Bühler technologies 4496 Series User manual

Gas Analysis
Installation and Operation Instructions
Original instructions
Sample gas cooler
TC-Standard (+)
BE440026
12/2020
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
E-Mail: [email protected]
Internet: www.buehler-technologies.com

Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
Internet: www.buehler-technologies.com
E-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 misusing
the product or unreliable function due to unauthorised modifications.
All rights reserved. Bühler Technologies GmbH 2021
Document information
Document No......................................................... BE440026
Version......................................................................... 12/2020

TC-Standard (+)
Contents
1 Introduction..................................................................................................................................................................................................................... 3
1.1 Intended use .........................................................................................................................................................................................................3
1.2 Overview ................................................................................................................................................................................................................ 3
1.3 Type plate .............................................................................................................................................................................................................. 3
1.4 Scope of delivery.................................................................................................................................................................................................. 3
1.5 Ordering instructions ........................................................................................................................................................................................4
1.5.1 Gas cooler models with one heat exchanger .............................................................................................................................. 4
1.5.2 Gas cooler models with two heat exchangers .............................................................................................................................5
1.5.3 Gas cooler model with two heat exchangers in series ............................................................................................................. 6
2 Safety instructions......................................................................................................................................................................................................... 7
2.1 Important advice................................................................................................................................................................................................. 7
2.2 General hazard warnings .................................................................................................................................................................................8
3 Transport and storage ..................................................................................................................................................................................................9
4 Installation and connection ...................................................................................................................................................................................... 10
4.1 Installation site requirements....................................................................................................................................................................... 10
4.2 Installation ..........................................................................................................................................................................................................10
4.2.1 Connecting the filter gas connections (optional) .....................................................................................................................10
4.2.2 Flow adapter connection (optional)..............................................................................................................................................10
4.2.3 Connecting the moisture detector (option).................................................................................................................................11
4.2.4 Peristaltic pump connector (optional) ..........................................................................................................................................11
4.2.5 Connecting the heat exchanger......................................................................................................................................................11
4.3 Electrical connections ...................................................................................................................................................................................... 12
4.4 Signal outputs.....................................................................................................................................................................................................13
5 Operation and control .................................................................................................................................................................................................15
5.1 Description of functions...................................................................................................................................................................................15
5.2 Delta T control option .......................................................................................................................................................................................15
5.3 Use of menu functions .................................................................................................................................................................................... 16
5.3.1 Lock Menu.............................................................................................................................................................................................16
5.3.2 Menu navigation overview.............................................................................................................................................................. 17
5.4 Description of menu functions ..................................................................................................................................................................... 19
5.4.1 Display menu.......................................................................................................................................................................................19
5.4.2 Main menu...........................................................................................................................................................................................19
5.4.3 Submenu 1 ...........................................................................................................................................................................................20
5.4.4 Submenu 1 (global settings) ............................................................................................................................................................ 21
5.4.5 Set favourite menu ........................................................................................................................................................................... 24
6 Maintenance.................................................................................................................................................................................................................. 25
7 Service and repair.........................................................................................................................................................................................................26
7.1 Troubleshooting ................................................................................................................................................................................................26
7.1.1 Error messages on the display........................................................................................................................................................27
7.2 Safety instructions............................................................................................................................................................................................28
7.3 Cleaning and removal of the heat exchanger...........................................................................................................................................29
7.4 Replacing the hoses of the peristaltic pump (option) ............................................................................................................................29
7.5 Replacing the filter element (option)..........................................................................................................................................................29
7.6 Drying of the moisture detector (option)...................................................................................................................................................30
7.7 Calibration of the moisture detector (option)..........................................................................................................................................30
7.8 Replacing the base unit...................................................................................................................................................................................30
7.9 Spare parts and accessories ............................................................................................................................................................................31
7.9.1 Consumables and accessories ........................................................................................................................................................ 31
8 Disposal........................................................................................................................................................................................................................... 32
9 Appendices..................................................................................................................................................................................................................... 33
9.1 Gas cooler technical data................................................................................................................................................................................ 33
9.2 Technical Data - Options .................................................................................................................................................................................34
9.3 Flow diagrams.................................................................................................................................................................................................... 35
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TC-Standard (+)
9.4 Performance curves..........................................................................................................................................................................................36
9.5 Heat exchanger.................................................................................................................................................................................................. 37
9.5.1 Heat exchanger description ............................................................................................................................................................37
9.5.2 Heat exchanger overview.................................................................................................................................................................37
9.6 Dimensions (mm)..............................................................................................................................................................................................38
10 Attached documents.................................................................................................................................................................................................. 40
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1 Introduction
1.1 Intended use
This unit is intended for industrial use in gas analysis systems. It's an essential component for conditioning the sample gas to
protect 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 pressure
and temperature limits.
1.2 Overview
The TC-Standard series was designed specifically for high cooling capacities and high ambient temperatures.
The TC-Standard+ series was designed specifically for the requirements in so-called automated measuring systems(AMS) ac-
cording to EN15267-3. The series connection of the heat exchangers will cool in two cycles to minimise wash out effects.
The Peltier cooler is distinguished by two types according to cooling capacity or operation temperature. This classification is re-
flected in the type designation. The exact item number of the model defined by you is determined by the model code in the cat-
egory ordering information.
Application Standard applications
Operation temperature 40 °C 50 °C
1 heat exchanger TC-Standard 6111 TC-Standard 6112 3rd digit=1
2 heat exchangers TC-Standard 6121 TC-Standard 6122 3rd digit=2
2 heat exchangers in series TC-Standard+ 6121 TC-Standard+ 6122 3rd digit=2
4th digit=1 4th digit=2
Additional components which every conditioning system should feature can optionally be integrated:
– Peristaltic pump for condensate separation,
– Filter,
– Moisture detector.
This allows for various configurations of cooler and options. Here the approach is to simplify creating a complete system in a
cost-efficient way through pre-installed components with hoses connected. We further paid attention to easy access to wear
parts and consumables.
1.3 Type plate
Example:
Manufacturer with address
Type description and voltage
ID-no., part-no.
Part description
Date of manufacturing
TC-Standard 230 V
101001081115 449621111111030101010
0...50°C
09/2018 BX440026
1.4 Scope of delivery
– Cooler
– Product documentation
– Connection-/mounting accessories (optional)
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1.5 Ordering instructions
1.5.1 Gas cooler models with one heat exchanger
The item number is a code for the configuration of your unit. Please use the following model code:
4496 2 1 1 X 1 X 1 X X X 0 X X X 0 X 0 Product Characteristics
Gas cooler models (with 1 heat exchanger)
1 TC-Standard 6111: Ambient temperature 40 °C
2 TC-Standard 6112: Ambient temperature 50 °C
Certifications
1 for common locations - FM
Supply voltage
1 115 V AC, 50/60 Hz
2 230 V AC, 50/60 Hz
4 24 V DC
Heat exchanger
1 1 0 Stainless steel, PTS, metric
1 1 5 Stainless steel, PTS-I, US
1 2 0 Duran glass, PTG, metric
1 2 5 Duran glass, PTG-I, US
1 3 0 PVDF, PTV, metric
1 3 5 PVDF, PTV-I, US
Peristaltic pumps *
0 0 without peristaltic pump
1 0 CPsingle with hose nipple, angled
3 0 CPsingle with screw connection
Moisture detector / filter
0 0 without filter, without moisture detector
0 1 without filter, 1 moisture detector with PVDF adapter **
1 0 1 filter, without moisture detector
1 1 1 filter with built-in moisture detector
Signal outputs
0 0 status output only
1 0 Analog output, 4…20 mA additional
Delta T control
0 0 without Delta T control
1 0 Delta T control option
* 24 V DC CPsingle not connected electrically.
** Also available in stainless steel.
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1.5.2 Gas cooler models with two heat exchangers
The item number is a code for the configuration of your unit. Please use the following model code:
4496 2 1 2 X 1 X 2 X X X 0 X X X 0 X 0 Product Characteristics
Gas cooler models (with 2 heat exchangers)
1 TC-Standard 6121: Ambient temperature 40 °C
2 TC-Standard 6122: Ambient temperature 50 °C
Certifications
1 for common locations - FM
Supply voltage
1 115 V AC, 50/60 Hz
2 230 V AC, 50/60 Hz
4 24 V DC
Heat exchanger
2 1 0 Stainless steel, 2 MTS, metric
2 1 5 Stainless steel, 2 MTS-I, US
2 2 0 Duran glass, 2 MTG, metric
2 2 5 Duran glass, 2 MTG-I, US
2 3 0 PVDF, 2 MTV, metric
2 3 5 PVDF, 2 MTV-I, US
Peristaltic pumps *
0 0 without peristaltic pump
2 0 CPdouble with hose nipple, angled
4 0 CPdouble with screw connection
Moisture detector / filter
0 0 without filter, without moisture detector
0 1 without filter, 1 moisture detector with PVDF adapter **
0 2 without filter, 2 moisture detectors with PVDF adapter **
1 0 1 filter, without moisture detector
1 1 1 filter with built-in moisture detector
2 0 2 filters, without moisture detector
2 1 2 filters, 1 moisture detector
2 2 2 filters, 2 moisture detectors
Signal outputs
0 0 status output only
1 0 Analog output, 4…20 mA additional
Delta T control
0 0 without Delta T control
1 0 Delta T control option
* 24 V DC CPdouble not connected electrically.
** Also available in stainless steel.
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1.5.3 Gas cooler model with two heat exchangers in series
The item number is a code for the configuration of your unit. Please use the following model code:
4496 2 1 2 X 1 X 1 X X X 0 X X X 0 0 0 Product Characteristics
Gas cooler models (with 2 in-line heat exchangers)
1 TC-Standard+ 6121: Ambient temperature 40 °C
2 TC-Standard+ 6122: Ambient temperature 50 °C
Certifications
1 for common locations - FM
Supply voltage
1 115 V AC, 50/60 Hz
2 230 V AC, 50/60 Hz
4 24 V DC
Heat exchanger
1 2 2 Duran glass, 2x MTG-2, metric
1 2 7 Duran glass, 2x MTG-2-I, US
1 3 2 PVDF, 2x MTV-2, metric
1 3 7 PVDF, 2x MTV-2-I, US
Peristaltic pumps *
0 0 without peristaltic pump
2 0 CPdouble with hose nipple, angled
4 0 CPdouble with screw connection
Moisture detector / filter
0 0 without filter, without moisture detector
0 1 without filter, 1 moisture detector with PVDF adapter **
1 0 1 filter, without moisture detector
1 1 1 filter with built-in moisture detector
Signal outputs
0 0 status output only
1 0 Analog output, 4…20 mA additional
* 24 V DC CPdouble not connected electrically.
** Also available in stainless steel.
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2 Safety instructions
2.1 Important advice
Operation of the device is only valid if:
– the product is used under the conditions described in the installation- and operation instruction, the intended application
according 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. Keep
this 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 not
avoided.
CAUTION
Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property or
minor or medium injuries if not avoided.
NOTICE
Signal word for important information to the product.
Warning signs
These instructions use the following warning signs:
Warns of a general hazard General information
Warns of voltage Unplug from mains
Warns not to inhale toxic gasses Wear respiratory equipment
Warns of corrosive liquids Wear a safety mask
Warns of explosive areas Wear gloves
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2.2 General hazard warnings
The 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. Prevent
malfunctions 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,
– compliance with national installation regulations.
– the device is protected from mechanical loads.
Maintenance, Repair
Please 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.
– Do not install damaged or defective spare part. If necessary, visually inspect prior to installation to determine any obvious
damage to the spare parts.
Always observe the applicable safety and operating regulations in the respective country of use when performing any type of
maintenance.
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
DANGER Toxic, corrosive gas/condensate
Sample 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.
DANGER Potentially explosive atmosphere
Explosion 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.
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