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
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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

TC-MINI4.4 SettingsRemarks on outlet dew pointNot all applications require an outlet dew point of 5 °C. In some applications a higher dew point is sufficient. In other applica-tions a stable outlet dew point doesn’t matter, it’s enough for the gas to be dry, so for the outlet dew point to have an adequatedifference in temperature below the ambient temperature.The advantage of a higher outlet temperature is that at a given ambient temperature the Peltier cooler provides significantlymore cooling performance. So on the e.g. TC-MINI version model 6111, at an ambient temperature of 40 °C this means:Outlet dew point:5 °C10 °C15 °CAvailable cooling capacity:16 kJ/h28 kJ/h39 kJ/hTo fully utilize these advantages, the electronics feature several parameter settings:1.Adjustable outlet dew pointAn outlet dew point of 3, 5, 10 or 15 °C can be set to reach the specified values. Here it’s important the ambient temperatureis always ABOVE the outlet dew point setting, or condensation may form in the lines after the cooler. So the ambient tem-perature range is limited.2.Delta-T ControlHere the electronics measures the ambient temperature an regulates the outlet dew point to a an about 15 °C or 30 °C lowervalue, but no less than the dew point set under 1. This extends the potential cooling capacity to the limits of the heat ex-changer. Here it’s important to note the outlet dew point fluctuates along with the ambient temperature and a stable dewpoint cannot be a prerequisite for the measurement.As seen in the following graphics using the TC-MINI 6111 as an example, a difference of 15 °C from the ambient temperaturemeans the focus is on drying the sample gas. The stability of the dew point then takes a backseat to the high performancewhich can be achieved.At a difference of 30 °C, at a set outlet dew point of 10 °C this means the dew point remains stable up to an ambient temper-ature of approx. 40 °C, and the safe drop is only preferred over the ambient temperature with ambient temperature peaksover 40 °C.
Cooling capacity in kJ/h
Output dew point
10 °C
Ambient temperature in °C
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TC-MINIDIP switchThe unit is configured using four DIP switches at the front of the cooler.
SW1
SW2
SW3
SW4
0
0
0
0
1
1
1
1
1ON switch0OFF switchSWSwitch, the following numbering of the SWs corresponds with the numbering on the DIPswitch.SW1 / SW2SW2SW1Gas outlet dew point003 °C015 °C (factory preset)1010 °C1115 °CSW3 / SW4SW3SW4Delta T control00Gas outlet dew point, fixed01Difference from ambient temperature approx. 15 °C10Difference from ambient temperature approx. 30 °C11Gas outlet dew point, fixed10Bühler Technologies GmbHBE440015 ◦ 10/2018

TC-MINI5 Operation and controlNOTICEThe device must not be operated beyond its specifications.After switching on the supply voltage the cooler starts to cool the cooling block. When switch off the contact between X2.1 andX2.2 is closed.The target temperature is preset to 5 °C at the factory. The alarm limit is defined at +5/-2 K.GreenLEDRedLEDStatusInternalstatusFFTemperatureDescriptionOFFOFFX2.1, X2.2Unit offWith the cooler switched off, the statusoutput corresponds to error status.ONOFFX2.1, X2.3OKOK (*)OKNormal operationOFFFlashingf = 1 HzX2.1, X2.2OKOK (*)ErrorOverload / temperature outside the tar-get rangeOFFONX2.1, X2.2OKErrorxxxMoisture penetrationOFFFlashingf = 5 HzX2.1, X2.2ErrorxxxxxxVarious possible causes, contact Service.OKNo errorErrorError presentxxxStatus not definedf =…LED flash frequencyX2.1, X2.2…Markings on terminals(*)Also applies if no moisture detector connectedIf the red LED lights up during operation, please refer to chapter “Troubleshooting“.11Bühler Technologies GmbHBE440015 ◦ 10/2018

TC-MINI6 MaintenanceThe basic version of the cooler does not require maintenance.However, it may have different options depending on the configuration ordered. In this case the following maintenance mustbe performed regularly:Filter option: Check filter elementDuring maintenance, remember:–The equipment must be maintained by a professional familiar with the safety requirements and risks.–Only perform maintenance work described in these operating and installation instructions.–When performing maintenance of any type, observe the respective safety and operation regulations.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.12Bühler Technologies GmbHBE440015 ◦ 10/2018

TC-MINI7 Service and repairThis chapter contains information on troubleshooting and correction should an error occur during operation.Repairs to the unit must be performed by Bühler authorised personnel.Please contact our Service Department with any questions:Tel.: [phone] or your agentIf the equipment is not functioning properly after correcting any malfunctions and switching on the power, it must be inspectedby the manufacturer. Please send the equipment inside suitable packaging to:Bühler Technologies GmbH- Reparatur/Service -Harkortstraße 2940880 RatingenGermanyPlease also attach the completed and signed RMA decontamination statement to the packaging. We will otherwise be unable toprocess your repair order.You will find the form in the appendix of these instructions, or simply request it by e-mail:[email protected].13Bühler Technologies GmbHBE440015 ◦ 10/2018

TC-MINI7.1 TroubleshootingProblem / MalfunctionPossible CauseActionNo LED lights up–Mains voltage interrupted–Connect to mains; check the plug is cor-rectly inserted–Fuse defective–Check fuse and replace if necessary–Defective LED–Send in cooler–Internal error–Send in coolerFlashing red LED (f = 1 Hz)Excess / insufficient temperature–Operating point not yet reached–Wait (max. 15 min)–Cooling output too long despite the coolerrunning–Be sure the vents are not covered (heatbuildup)–Flow rate / dew point / gas temperature toohigh–Maintain limits / install pre-separator–Installed fan stopped–Check and replace if necessary–Faulty control–Send in cooler–Short circuit–Temperature sensor defective: Send incooler–Broken wire–Temperature sensor defective: Send incoolerFlashing red LED(f = 5 Hz)–Internal error–Send in coolerSteady red LEDMoisture in the sample gas(If the moisture detector wastriggered, it must then bedried)–Cooler overloaded, flow rate / dew point /gas temperature too high–Maintain limits / install pre-separator–Cooling output too long despite the coolerrunning–Be sure not to cover the ventilation slots(heat buildup); maintain limits–Condensate trap full–Empty condensate trap–Water penetrating from water bag–Observe delivery rate of peristaltic pumps–Install condensate drain with downwardslope–Cable break in the moisture detector con-nection line–Check connection line and plug-in connec-tionCondensate inside the gas out-let–Condensate trap full–Empty condensate trap–Valve inside the automatic condensatedrain may be stuck–Flush in both directions–Cooler overloaded–Maintain limitsReduced gas flow rate–Gas circuit clogged–Uninstall and clean heat exchanger–if necessary, replace filter element–Condensate output iced over–Send in cooler14Bühler Technologies GmbHBE440015 ◦ 10/2018

TC-MINI7.2 Safety instructions–The device must be operated within its specifications.–All repairs must be carried out by Bühler authorised personnel only.–Only perform modifications, servicing or mounting described in this manual.–Only use original spare parts.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.CAUTIONHealth hazard if the heat exchanger leaksThe heat exchanger is charged with glycol-based coolant.In the event of a heat exchanger leak:a)Avoid contact with the skin and eyes.b)In the event of a leak, do not restart the cooler under any circumstances The coolermust be repaired by the manufacturer.7.3 Replacing the fuse of the cooler–Close the gas supply.–Switch off and unplug the device.–Loosen the screws on the cover.–Carefully remove the cover.–The fuse is located on the board under a plastic cap. Replace microfuse and put the cap back on. Please note the mainsvoltage in order to select the correct microfuse.–Reattach cover. Screw in mounting screws.–Restore the power and gas supply.7.4 Cleaning and removal of the heat exchangerHeat exchangers only need to be replaced or maintained if clogged or damaged. If they are clogged, we recommend checking ifusing a filter will avoid future occurrences.–Close gas supply.–Switch off device and disconnect all plugs (e.g. connector plug alarm output, supply input, etc.).–Disconnect gas connections and condensate drain.–Pull the heat exchanger up and out.–Clean the heat exchanger hole (hole inside the cooler block), as the heat exchangers are installed with silicone grease.–Flush the heat exchanger until all contaminants have been removed.–Grease the cooled outside surface external surface with silicone grease.–Reinsert the heat exchanger into the cooling nest with a rotating movement.–Reconnect the gas supply and condensate drain. The gas inlet is marked red.–Restore power/gas supply and wait for unit to be ready for operation.–Open gas supply.15Bühler Technologies GmbHBE440015 ◦ 10/2018

TC-MINI7.5 Replacing the filter element (option)CAUTIONGas leakageThe filter should not be dismantled under pressure.Don’t use damaged parts again.–Close the gas supply.–Switch off and unplug the device.–Pull the bracket, holding on to the filter glass.–Whilst holding the filter head, move the glass back and forth and carefully remove downward.–Remove the filter element and insert a new one.–Check for leaks and replace, if necessary.–Whilst holding the filter head, move the glass back and forth and carefully reattach the filter head, attach the bracket, andensure it is seated securely.–Restore the power and gas supply.NOTICE!Please observe legal regulations when disposing of filter elements.7.6 Drying of the moisture detector (option)The moisture detector must be dried if moisture enters.–Close the gas supply.–Switch off and unplug the device.–Loosen the swivel nut for the moisture detector connection line and disconnect the line.–Unscrew the moisture detector counter-clockwise and remove.–Dry moisture detector.–Reinsert the moisture detector and carefully tighten the screw connection.–Connect the connection line and tighten the swivel nut.–Restore the power and gas supply.7.7 Spare parts and accessoriesPlease also specify the model and serial number when ordering parts.Upgrade and expansion parts can be found in our catalog.Available spare parts:Item no.Description40 11 00 0Flow adapter type G, PVDF G1/440 11 00 0 IFlow adapter type NPT, PVDF NPT 1/4"41 11 10 0Moisture detector FF-3-N, without cable91 44 05 00 81Moisture detector connection cable, 300 mm91 44 05 00 82Moisture detector connection cable, 450 mm91 10 00 00 31Sample gas cooler micro-fuse 24 VDC, 5 x 20 mm, 5 A, delayed action55 30 00 09 93 2Fan, 24 VDC16Bühler Technologies GmbHBE440015 ◦ 10/2018

TC-MINI7.7.1 Consumables and accessoriesItem no.Description91 12 00 00 3924 V top-hat rail power supply91 12 00 00 4024 V top-hat rail power supply for using the 24 V output45 10 008Automatic condensate drain AK 5.245 10 028Automatic condensate drain AK 5.544 10 004Automatic condensate drain AK 2044 10 001Automatic condensate drain 11 LD V 3841 03 00 50Replacement filter element F2; 2 µm, Unit 5 count43 81 045Screw connection G1/4 - DN 8/12 for passive condensate connection MTS and MTV43 81 048Screw connection NPT 1/4" for passive condensate connection MTS and MTV17Bühler Technologies GmbHBE440015 ◦ 10/2018

TC-MINI8 DisposalThe heat exchanger is charged with glycol-based coolant.Dispose of parts so as not to endanger the health or environment. Follow the laws in the country of use for disposing of elec-tronic components and devices as well as hazardous materials during disposal.18Bühler Technologies GmbHBE440015 ◦ 10/2018