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Installation-, Operating-, Maintenance-Manual, Spare Part List

BCR05

AGT-PSG GmbH & Co.KG

Errors and printing mistakes excepted

Page 24

Translation - Manual BCR05 Rev. 06/2017

Service

Spare Parts

Control Unit 230V 50/60Hz

Article-Description

RI Flow Schema

Circuit Diagram

Artikel-No.

Complete EEx Control Unit

20.0

8813042

Protective switch refrigerant compressor

KTA2100659

Switch relay refrigerant compressor

KTA6100069

On delay startup relay

KTA6100072

Startup capacitor

KTA2100651

Control Unit 115V 50/60Hz

Article-Description

RI Flow Schema

Circuit Diagram

Artikel-No.

Complete EEx Control Unit

20.0

8813043

Protective switch refrigerant compressor

KTA6300021

Switch relay refrigerant compressor

KTA6100170

On delay startup relay

KTA6100171

Startup capacitor

KTA2100651

Temperature Monitoring and Protective Switches

Article-Description

RI Flow Schema

Circuit Diagram

Artikel-No.

Temperature display / Contact thermometer

6501042

Combined safety pressure limiter

20.1

F2/F3

KTA6300039

Safety temperature limiter

20.2/20.3

F4/F5

KTA2100662

Heat-Exchanger

Article-Description

RI Flow Schema

Artikel-No.

Heat Exchanger PVDF Mono

8410948

Heat Exchanger PVDF Duo

8410951

Heat Exchanger Glass Mono

8410949

Heat Exchanger Stainless-Steel Mono

8410950

Heat Exchanger Stainless-Steel Duo

8410942

Thermal transmission paste tube 50g

6938110

Thermal transmission paste tube 250g

6938111

DANGER: Explosive Area! This sample gas cooler may be maintained and repaired exclusively

in a non-explosive area considering the instructions of the manufacturer.

Only qualified personnel should perform troubleshooting, maintenance or repair operations.

Please contact directly the manufacturer AGT-PSG if the sample gas cooler fails. Tampering the

safety and security devices is not permissible.

Содержание PSG BCR05

Страница 1: ...BCR05 Sample Gas Cooler Installation Manual Operating Manual Maintenance Manual Spare Part List ...

Страница 2: ...eline It corresponds to the essential requirements of these guidelines The following hormonized 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 EMC interference resistance EN 61000 ...

Страница 3: ...ontinuous 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 copy ...

Страница 4: ...ies 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 Only skilled workers of the manufacturer are authorized to work on the cooling system In the case of warranty claims...

Страница 5: ...perienced 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 devices Before attempting maintenance the following pre conditions must be satisfied Ensure that main power is ...

Страница 6: ...g in a dust free 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 ...

Страница 7: ...e manufacturer or a comparable construction The brackets must hold 4 times the given weights Only use the existing fastening points at the bottom of the housing The cooler 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 Convecti...

Страница 8: ...ation Site Fasten mounting rails 1 and 2 in perfect vertical position at the wall The fastening points 3 und 4 need an exact distance of 365mm Mount the console rails 5 and 6 with identical high in horizontal position The high itself is variable Fasten the sample gas cooler on the console rails Therefore carefully dismount the right side panel and the front panel of the sample gas cooler Bold the ...

Страница 9: ...ple 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 HE1 red Gas outlet HE1 blue Condensate outlet HE1 Gas inlet HE2 red Gas outlet HE2 blue Condensate outlet HE2 The feed lines of the numerous possible heat exchanger types material PVDF glass SS316 construct...

Страница 10: ...pneumatically 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 w...

Страница 11: ... disconnect any power supply WARNING Automatic start After you built up the electrical connections the cooler can start automatically The sample gas cooler has to be installed as shown at the circuit diagram The cross section of the power supply cables must comply with the consumption of the dryer while keeping into account also the ambient temperature the conditions of the mains installation the ...

Страница 12: ... Security gray polyester box Lay the line through one of the free cable feedthroughs at the bottom of the shielded enclosure Therefore only use the pre mounted cable gland Apply the electrical supply line to the corresponding rail mounted terminals Remount accurately all dismantled components Right side panel Cable feedthroughs Shielded enclosure Advanced Security Remote Monitoring Connection The ...

Страница 13: ...5 Rev 06 2017 Assembly and Installation Shielded Enclosure Advanced Security The electrical lines need to be applied exclusively to the rail mounted terminals in the shielded enclosure Advanced Security X1 04 05 06 notice circuit diagram X1 Rail mounted terminals X1 01 02 03 3 pole remote monitoring connection X1 04 05 06 Electrical supply line L1 N PE ...

Страница 14: ...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...

Страница 15: ...Cooler start up Switch on the power supply After switching on the power supply the cooler will start automatically 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 WARNING Automatic start After switching on the power supply...

Страница 16: ...tched off 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 is to be dismantled it has to be split into homogeneous groups of materials NOTICE Environment protection We recommend to comply with the safety rules in force for the disposal of each...

Страница 17: ... limit 0 C green hand Reference value 3 to 7 C Upper limit 10 C red hand Error Diagniosis Checklist Fault Cause Remedy Failure of sample gas cooler Interrupted power supply Re establish the power supply Protective switch activated Check operating conditions reset protective switch manually Defective refrigerant circuit Contact AGT Service Sample gas flow blocked Gas paths contaminated Contaminatio...

Страница 18: ...turer Any other tampering the safety and security devices is not permissible WARNING Open housing Never operate equipment with panels removed Remount accurately all dismantled components before re commissioning the sample gas cooler notice chapter Commissioning Notice the advices of the chapters Functional Characteristics of the Refrigerant Circuit Functional Characteristics of the EEx Protection ...

Страница 19: ...t of protection switches and safety devices may be processed exclusively in a non explosive area considering the instructions of the manufacturer DANGER Supply voltage Be sure that no part of the sample gas cooler is powered Notice the advices of the attached operation instruction BARTEC Ex d Control Station Type 07 4C40 01 4000 7D0001 C 05 17 STVT 375605 Dismantle the right panel and the top pane...

Страница 20: ...e sample gas cooler is in a non explosive area DANGER Explosive Area The reset of protection switches and safety devices may be processed exclusively in a non explosive area considering the instructions of the manufacturer DANGER Supply voltage Be sure that no part of the sample gas cooler is powered Dismantle the right panel of the sample gas cooler Reset the low pressure and high pressure limite...

Страница 21: ...he sample gas cooler is in a non explosive area DANGER Explosive Area The reset of protection switches and safety devices may be processed exclusively in a non explosive area considering the instructions of the manufacturer DANGER Supply voltage Be sure that no part of the sample gas cooler is powered Dismantle the right panel of the sample gas cooler Reset the safety temperature limiters 20 2 20 ...

Страница 22: ... drain Maintenance monthly or every 3000 hours of operation Verify for tightness all the screws of the electric system inspect the cables Cleaning of the condenser Visual inspection of heat exchanger unit and insulation Inspect refrigerating circuit for signs of oil and refrigerant leakage Maintenance of the encapsulated control unit DANGER Explosive Area This sample gas cooler may be maintained a...

Страница 23: ...rigerant leak contact directly the manufacturer of the sample gas cooler The room is to be aired before any intervention Data of the use refrigerant liquids Refrigerant Chemical Formula TLV GWP R134a HFC CH2FCF3 1000 ppm 1300 Maintenance Operation on the Condenser Unit The degree of contamination of the condenser can adversely affect the performance of the device Clean the air cooled condensers us...

Страница 24: ...ure Monitoring and Protective Switches Article Description RI Flow Schema Circuit Diagram Artikel No Temperature display Contact thermometer B1 6501042 Combined safety pressure limiter 20 1 F2 F3 KTA6300039 Safety temperature limiter 20 2 20 3 F4 F5 KTA2100662 Heat Exchanger Article Description RI Flow Schema Artikel No Heat Exchanger PVDF Mono 7 8410948 Heat Exchanger PVDF Duo 7 8410951 Heat Exch...

Страница 25: ...e 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 AGT PSG by email info agt agt psg de about the shipment of the cooler and the approxima...

Страница 26: ...the declaration to the packing Otherwise your repair cannot be processed Gevice 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...

Страница 27: ...Installation Operating Maintenance Manual Spare Part List BCR05 AGT PSG GmbH Co KG Errors and printing mistakes excepted Page 27 Translation Manual BCR05 Rev 06 2017 Dimension Sheet ...

Страница 28: ...Installation Operating Maintenance Manual Spare Part List BCR05 AGT PSG GmbH Co KG Errors and printing mistakes excepted Page 28 Translation Manual BCR05 Rev 06 2017 RI Flow Schema ...

Страница 29: ...Installation Operating Maintenance Manual Spare Part List BCR05 AGT PSG GmbH Co KG Errors and printing mistakes excepted Page 29 Translation Manual BCR05 Rev 06 2017 Electrical Components Overview ...

Страница 30: ...Installation Operating Maintenance Manual Spare Part List BCR05 AGT PSG GmbH Co KG Errors and printing mistakes excepted Page 30 Translation Manual BCR05 Rev 06 2017 Electrical Components Details ...

Страница 31: ...Installation Operating Maintenance Manual Spare Part List BCR05 AGT PSG GmbH Co KG Errors and printing mistakes excepted Page 31 Translation Manual BCR05 Rev 06 2017 Circuit Diagram ...

Страница 32: ...expanded and fluid refrigerant flows through the heat exchanger pipes 6 of the evaporator 5 By energy input of the exchangeable heat exchanger 7 the fluid refrigerant evaporates and cools down the passed through sample gas to a temperature of 3 C Over the liquid separator 10 the refrigerant compressor 1 sucks again the vaporous refrigerant Over the power regulator 9 0 the sample gas conditioner pe...

Страница 33: ...sure of the refrigerant If the pressure rises over the permitted maximum pressure it switches off the refrigerant compressor defined acting point 20bar After problem solving it needs a manual reset The high pressure limiter monitors the pressure of the refrigerant If the pressure falls below the permitted minimum pressure it switches off the refrigerant compressor defined acting point 1bar After p...

Страница 34: ...ed off over the relay output of the switch amplifier so that the refrigerant compressor stops working The second switch amplifier provides an intrinsically safe circuit to the temperature control unit B1 and switches a changeover contact This changeover contact is potential free and can be used as an alarm or operation notification F1 Protection switch refrigerant compressor mounted in the pressur...

Страница 35: ...ers instructions Pmax without cond pump bar 2 5 2 0 100 0 2 5 2 0 100 0 2 5 100 0 Gas connection mm Gas inlet outlet DN4 6 condensate outlet D12 Dead space ml 67 98 67 2x67 2x98 2x67 4x55 4x55 Ambient temperature C 5 C to 45 C Cooling power W 300W at 25 C ambient temperature Protection rate IP20 acc EN 60529 EN 61010 Certifications ATEX EX II 2G Ex px de ai IIC T4 Gb for Zone 1 and 2 Housing Conso...

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