Instruction Manual Gas Converter CG® Versions CG-2/-2M, CG-2H-W/-2MH-W Gas sampling and conditioning technology 9-0.
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.
List of Contents 1 2 3 4 5 6 7 8 General information ..................................................................................................................... 5 Declaration of conformity ........................................................................................................... 5 Safety instructions....................................................................................................................... 6 Warranty .................................................
List of Illustrations Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Functional diagram of CG-2 and CG-2M .............................................................................9 Functional diagram CG-2H-W and CG-2MH-W ....................................................................9 Notch to differentiate the two cartridge types......................................................................11 CG-2 and CG-2M .....
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.
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.
5 USED TERMS AND SIGNAL INDICATIONS 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. This means that minor physical injuries may occur in case the respective safety measures are not fulfilled.
6 INTRODUCTION In combustion processes, such as, for example, in large furnaces in which the nitrogen dioxide content amounts to more than 5% of the nitrogen oxide emission, continuous measurement of nitrogen oxide NOx consisting of nitrogen monoxide NO and nitrogen dioxide NO2 is prescribed by law in Germany and many other countries. 7 APPLICATION The M&C gas converters CG... convert the NO2 content of the sample gas by catalysis into NO.
Figures 1 and 2 show the functional scheme of the gas converter type CG.. D B 1.2 350 B 1.1 A 350 E1 B 1.0 Y2 °C Y1 B A B C D B 1.0 B 1.1 B 1.
The reaction equilibrium is shifted at room temperature onto the side of the original material NO2. A shift of the equilibrium towards the products and the resultant high product yield can only be achieved as subject to a high energy input, i.e. increase of temperature. A nearly 100% conversion of NO2 and therefore a complete conversion to NO is achieved with a cartridge filled with a metal catalyst within a temperature range of 620°C to 680°C.
Type SS Figure 3 Notch to differentiate the two cartridge types NOTE! 8.2 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 or N2 is not possible. SELECTION OF THE APPROPRIATE CATALYST TEMPERATURE The converter with carbon-molybdenum cartridge filling is pre-adjusted to 350°C in the factory. In case of a metallic cartridge filling, the converter temperature is adjusted to 660°C.
8.3 CROSS SENSITIVITIES AND INFLUENCE OF INTERFERING/CARRIER GAS From operating experiences in different applications as well as laboratory measurements with differrent CG-converter- 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 adequate catalyst type as well as give an indication for the integration of the CG-converter into a certain system environment.
9 TECHNICAL DATA Converter Series CG ® Version Part-No. Converter Part-No.Converter cartridge Type C CarbonMolybdenum Part-No.Converter cartridge Type SS metallic Filling Gas inlet and –outlet non-heated (cold) or heated (hot) Bypass solenoid valves Gas inlet temperature Temperature adjustment of converter Gas flow rate Operating pressure Warm-up time Volume of the converter cartridge Operating temp. converter cartridge type C Operating temp. converter cartridge type SS Max.
10 DESCRIPTION Figure 4 shows the conversion unit version CG-2 and CG-2M in the 9”-rack housing. 483 (84TE) 325 260 44 350 350 132,5 (3HE) ! Converter CG 10 Back view 7 465.
Figure 5 CG-2H-W and CG-2MH-W The M&C gas converters type CG-2 and CG-2M are designed as compact, user-friendly and easy to service 19" plug-in units (figure 4) suitable for mounting in 19" cabinet systems. When fitted with the optional mounting bracket with a vertical swivel-holder (50 A 3000), the converters can also be wallmounted. The M&C gas converters type CG-2H-W and CG-2MH-W are executed in a compact, user-friendly and easy to service manner for wall mounting (figure 5).
internally: Switch position "up" - upper LED lights up green - sample gas path selected via bypass Switch position "down" - lower LED lights up green - sample gas path selected via catalyst Only for version CG-2MH-W: Switch position "up" - upper LED lights up green - sample gas path selected via catalyst Switch position "down" - lower LED lights up green - sample gas path selected via bypass The supply-connections are located on the rear or on the upper and lower side of the converter housing.
The converter should be installed away from sources of heat and in a position which allows air to circulate freely in order to avoid any heat accumulation. To avoid a heating-up of other devices in case of a 19”-rack, we recommend a minimum mounting height of 4U (HE) 13 SUPPLY CONNECTIONS 13.1 HOSE/TUBE CONNECTIONS The gas inlet and outlet hoses/tubes of versions CG-2/-2M are connected on the rear of the converter. Here, the standard executions provides G 1/4" threaded joints.
13.2 ELECTRICAL CONNECTIONS The wrong mains voltage can destroy the device. When connectW A R N I N G ! ing, take care that the mains voltage corresponds with the information provided on the type identification plate! For the erection of power installations with rated voltages up to 1000V, the requirements of VDE 0100 and relevant standards and specifications must be observed! A main switch must be provided externally.
NOTE! If the converter is controlled internally, the bridge between contacts 1 and 6 in the D-sub plug is absolutely necessary ! External switching is carried out by the customer using potential-free contacts (see figure 6). NOTE! If the converter is controlled externally, the bridge between contacts 1 and 6 in the D-sub plug must be removed ! With external control, the switch on the front plate of the converter is out of function. The chosen gas way is indicated by the two LED‟s.
15 CLOSING DOWN NOTE! The location at which the converter is mounted must remain frost-free even when the device is switched off ! No special measures need to be taken when the converter is taken out of operation for a short period. In order to avoid unnecessary consumption of the catalyst and to ensure that the catalyst is ready for use at short notice, the catalyst temperature should be reduced below 300°C in the "stand-by" during brief operational pauses.
Life time [days] 21 700 600 500 400 300 200 100 0 30 l/h 60 l/h 90 l/h 5 10 15 20 25 30 35 40 45 50 NO2 [ppm] 5 Vol.-% O2 Catalyst life depending on the NO2 concentration for varying flow rates and an Oxygen concentration of 5 Vol.-% Life time [days] Figure 7 450 400 350 300 250 200 150 100 50 0 30 l/h 60 l/h 90 l/h 5 10 15 20 25 30 35 40 45 50 NO2 [ppm] 10 Vol.-% O2 Catalyst life depending on the NO2 concentration for varying flow rates and an Oxygen concentration of 10 Vol.
16.1 CHECK OF THE EFFICIENCY To check the efficiency of the converter cartridge a test gas with a NO2-concentration according to the concentration in the sample gas (e.g. 20ppm in N2) is necessary. Feed test gas upstream the converter and read measured NO-concentration at the analyser.
against unauthorised access! Turn the closing cap/adapter with handle (see figures 4 and 5) counter-clockwise. Pull the catalyst cartridge at the closing cap with a rotary motion out of the adapter; The re-inserting has to be done in the opposite way. NOTE! NOTE! 17.2 In order to obtain the required gas-tightness, take care that the cartridge is always inserted into the adapter right up to the stop. Moisten the outer O-rings helps placing the cartridge into the oven.
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 appropriate seal groove using a blunt instrument. Take care when re-mounting the O-ring seals: Do not damage the O-rings and take care that they are correctly positioned ! NOTE! 17.
Set-point display, green PGM key - to select the parameters Decrement key - to alter values Increment key - to alter values EXIT key - to quit the levels LED for ramp/programme function, green LED for status indication, yellow - outputs 1 to 3 18.
Standard indication (setting value below, actual value above (see photo)) must to be seen. Press both together, key PGM and for 5 seconds, Indication = Code 3 (all levels are locked) Press PGM Change the value from 3 to 2 by using the key The display flashes after approx. 2 seconds and the alteration is taken over. The user level is now cleared. Press EXIT .
Another method for a reset that functions without problem is to cut the mains voltage for a short moment (remove the mains plug). NOTE! 19 Watch carefully the control characteristic after reset. This simplifies the diagnosis of errors when a failure happens again! TROUBLE SHOOTING The following table is intended to show the possible sources of errors and their rectification Problem/Display Possible Cause Gas sampling and conditioning technology Check/Rectification 9-0.
LED‟s do not light up No mains power Valves do not switch over Temperature controller out of order Converter does not heat up LED K1 off Valves do not switch over LED‟s do not light up Valves do not switch over LED‟s light up No sample gas flow No conversion 20 Mains „ON‟ OK. Check that mains cable fits properly (X1); OK. Sub-D-plug not inserted in Check whether sub-D-plug is present socket X2 and is properly plugged in; OK. Check whether bridge in sub-D-plug exists (s. Fig. 6); OK.
(C) Consumable parts, (R) Recommended spare parts and (S) Spare parts C/R/S recommended quantity CG beeing in operation [years] (a.r. = as required) 1 2 3 95 A 9003 Catalyst cartridge CG2-C C a.r. a.r. a.r. 95 A 9004 Catalyst cartridge CG-2-SS C a.r. a.r. a.r. 95 A 9070 O-ring set for CG2 S - - 1 95 A 9040 Control board compl. CG - 230V S - - 1 95 A 9040a Control board compl.
Figure 11 Wiring plan CG-2M, Drawing No.: 2224-5.04.0 Gas sampling and conditioning technology 9-0.
Figure 12 Wiring plan CG-2H-W, Drawing No. : 2224-5.04.4 Gas sampling and conditioning technology 9-0.
Figure 13 Wiring plan CG-2MH-W, Drawing No. : Gas sampling and conditioning technology 2224-5.04.5 9-0.
