Bühler technologies TC MINI User manual

AnalysentechnikInstallation and Operation InstructionsOriginal instructionsSample gas coolerTC-MINIBE44001510/2018Bühler Technologies GmbH, Harkortstr. 29, D-40880 RatingenTel. +49 (0) 21 02 / 49 89-0, Fax: [phone] / 49 89-20E-Mail: [email protected]Internet: www.buehler-technologies.com

Bühler Technologies GmbH, Harkortstr. 29, D-40880 RatingenTel. +49 (0) 21 02 / 49 89-0, Fax: [phone] / 49 89-20Internet: www.buehler-technologies.comE-Mail: [email protected]Read this instruction carefully prior to installation and/or use. Pay at-tention particularly to all advises and safety instructions to prevent in-juries. Bühler Technologies can not be held responsible for misusingthe product or unreliable function due to unauthorised modifications.All rights reserved. Bühler Technologies GmbH 2018Document informationDocument No..........................................................BE440015Version..........................................................................10/2018

TC-MINIContents1Introduction.....................................................................................................................................................................................................................21.1Intended use.........................................................................................................................................................................................................21.2Types.......................................................................................................................................................................................................................21.3Scope of delivery..................................................................................................................................................................................................21.4Ordering instructions ........................................................................................................................................................................................22Safety instructions......................................................................................................................................................................................................... 32.1Important advice.................................................................................................................................................................................................32.2General hazard warnings .................................................................................................................................................................................43Transport and storage.................................................................................................................................................................................................. 54Installation and connection........................................................................................................................................................................................64.1Installation site requirements.........................................................................................................................................................................64.2Installation............................................................................................................................................................................................................64.2.1Connecting the filter gas connections (optional) .......................................................................................................................74.2.2Flow adapter connection (optional)................................................................................................................................................74.2.3Connecting the moisture detector (option)..................................................................................................................................74.3Electrical connections ........................................................................................................................................................................................74.4Settings...................................................................................................................................................................................................................95Operation and control .................................................................................................................................................................................................116Maintenance...................................................................................................................................................................................................................127Service and repair..........................................................................................................................................................................................................137.1Troubleshooting................................................................................................................................................................................................147.2Safety instructions.............................................................................................................................................................................................157.3Replacing the fuse of the cooler.....................................................................................................................................................................157.4Cleaning and removal of the heat exchanger............................................................................................................................................157.5Replacing the filter element (option)..........................................................................................................................................................167.6Drying of the moisture detector (option)...................................................................................................................................................167.7Spare parts and accessories ...........................................................................................................................................................................167.7.1Consumables and accessories ........................................................................................................................................................178Disposal...........................................................................................................................................................................................................................189Appendices.....................................................................................................................................................................................................................199.1Gas cooler technical data................................................................................................................................................................................199.2Technical Data - Options.................................................................................................................................................................................199.3Dimensions (mm)............................................................................................................................................................................................. 209.4Performance data............................................................................................................................................................................................. 209.5Heat exchanger.................................................................................................................................................................................................. 219.5.1Heat exchanger description............................................................................................................................................................219.5.2Heat exchanger overview.................................................................................................................................................................2110Attached documents...................................................................................................................................................................................................22iBühler Technologies GmbHBE440015 ◦ 10/2018

TC-MINI1 Introduction1.1 Intended useThis unit is intended for industrial use in gas analysis systems. It's an essential component for conditioning the sample gas toprotect the analysis instrument from residual moisture in the sample gas.Please note the specifications in the data sheet on the specific intended use, existing material combinations, as well as pressureand temperature limits.1.2 TypesThe device is delivered with different configurations. The part number given on the type plate informs you about the specificconfiguration of your device.1.3 Scope of delivery–Cooler–Product documentation–Connection-/mounting accessories (optional)1.4 Ordering instructionsThe item number is a code for the configuration of your unit. Please use the following model key:4496111X04XXX00XX1Product characteristicGas cooler models (with 1 heat exchanger)1TC MINI 6111: moderate ambient temperature 40 °C2TC MINI 6112: higher ambient temperature 50°CCertifications0Standard unit, no special certificationSupply voltage424 V DCHeat exchanger 1)110MTS, metric fittings115MTS-I, US fittings120MTG, metric fittings125MTG, US fitting130MTV, metric135MTV-I, US fittingSample gas pumps00without sample gas pumpMoisture detector / filter00without filter, without moisture detector01without filter, 1 moisture detector with block101 filter, without moisture detector111 filter with built-in moisture detectorStatus outputs1Analogue output, 4…20 mA1) Filter tubing, metric or US, respectively2Bühler Technologies GmbHBE440015 ◦ 10/2018

TC-MINI2 Safety instructions2.1 Important adviceOperation of the device is only valid if:–the product is used under the conditions described in the installation- and operation instruction, the intended applicationaccording to the type plate and the intended use. In case of unauthorized modifications done by the user Bühler Technolo-gies GmbH can not be held responsible for any damage,–when complying with the specifications and markings on the nameplates.–the performance limits given in the datasheets and in the installation- and operation instruction are obeyed,–monitoring devices and safety devices are installed properly,–service and repair is carried out by Bühler Technologies GmbH,–only original spare parts are used.This manual is part of the equipment. The manufacturer keeps the right to modify specifications without advanced notice. Keepthis manual for later use.Signal words for warnings
DANGER
Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.
WARNING
Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if notavoided.
CAUTION
Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property orminor or medium injuries if not avoided.
NOTICE
Signal word for important information to the product.Warning signsThese instructions use the following warning signs:Warns of a general hazardUnplug from mainsWarns not to inhale toxic gassesWear respiratory equipmentWarns of corrosive liquidsWear a safety maskWarns of explosive areasWear glovesGeneral information3Bühler Technologies GmbHBE440015 ◦ 10/2018

TC-MINI2.2 General hazard warningsThe 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. Preventmalfunctions and avoid personal injuries and property damage.The operator of the system must ensure:–Safety notices and operating instructions are available and observed,–The respective national accident prevention regulations are observed,–The permissible data and operational conditions are maintained,–Safety guards are used and mandatory maintenance is performed,–Legal regulations are observed during disposal.Maintenance, RepairPlease note during maintenance and repairs:–Repairs to the unit must be performed by Bühler authorised personnel.–Only perform conversion-, maintenance or installation work described in these operating and installation instructions.–Always use genuine spare parts.Always observe the applicable safety and operating regulations in the respective country of use when performing any type ofmaintenance.DANGERToxic, corrosive gas/condensateSample 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. Wear appropriate protective equipment.DANGERPotentially explosive atmosphereExplosion hazard if used in hazardous areas.The device is not suitable for operation in hazardous areas with potentially explosive at-mospheres.Do not expose the device to combustible or explosive gas mixtures.4Bühler Technologies GmbHBE440015 ◦ 10/2018

TC-MINI3 Transport and storageOnly transport the product inside the original packaging or a suitable alternative.The equipment must be protected from moisture and heat when not in use. It must be stored in a covered, dry and dust-freeroom at a temperature of -20 °C to 60 °C (-4 °F to 140 °F).5Bühler Technologies GmbHBE440015 ◦ 10/2018

TC-MINI4 Installation and connection4.1 Installation site requirementsThe unit is only intended for wall-mounted use in enclosed areas. Adequate protection from the weather must be providedwhen used outdoors.Install the unit leaving enough room below the cooler to discharge the condensate. Leave room above for the gas supply.Be sure to maintain the approved ambient temperature. Do not obstruct the convection of the cooler. The vents must haveenough room to the next obstacle. The distance must especially be a minimum of 10 cm on the air outlet side.Ensure adequate ventilation when installing in enclosed housings, e.g. analyser cabinets. If the convection is inadequate, we re-commend aerating the cabinet or installing a fan to lower the inside temperature.When wall mounting the sample gas cooler, be sure the wall or the cabinet provide adequate weight bearing and stability.4.2 InstallationRun the gas supply to the cooler with a downward slope. The gas inputs are marked in red and additionally labelled "IN".If a large amount of condensate accumulates, we recommend using a condensate trap with automatic condensate drain. Ourcondensate drains, 11LDV38, AK20, AK5.5 OR AK5.2, are suitable.Glass vessels and automatic condensate drains are available for draining condensate for external mounting below the unit.When using automatic condensate drains, the sample gas pump must be installed upstream of the cooler (pressure operation)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 traps or peri-staltic pumps.Connecting the condensate drainsDepending on the material, build a connecting line with fittings and tubing or hose between the heat exchanger and condens-ate drain. For stainless steel the condensate drain can be suspended directly to the connecting tube, for hoses the condensatedrain must be secured separately using a clamp.The condensate drain can be mounted directly to the heat exchanger.Condensate lines must always be installed with a slope and a minimum inside diameter of DN 8/10 (5/16”), with passive dis-charge via traps or automatic condensate drains. Use screw joints with a minimum inner span of 7 mm, sold separately as ac-cessories. The MTG heat exchanger in glass cannot be operated in conjunction with an automatic condensate drain.Connecting the heat exchangerThe gas inputs are marked in red.On glass heat exchangers the correct position of the seal is important when connecting the gas lines (see image). The seal con-sists of a silicone ring with a PTFE sleeve. The PTFE side must face the glass thread.
Glass PTFE
6Bühler Technologies GmbHBE440015 ◦ 10/2018

TC-MINI4.2.1 Connecting the filter gas connections (optional)The connection G1/4 or NPT 1/4” (filter head marked NPT) for the gas outlet must be carefully and properly connected using asuitable screw connection.When ordering the cooler with the option filter without Moisture detector, a bypass may be connected to the filter head.The filter head is intended for a G1/4 internal screw thread which is plugged at the factory. To use it, unscrew the plug and screwin a suitable screw connection. Pay attention to leaks.NOTICEInstalling filters limits the maximum approved operating pressure in the system!Operating pressure ≤ 2 bar4.2.2 Flow adapter connection (optional)When ordering the cooler with the option moisture detector without filter, it will be factory installed inside a flow adapter.The connection between the heat exchanger outlet and the flow adapter inlet does not have tubing included. The connectionG1/4 or NPT1/4" (flow adapter marked NPT) for the gas inlet/outlet must be carefully and properly connected using a suitablescrew connection. Here the direction of flow is not relevant.4.2.3 Connecting the moisture detector (option)When ordering the cooler with moisture detector option, it will be factory installed inside a flow adapter, or for the filter optioninstalled and connected in the filter head.4.3 Electrical connectionsNOTICEThe connection must be made by a trained professional.CAUTIONWrong mains voltageWrong mains voltage may damage the device.Regard the correct mains voltage as given on the type plate.The sample gas cooler features plug-in connectors at the top for connecting the power supply and the status outputs.The unit features an output for status messages. The maximum switching capacity of the alarm output is 70VDC or 33VAC,both at 1A.An alarm is triggered if the temperature of the cooler is outside the specified limits. It does not indicate if the alarm wastriggered due to excess temperature or insufficient temperature.When the moisture detector (optional) is installed, an alarm is activated if the moisture is still present in the prepared samplegas. This is the same alarm output as for the temperature.7Bühler Technologies GmbHBE440015 ◦ 10/2018

TC-MINI
X2.5X2.1
X2.10
X2.6
X1.1
DIP Switch / Settings
LED green
LED red
Inlets/OutputsTerminalFunctionDescriptionMoisture detectorX1.1FF.1 (white)Moisture detectorX1.2FF.2 (brown)X1.3PEShield for moisture detector inletStatusX2.1Status NC (Alarm)Alarm / StatusChangeover contact, potential-free, max. 250 V AC, 1 AX2.2Status COMX2.3Status NO (ok)24 V inputX2.424 V DC -Power supplyX2.524 V DC +Analogue outputX2.6PEShield for analogue outputX2.7mA +Analogue output4…20 mA, 0 - 80 °CX2.8mA -24 V output *X2.924 V DC -Supply for optional add-on unitsmax. 1 AX2.1024 V DC +* Add-on units, e.g. a pump, with 24 V supply can be connected to the outlet, switched via the status output. The 24 V supplymust then be configured appropriately (see data sheet).8Bühler Technologies GmbHBE440015 ◦ 10/2018