C A T I O N SCHEDULE EC TYPE-EXAMINATION CERTIFICATE Sira 99ATEX3172U Issue 6 CONDITIONS OF CERTIFICATION 17.1 The use of this certificate is subject to the Regulations Applicable to Holders of Sira Certificates. 17.2 Holders of EC type-examination certificates are required to comply with the production control requirements defined in Article 8 of directive 94/9/EC.
- Page 57 Certificate Annexe Certificate Number: Sira 99ATEX3172U Component: BPG Range of Enclosures C E R T I F I C A T I O N Applicant: ABTECH Limited Issue 0 and 1: The drawings associated with these Issues were rationalised by those listed in Issue 2. Issue 2 Number Sheet...
- Page 58 ABTQ-29 rev 03 (Last review: 21 Jul 12) INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR ABTECH ‘BPG’ Range Enclosures – SIRA 99ATEX3172U Marking The marking shown is for a component certified enclosure. The user must submit the completed unit for type examination if it is to be used in a hazardous TYPE BPG area.
- Page 59 ABTQ-29 rev 03 (Last review: 21 Jul 12) and where a window is fitted metallic slotted trunking must be used. Trunking may be mounted in any orientation in the box, vertically, horizontally or diagonally. Secure the lid by closing the lid and tightening the lid fixing screws. Earthing/Grounding The enclosure may be provided with an external earth/ground connection.
- Page 60 RMA-Formular und Erklärung über Dekontaminierung RMA-Form and explanation for decontamination RMA-Nr./ RMA-No. Die RMA-Nummer bekommen Sie von Ihrem Ansprechpartner im Vertrieb oder Service./ You may obtain the RMA number from your sales or service representative. Zu diesem Rücksendeschein gehört eine Dekontaminierungserklärung. Die gesetzlichen Vorschriften schreiben vor, dass Sie uns diese Dekontaminierungserklärung ausgefüllt und unterschrieben zurücksenden müssen.
- Page 61 Dekontaminierungserklärung DE000011 Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen 01/2019 Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20 E-Mail: service@buehler-technologies.com Internet: www.buehler-technologies.com...
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