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Gas Converter CG

®

CG-2/-2M, CG-2H-W/-2MH-W

Instruction Manual
Version 1.04.00

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Summary of Contents for CG Series

Page 1: ...Gas Converter CG CG 2 2M CG 2H W 2MH W Instruction Manual Version 1 04 00 ...

Page 2: ...on t hesitate to contact M C or your M C authorized distributor You will find all the addresses in the appendix of this manual For additional information about our products and our company please go to M C s website www mc techgroup com There you will find the data sheets and manuals of all our products in German and English This Operating Manual does not claim completeness and may be subject to t...

Page 3: ...he CG 18 12 Storage 18 13 Installation instructions 18 14 Supply connections 19 14 1 Hose tube connections 19 14 2 Electrical connections 20 15 Starting up 21 16 Closing down 22 17 Determining the catalyst service life 22 17 1 Check of the efficiency 24 17 2 Conversion ppm mg m3 24 18 Maintenance 25 18 1 Replacing the catalyst cartridge 25 18 2 Replacing the o ring seals 26 18 3 Checking for gas t...

Page 4: ...g on the NO2 concentration for varying flow rates and an Oxygen concentration of 5 vol 23 Figure 8 Catalyst life time depending on the NO2 concentration for varying flow rates and an Oxygen concentration of 10 vol 23 Figure 9 Catalyst life time depending on the NO2 concentration for varying flow rates and an Oxygen concentration of 21 vol 23 Figure 10 Adapter for catalyst cartridge with handle 26 ...

Page 5: ...ualified personnel Please follow all instructions and warnings closely Please read this manual carefully before commissioning and operating the device If you have any ques tions regarding the product or the application please don t hesitate to contact M C or your M C au thorized distributor 2 DECLARATION OF CONFORMITY CE Certification The product described in this operating manual complies with th...

Page 6: ...nnected Operate the device only in the permitted temperature and pressure ranges For details please refer to the technical data sheet or manual Install the device only in protected areas sheltered from sun rain and moisture The product should not be exposure to the elements The converter CG is NOT certified to be installed or operated in explosive hazardous areas Installation maintenance inspectio...

Page 7: ...ional status may occur in case the respective note is not respected NOTE These are important information about the product or parts of the op erating 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 Risk of fire hazard Highly flamable materials are present There is an imminent fi...

Page 8: ...8 CG 2 1 04 00 www mc techgroup com Hot surface Contact may cause burn Do not touch ...

Page 9: ... heating circuit for hot gas conversion For test purposes the catalyst can be bypassed via two 3 2 way solenoid valves out of PVDF with version CG 2M and one solenoid valve out of stainless steel with version CG 2MH W The solenoid valves can be controlled internally or externally The versions CG 2 and CG 2H W are delivered without bypass valves The M C gas converters CG 2 and CG 2M are designed as...

Page 10: ... Valve not with version CG 2 Y 2 3 2 Way Solenoid Valve not with version CG 2 Figure 1 Functional diagram of CG 2 and CG 2M A Temperature Status Alarm B Connection for Power Supply C Sample Gas Inlet D Sample Gas Outlet B 1 0 Temperature Controller B 1 1 Temperature Alarm B 1 2 Temperature Display E 1 Tube Furnace E2 Heating bar sample gas inlet and outlet and Y1 Y 1 3 2 Way Solenoid Valve not wit...

Page 11: ... this type of catalyst a nearly complete conversion of NO2 to NO is achieved within a temperature range of 320 to 380 C 608 to 716 F The catalyst is supplied as a ready to use formatted cartridge NOTE Dust loaded gases may choke up the catalyst filling For this reason an ap propriate gas conditioning system is to be mounted upstream of the convert ers CG in order to separate out suspended particle...

Page 12: ...n N2 is possible Alternatively to type C a cartridge with metal filling type SS is available It is possible to convert NO2 concentrations of up to 2000 ppm into NO A temperature adaption might also be necessary Figure 3 Notch to differentiate the two cartridge types NOTE For catalyst type SS oxygen in the sample gas as well as in the test gas 1 vol O2 is necessary A calibration with NO2 in N2 is n...

Page 13: ...nverter and catalyst types we got a lot of experiences about influencing factors on the NO2 NO conversion process The following hints make no claim to be complete but can help choosing the ade quate catalyst type as well as give an indication for the integration of the CG converter into a certain system environment In practice often several influencing factors have any effect at the same time With...

Page 14: ... Therefore a SO2 measurement should not be installed downstream the con verter with catalyst type SS but with a separate sample gas way NOTE Ammonia NH3 In the operating temperature range of the catalyst type SS of 600 C 1112 F existing concentrations of ammonia are almost completely transformed into NO if as required for type SS enough oxygen is in the sample gas In the operating temperature rang...

Page 15: ...ifferential pressure 20 60 mbar depending on type Ambient temperature 10 to 50 C 50 to 122 F Storage temperature 25 to 65 C 13 to 149 F Relative air humidity 80 Connection sample gas inlet and outlet PVDF fitting G1 4 i DIN 228 1 ø6 mm tube fitting 1 4571 316Ti Power 230 V 48 62 Hz or 115 V 48 62 Hz a 230 V 48 62 Hz or 115 V 48 62 Hz a Power consumption 520 W 620 W 940 W Electrical connections Mai...

Page 16: ... outlet G1 4 i sample gas inlet G1 4 with CG 2 2M sample gas inlet 6mm tube connection with CG 2H 2MH Standard 10 0 39 7 0 28 44 1 73 260 10 24 325 12 8 483 approx 19 435 17 13 465 6 18 33 120 4 72 ø6mm 350 350 G1 4 i Converter CG 57 2 24 132 5 3HE 5 22 Figure 4 CG 2 and CG 2M Figure 5 shows the conversion unit versions CG 2H W and CG 2MH W in a wall mounting housing Figure 5 CG 2H W and CG 2MH W ...

Page 17: ... reaction see chapter 18 3 An alarm for excessively high and low temperatures is provided as a status contact output at the 9 pin sub D plug terminals 5 and 9 on the rear side of the converter With the version CG 2M and CG 2MH W internally or externally controlled PVDF 3 2 way bypass sole noid valves allow the catalyst to be bypassed for example for test purposes The desired sample gas path is sel...

Page 18: ...M is designed as a 19 unit and is also suitable for wall mounting or mounting plate by using a special mounting bracket The versions CG 2H W and CG 2MH W are executed as wall mounting housing NOTE Because of the system of protection IP 20 EN60529 the converter has to be built into a protective cabinet respectively housing When mounting outdoors the converter must be installed in a protective housi...

Page 19: ...onnections pay attention to the following points NOTE The tightness of the connections can only be guaranteed if the end section of the connection hose tube is flat use a hose cutter Loosen the sleeve nut of the clamping ring threaded joint by turning to the left Take care that the nut is removed carefully from the body of the threaded joint to avoid losing the clamping ring which is mounted loose...

Page 20: ...m for signalling temperatures outside the permitted range and the facility for connecting the solenoid valves externally are provided at the 9 pin sub D plug on the rear or lower side of the converter housing NOTE Correct functioning of the converter is only guaranteed when the sub D plug X2 is mounted Figure 6 shows the pin configuration in the sub D plug X2 1 2 3 4 5 6 7 8 9 Common status alarm ...

Page 21: ...ample gas path to bypass if possible Insert catalyst cartridge into the mounting adapter see 17 1 Introduce cartridge into the tube furnace until the limit stop and screw on the closing cap by hand inserting the cartridge is eased when the outside O rings are humidified Set desired catalyst temperature pre adjusted at the works to 350 C 662 F resp 660 C 1220 F using the temperature controller see ...

Page 22: ...ply 17 DETERMINING THE CATALYST SERVICE LIFE The catalyst service life depends essentially on the following factors Converter temperature NO2 concentration in the sample gas O2 concentration in the sample gas Gas flow rate Interfering carrier gases Figures 7 to 9 show the service life curves of the NO2 NO catalyst cartridge type C at 350 C 662 F depending on the flow rate and the oxygen concentrat...

Page 23: ...on of 10 vol Figure 9 Catalyst life time depending on the NO2 concentration for varying flow rates and an Oxygen concentration of 21 vol 0 100 200 300 400 500 600 700 5 10 15 20 25 30 35 40 45 50 Life time days NO2 ppm 30 l h 60 l h 90 l h 5 vol O2 0 50 100 150 200 250 300 350 400 450 5 10 15 20 25 30 35 40 45 50 Life time days NO2 ppm 30 l h 60 l h 90 l h 10 vol O2 0 50 100 150 200 250 5 10 15 20...

Page 24: ...ONVERSION PPM MG M3 1 ppm mg m3 DIN 1343 NTP STP SATP T 0 C T 20 C T 25 C T 25 C p 1013 mbar p 1013 p 1000 p 1013 Nitrogen monoxide NO 1 34 mg m3 1 25 1 21 1 23 Nitrogen dioxide NO2 2 05 mg m3 1 91 1 86 1 88 Standard conditions DIN 1343 Standard conditions in Germany NTP Normal temperature and Pressure mainly in the USA STP Normal conditions weltweit standardized SATP new Normal conditions Standar...

Page 25: ... to be switched off to replace the cartridge The following steps should be followed Switch the converter s sample gas path either internally or externally to bypass W AR N I N G Hot catalyst cartridge Touching the cartridge can lead to very se vere burns Wear protective gloves and safeguard cartridge against unauthorised access Turn the closing cap adapter with handle see figures 4 and 5 counter c...

Page 26: ...hematically the location of the two inside and outside O ring seals Figure 10 Adapter for catalyst cartridge with handle The inside seals can be removed using a pointed tool e g a needle When replacing the outside seals they have to be pushed over the adapter into the appropriate seal groove The inside seals are to be mounted as follows Lay the seal in the adapter aperture Push the O ring into the...

Page 27: ...ightness Switch sample gas path to catalyst operation lower green LED lights up Seal sample gas outlet tightly Connect sample gas outlet with U tube manometer or similar for 0 6 bar and upstream stopcock Release air using the stopcock until the manometer displays a pressure of approximately 0 5 bar NOTE Do not exceed the maximum operating pressure of 2 bar absolute Close stopcock A pressure drop o...

Page 28: ... for status indication yellow outputs 1 to 3 19 2 OPERATING STATE OF THE TEMPERATURE CONTROLLER The operating state is displayed via the LED s 1 to 3 like Operating state 1 2 3 Heating up off on blinking Normal heating on on on on heating off on on off Alarm Error X off X In the event of an alarm over or under temperature alarm the controller automatically switches to the state of the self retaini...

Page 29: ...ication Lo t relative temperature to temperature setting value for low tempera ture alarm adjustment at works 10 Press indication rASL ramp gradient temperature increase in C min adjustment at works 30 In order to change one of these parameters you must press the PGM key again after SP ALSE Lo t or rASL are to be read on the display The respective value is flashing now on the display and can be mo...

Page 30: ... EXIT and A reset only happens in case the actual temperature deviates by 10 C 18 F from the set temper ature Another method for a reset that functions without problem is to cut the mains voltage for a short moment remove the mains plug NOTE Watch carefully the control characteristic after reset This simplifies the di agnosis of errors when a failure happens again ...

Page 31: ...uit Measure voltage at terminals X4 2 and 3 OK Replace heater Not OK Measure voltage at terminal X4 6 and 7 Voltage 8 V DC Check controller according to operating instructions Voltage 8 V DC Replace solid state relay Change sensor Valves do not switch LED s do not light up No mains supply see above Sub D plug not inserted into socket X2 see above Internal circuit No solder link 1 6 in sub D plug E...

Page 32: ... C a r a r a r 95 A 9070 O ring set for CG 2 S 1 95 A 9040 Control board compl CG 230 V S 1 95 A 9040a Control board compl CG 115 V S 1 95 A 9057 Heater CG2 230 V 50 60 Hz S 1 95 A 9057a Heater CG2 115 V 50 60 Hz S 1 01 B 8401 Temperature controller CG Typ 70304 S 1 90 K 6045 Fan 80 x 80 24 V C 1 2 05 V 1060 Male connector G1 4 DN4 6 PVDF R 2 4 4 05 V 6600 Ferrule 4 6 PV R 5 10 15 05 V 6605 Union ...

Page 33: ...www mc techgroup com CG 2 1 04 00 33 Figure 11 Wiring plan CG 2M Drawing No 2224 5 04 0 ...

Page 34: ...34 CG 2 1 04 00 www mc techgroup com Figure 12 Wiring plan CG 2MH W Drawing No 2224 5 04 4 ...

Page 35: ...www mc techgroup com CG 2 1 04 00 35 Figure 13 Wiring plan CG 2H W Drawing No 2224 5 04 5 ...

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