AGT PSG MAK10 Installation Manual, Operating Manual, Maintenance Manual, Spare Part List Download Page 1

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MAK10
Sample Gas Conditioner

Installation Manual
Operating Manual

Maintenance Manual
Spare Part List

Summary of Contents for PSG MAK10

Page 1: ...MAK10 Sample Gas Conditioner Installation Manual Operating Manual Maintenance Manual Spare Part List ...

Page 2: ...ipment and 93 68 EWG CE marking guideline It corresponds to the essential requirements of these guidelines The following harmonized standards in actual revision have been used DIN EN ISO 12100 1 2 security of machines EN 983 security of pneumatics EN 378 1 bis 4 refrigerant plants and heat pumps EN 60335 2 34 electrical security engine compressors EN 61326 1 EMC general requirements EN 61000 6 2 E...

Page 3: ...he continuous technical evolution we reserve the right to introduce any necessary change without giving previous notice This manual must be maintained available in any moment for future references and it has to be intended as inherent part of the sample gas cooler These operating instructions must be continuously available at the site where the sample gas cooler is used We recommend to prepare a c...

Page 4: ...are excluded Wear parts and operating supplies damages caused by improper installation damages cause by improper use or overload of the cooler damages cause by lack of service damages caused by events which are not within the sphere of influence of the manufacturer Tampering the safety and security devices is not permissible In the case of warranty claims the sample gas cooler has to be in its ori...

Page 5: ...lled workers of the producer are authorized to work on the refrigeration system After this through well experienced staff according DIN EN 378 The operator of the sample gas cooler must keep it in good condition operate it correctly monitor and maintain it regulary Safety Indications DANGER Supply voltage Only qualified personnel are authorized to maintain and to operate electrically powered devic...

Page 6: ...ee and protected site at a temperature of 2 65 C and a non condensing specific humidity of 20 80 Should the stocking time exceed 6 months please contact the manufacturer NOTICE Recycling The packaging materials are recyclable Dispose of material in compliance with the rules and regulations in force in the destination country If damages are discovered after initial operation the user is committed t...

Page 7: ... use the existing fastening points of the housing The dryer has to be mounted in perfect upright position Ensure unhindered cooling air circulation while installing the sample gas cooler Do not install the sample gas cooler directly over under or beneath possible sources of heat CAUTION Ambient conditions Do not install the cooler in areas of extreme dust and dirt or in corrosive environment CAUTI...

Page 8: ...ng feed lines must be connected Sample gas pipelines to the gas inlet connections Analyzers to the gas outlet connections Condensate pumps tanks to the condensate outlet connections Marking Gas inlet Marking Gas outlet Gas inlet left Gas outlet right Condensate outlet Depending on model type your sample gas cooler can be equipped with without condensate pumps Some model types can be equipped with ...

Page 9: ... a flexible modular sample gas connection system The media connections can be on the top panel standard housing or on the rear panel 19 rack housing As a standard the media connections are designed as PVDF screwed joints for 6 4mm hose drawing A Optionally they can be designed as stainless steel bolt joints for 6 4mm hose drawing B Beyond that several other connection variants are optionally avail...

Page 10: ... tight drainage eg peristaltic pump float drain condensate tank etc For each gas path and condensate outlet a separate drain must be provided Without suitable condensate drainage the device will not function properly Lay the condensate drain line outside the device with an adequately dimensioned gradient and without counter pressure Avoid unwanted pipe bends and level differences as well If the de...

Page 11: ...the dryer while keeping into account also the ambient temperature the conditions of the mains installation the length of the cables and the requirements enforced by the local power provider Also requirements of VDE 0100 as well as relevant standards and guidelines must be adhered to while setting up high voltage devices with rated voltages of up to 1000V The local protection of the sample gas cool...

Page 12: ...onnecting components Conntecting the contact strip Contact 11 13 Operational monitoring of moisture guard 2 optional Contact 9 10 Connection of external moisture guard 2 optional Contact 6 8 Operational monitoring of moisture guard 1 optional Contact 4 5 Connection of external moisture guard 1 optional Contact 1 3 Standard operational monitoring of the sample gas cooler Contacts 4 8 are only activ...

Page 13: ...uous motor gearbox with return stop Slow speed hose with long service life Can operate in any installed position Filter optional In gas analytic systems occuring solid contaminants especially fine particles up to 0 1 micron are reliably filtrated by this teflon depth filter The large filter surface of ca 67 m of the cylindrical filtercartridge ensures a reliable micro filtration and a long service...

Page 14: ...o 150 l h for 19 rack models 90 installation position FEATURES FM140 FM150 Dosage of aggressive gaseous media With fine adjustment valve High chemical resistance Optional light barrier Optional electronic control Condensate Pre Separator optional Condensate pre separators can be used for measuring points at high inlet temperatures of up to 160 C and high inlet dew points greater than 65 C The capa...

Page 15: ...est amounts of liquid will trigger a fast and reliable alarm Control alert served by an appropriate electronic control FEATURES MS Protection against condensate break through Reliable detection of smallest amounts of liquid Line break monitoring High chemical resistance Optional electronic control Electronic Control Unit optional The electronic control unit serves moisture sensors and light barrie...

Page 16: ...ixed in a swirl line FEATURES AI Reduction of SO2 loss Washing of alkaline gases Acid dosage by peristaltic pump Dosage 12ml h or 42ml h Injection with swirl line Sample Gas Pump optional Into the cooler integrated sample gas pumps transport continuously and reliably the sample gas through the whole system There are several pump model types available optimized for different applications All pumps ...

Page 17: ...n to avoid consequential damage First actions could be to switch off the sample gas flow and the main power connection Qualified personnel must perform the start up When installing and operating this equipment comply with all national electrical code and any applicable federal state and local codes Who is operating the unit is responsible for the proper and safe operation of the cooler CAUTION Exc...

Page 18: ...switched off Step 2 Cooler start up Switch on the power supply Then switch on the on off switch of the cooler After switching on the on off switch the cooler will start Wait some minutes until the cooler reached its operating temperature Step 4 Sample gas feed Slowly load the cooler with sample gas Check the connections and the piping for gas leakage Ensure that the condensate draining works WARNI...

Page 19: ...Then switch off the power supply Double check very carefully Step 1 and Step 3 Ensure that the sample gas feed is stopped and the power supply is really switched off Unplug the sample gas cooler CAUTION Follow system and process specific safety measures System and process specific safety measures must be followed before decommissioning Dismantling Dismantling of the Sample Gas Cooler If the cooler...

Page 20: ...nitoring and Error Diagnosis Digital Display Control MAK10 The digital display control MAK10 controls all the operations the alarms and the operational setting of the cooler MAK10 has a multi function LCD display 3 operation status indicators ALARM SERVICE POWER and 3 buttons ON OFF MODE SET CAUTION Warranty lost A change of the original setup may lead to a total loss of warranty ...

Page 21: ...Lo temperature is displayed again if a keypad input is not given within 10 seconds Changing operation modes Press the button once for 2 seconds mode for changing the switch on time of the condensate pumps The switch on time of the condensate pump can be changed when button 2 is pressed one or more times Setting range 2 10 min Press the button once for 2 seconds and then press it once mode for chan...

Page 22: ... or extreme exceed of maintenance interval Service Alarm When the red yellow and the green LEDs light up it indicates that the service interval has exceeded twice the scheduled service period over 9000 operating hours The potential free alarm contact remote monitoring connection is activated Temperature Alarm A temperature overshoot TLo 0 5 C 34 F or 10 0 C 50 F TA 5 0 C 41 F or 45 0 C 113 F has b...

Page 23: ...the operation buttons 2 TEMP and 3 MODE the operating hours counter can be reset to zero This action should take place only after proper maintenance of the cooler Service required The sample gas cooler must be serviced Alarm Service or temperature alarm has been activated Alarm log An alarm notification has been activated Alarm log indicator The indicator is switched off as soon as all new logged ...

Page 24: ...tion contaminated Replace filtercartridge Condensate in gas outlet Gas inlet outlet connected incorrectly Connect gas inlet outlet correctly Condensate outlet blocked Clear condensate outlet check installation Condensate in gas inlet Ensure pre separation check installation Too high gas flow rate Reduce gas flow rate adhere to operation data Temperature 10 C Sample gas cooler overloaded Check oper...

Page 25: ...ery 3 months as a precautionary measure Depending on the sample gas quality the filter option will show different degrees of contamination We recommend replacement of the filter cartridge every 3 months as a precautionary measure Only qualified personnel should perform troubleshooting maintenance or repair operations Make sure that maintenance personnel have read and understand the safety and oper...

Page 26: ...mps especially the condition of the pump hoses Check the filter option for contamination Maintenance yearly or every 3000 hours of operation Verify for tightness all the screws of the electric system inspect the cables Replace the fuse Clean the cooling units fins Visual inspection of heat exchanger unit and insulation Replace the pump hoses if necessary replace roller carriers and conveying belts...

Page 27: ... the heat exchanger unit Inspect the heat exchange unit and its insulation visually for damage or condensate formation The formation of condensate indicates damaged insulation and refrigeration loss The consequences can be increased energy consumption and reduced performance of the device Maintenance operation on the condensate pump s When the condensate pump is operated for a long time the pump h...

Page 28: ...ter casing can then be removed Notice The filter glass may slip out of the clamping nut Protect the filter glass from falling After unscrewing the clamping nut the filter cartridge can be replaced by taking it out an inserting a new one The clamping nut must now be fixed along with the filter glass Reset the operating hours counter By simultaneously pressing 2 sec the operation buttons 2 TEMP and ...

Page 29: ...densate Pump Article Description Type Article No Complete condensate pump SR25 5u min installation version 6406008 Replacement hose set N3 2x1 6mm with bolted joint 210ml h Standard 8600002 Replacement hose set N4 1x1 6mm with bolted joint 210ml h Special 8600004 Replacement roller carrier 6406053 Replacement conveying belt 6406061 Filter Option Article Description Type Article No Complete filter ...

Page 30: ...oupling PVDF G1 8 DN4 6 6353979 Acid Injection Option Article Description Type Article No Complete condensate pump SR25 1u min installation version 6406008 Replacement hose set N3 2x1 6mm with bolted joint 42ml h Standard 8600002 Replacement hose set N1 6x1 6mm with clamps 12ml h Special 8480177 Replacement roller carrier 6406053 Replacement conveying belt 6406061 Heat Exchanger Article Descriptio...

Page 31: ... is best to tie down the individual package on a pallet Do not stack Mark your package with appropriate icons Fill in this form and the subsequent declaration of decontamination completely Send the device along with the forms DDP Delivery Duty Paid AGT PSG will only accept deliveries if freight and customs are fully paid to AGT PSG GmbH Co KG Richard Lucas Straße 6 41812 Erkelenz Germany Inform AG...

Page 32: ...the declaration to the packing Otherwise your repair cannot be processed Device Articlenumber Serialnumber Reason for return I herewith declare that the device specified above has been properly cleaned and decontaminated and that there are no risks present when dealing with the device In other cases please describe the hazards in detail Explosives Acute toxicity Flammable Oxidizing Environmental h...

Page 33: ...llation Operating Maintenance Manual Spare part List MAK10 AGT PSG GmbH Co KG Errors and printing mistakes excepted Page 33 Translation Manual MAK10 Rev 11 2017 Circuit Diagram 230V 50 60Hz and 115V 50 60Hz ...

Page 34: ...tion Operating Maintenance Manual Spare part List MAK10 AGT PSG GmbH Co KG Errors and printing mistakes excepted Page 34 Translation Manual MAK10 Rev 11 2017 Circuit Diagram Addendum for Sample Gas Pump Option ...

Page 35: ... and printing mistakes excepted Page 35 Translation Manual MAK10 Rev 11 2017 RI Flow Schema Scope of supply of MAK10P Heat exchanger Condensate pump Pre separator Filter Flowmeter Electronic control unit Moisture sensor MAK10 1101 X 00 X MAK10 1101 X 10 X MAK10 1101 X 11 X MAK10 1101 X 1F X ...

Page 36: ...and printing mistakes excepted Page 36 Translation Manual MAK10 Rev 11 2017 RI Flow Schema Scope of supply of MAK10P Heat exchanger Condensate pump Pre separator Filter Flowmeter Electronic control unit Moisture sensor MAK10 1112 X 00 X MAK10 11121 X 11 X MAK10 2202 X 00 X MAK10 2202 X 20 X ...

Page 37: ... and printing mistakes excepted Page 37 Translation Manual MAK10 Rev 11 2017 RI Flow Schema Scope of supply of MAK10P Heat exchanger Condensate pump Pre separator Filter Flowmeter Electronic control unit Moisture sensor MAK10 2202 X 22 X MAK10 2202 X 1F X MAK10 2222 X 00 X MAK10 2224 X 22 X ...

Page 38: ... and printing mistakes excepted Page 38 Translation Manual MAK10 Rev 11 2017 RI Flow Schema Scope of supply of MAK10P Heat exchanger Condensate pump Pre separator Filter Flowmeter Electronic control unit Moisture sensor MAK10 3303 X 00 X MAK10 3303 X 1F X MAK10 4404 X 00 X MAK10 4404 X IF X ...

Page 39: ...ration pressure 210kPa This expanded and fluid refrigerant flows through the evaporator of the heat exchanger By energy input of the heat exchanger the fluid refrigerant evaporates and cools down the passed through sample gas to a temperature of 3 C Over the steam dome the refrigerant compressor sucks again the vaporous refrigerant Over the power regulator the sample gas conditioner performs a sel...

Page 40: ...ating Maintenance Manual Spare part List MAK10 AGT PSG GmbH Co KG Errors and printing mistakes excepted Page 40 Translation Manual MAK10 Rev 11 2017 Dimension Sheets MAK10 1101 4 00 X MAK10 1101 4 10 X MAK10 1101 4 11 X ...

Page 41: ...tion Operating Maintenance Manual Spare part List MAK10 AGT PSG GmbH Co KG Errors and printing mistakes excepted Page 41 Translation Manual MAK10 Rev 11 2017 Dimension Sheets MAK10 1112 4 00 X MAK10 1112 4 11 X ...

Page 42: ...ating Maintenance Manual Spare part List MAK10 AGT PSG GmbH Co KG Errors and printing mistakes excepted Page 42 Translation Manual MAK10 Rev 11 2017 Dimension Sheets MAK10 2202 4 00 X MAK10 2202 5 20 X MAK10 2202 5 22 X ...

Page 43: ...tion Operating Maintenance Manual Spare part List MAK10 AGT PSG GmbH Co KG Errors and printing mistakes excepted Page 43 Translation Manual MAK10 Rev 11 2017 Dimension Sheets MAK10 2202 5 1F X MAK10 2224 5 00 X ...

Page 44: ...tion Operating Maintenance Manual Spare part List MAK10 AGT PSG GmbH Co KG Errors and printing mistakes excepted Page 44 Translation Manual MAK10 Rev 11 2017 Dimension Sheets MAK10 2224 5 22 X MAK10 3303 5 00 X ...

Page 45: ...tion Operating Maintenance Manual Spare part List MAK10 AGT PSG GmbH Co KG Errors and printing mistakes excepted Page 45 Translation Manual MAK10 Rev 11 2017 Dimension Sheets MAK10 3303 5 1F X MAK10 4404 5 00 X ...

Page 46: ...tion Operating Maintenance Manual Spare part List MAK10 AGT PSG GmbH Co KG Errors and printing mistakes excepted Page 46 Translation Manual MAK10 Rev 11 2017 Dimension Sheets MAK10 4404 6 1F X 19 Rack Versions ...

Page 47: ... separators Number of teflon filtes 1 1 Number of electronic controls 1 1 Number of flowmeters 1 Operation data Gas flow per gas path at 65 55 tp 125Nl h 2 0lpm 175Nl h 2 9lpm Ready for start up 5min Design data Dimensions BxHxT 310mm x 266mm x 321mm Weight 17 3kg 17 4kg Electrical data Power consumption 220W ta 45 C General Data Operation data Gas temperature at inlet max 140 C Ambient temperatur...

Page 48: ...tors Number of teflon filtes 1 Number of electronic controls 1 Number of flowmeters 1 Operation data Gas flow per gas path at 65 55 tp 125Nl h 2 0lpm 175Nl h 2 9lpm Ready for start up 10min Design data Dimensions BxHxT 310mm x 266mm x 321mm 449mm x 266mm x 321mm Weight 18 2kg 20 6kg Electrical data Power consumption 220W ta 45 C General Data Operation data Gas temperature at inlet max 140 C Ambien...

Page 49: ...pre separators 2 2 Number of teflon filtes 2 Number of electronic controls 2 Number of flowmeters Operation data Gas flow per gas path at 65 55 tp 150Nl h 2 5lpm 200Nl h 3 3lpm Ready for start up 10min Design data Dimensions BxHxT 449mm x 266mm x 321mm Weight 21 1kg 22 0kg Electrical data Power consumption 220W ta 45 C General Data Operation data Gas temperature at inlet max 140 C Ambient temperat...

Page 50: ...4 Number of pre separators Number of teflon filtes 1 Number of electronic controls 1 Number of flowmeters 1 Operation data Gas flow per gas path at 65 55 tp 100Nl h 1 7lpm 140Nl h 2 3lpm Ready for start up 15min Design data Dimensions BxHxT 449mm x 266mm x 321mm 587mm x 266mm x 321mm Weight 22 6kg 25 1kg Electrical data Power consumption 300W ta 45 C General Data Operation data Gas temperature at ...

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