Bühler technologies TC-Double Plus User manual

Gas Analysis
Installation and Operation Instructions
Original instructions
Sample gas cooler
TC-Double (+)
BE440021
09/2021
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.......................................................... BE440021
Version......................................................................... 09/2021

TC-Double (+)
Contents
1 Introduction..................................................................................................................................................................................................................... 3
1.1 Intended use ......................................................................................................................................................................................................... 3
1.2 Overview ................................................................................................................................................................................................................ 3
1.3 Scope of delivery.................................................................................................................................................................................................. 3
1.4 Ordering instructions ........................................................................................................................................................................................4
1.4.1 TC-Double .............................................................................................................................................................................................. 4
1.4.2 TC-Double+.............................................................................................................................................................................................5
2 Safety instructions.........................................................................................................................................................................................................6
2.1 Important advice.................................................................................................................................................................................................6
2.2 General hazard warnings ................................................................................................................................................................................. 7
3 Transport and storage ..................................................................................................................................................................................................8
4 Installation and connection ........................................................................................................................................................................................9
4.1 Installation site requirements.........................................................................................................................................................................9
4.2 Installation ............................................................................................................................................................................................................9
4.2.1 Flow adapter connection (optional)............................................................................................................................................... 9
4.2.2 Connecting the moisture detector (option)................................................................................................................................. 9
4.2.3 Connecting the peristaltic pump (option) ................................................................................................................................... 9
4.2.4 Sample gas pump connection gas lines (optional) ..................................................................................................................10
4.2.5 Connecting the heat exchanger.....................................................................................................................................................10
4.3 Electrical connections ....................................................................................................................................................................................... 11
4.4 Signal outputs.....................................................................................................................................................................................................13
5 Operation and control ................................................................................................................................................................................................ 14
5.1 Description of functions.................................................................................................................................................................................. 14
5.2 Use of menu functions .....................................................................................................................................................................................15
5.2.1 Lock Menu............................................................................................................................................................................................. 15
5.2.2 Menu navigation overview..............................................................................................................................................................16
5.3 Description of menu functions ..................................................................................................................................................................... 18
5.3.1 Display menu.......................................................................................................................................................................................18
5.3.2 Main menu...........................................................................................................................................................................................18
5.3.3 Submenu 1 ............................................................................................................................................................................................19
5.3.4 Submenu 1 (Global Settings) .......................................................................................................................................................... 20
5.3.5 Set favourite menu ........................................................................................................................................................................... 24
5.4 Using the Digital Interface .............................................................................................................................................................................24
5.5 Modbus Configuration....................................................................................................................................................................................24
5.6 Modbus Communication................................................................................................................................................................................24
5.7 Modbus Register................................................................................................................................................................................................ 25
6 Maintenance..................................................................................................................................................................................................................29
7 Service and repair.........................................................................................................................................................................................................30
7.1 Troubleshooting ................................................................................................................................................................................................30
7.1.1 Error messages on the display........................................................................................................................................................31
7.2 Safety instructions............................................................................................................................................................................................32
7.3 Cleaning and removal of the heat exchanger........................................................................................................................................... 33
7.4 Replacing the fuse of the cooler.................................................................................................................................................................... 33
7.5 Replacing the hoses of the peristaltic pump (option) ............................................................................................................................33
7.6 Replacing the filter element (option) ..........................................................................................................................................................34
7.7 Drying of the moisture detector (option)...................................................................................................................................................34
7.8 Calibration of the moisture detector (option)..........................................................................................................................................34
7.9 Replacing sample gas pump inlet and outlet valves (optional)..........................................................................................................35
7.10 Replacing the O-ring on the bypass valve (optional).............................................................................................................................. 35
7.11 Replacing the bellow (optional) ....................................................................................................................................................................36
7.12 Spare parts and accessories ...........................................................................................................................................................................36
7.12.1 Consumables and accessories ........................................................................................................................................................37
8 Disposal...........................................................................................................................................................................................................................38
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TC-Double (+)
9 Appendices.....................................................................................................................................................................................................................39
9.1 Gas Cooler Technical Data ..............................................................................................................................................................................39
9.2 Technical Data - Options ................................................................................................................................................................................ 40
9.3 Flow chart ............................................................................................................................................................................................................ 41
9.4 Performance curves.......................................................................................................................................................................................... 41
9.5 Heat exchanger..................................................................................................................................................................................................42
9.5.1 Heat exchanger description ........................................................................................................................................................... 42
9.5.2 Heat exchanger overview................................................................................................................................................................ 42
9.6 Dimensions (mm)..............................................................................................................................................................................................43
10 Attached documents...................................................................................................................................................................................................44
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TC-Double (+)
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-Double series was designed specifically for high cooling capacities, high ambient temperatures and to cool in two cycles
to minimise wash out effects. The two cooling blocks on the TC-Double+ can be set do different temperatures.
Any other use of this cooler is determined by the type of built-in passive pre-cooling, i.e. the first cooling level is not controlled
electronically.
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
2 heat exchangers in series TC-Double 6111 TC-Double 6112
2 heat exchangers in series TC-Double+ 6111 TC-Double+ 6112
Additional components which every conditioning system should feature can optionally be integrated:
– Peristaltic pump for condensate separation,
– Filter,
– Moisture detector,
– sample gas pump.
In addition, we offer different signal outputs:
– Status output
– Analog output, 4…20 mA, incl. status output,
– Modbus RTU digital output, incl. status output
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 Scope of delivery
– Cooler
– Product documentation
– Connection-/mounting accessories (optional)
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1.4 Ordering instructions
1.4.1 TC-Double
The item number is a code for the configuration of your unit. Please use the following model code:
4496 6 1 1 X 0 X 1 X X X X X X X 0 0 0 Product Characteristics
Gas cooler type
1 TC-Double 6111: Ambient temperature 40 °C
2 TC-Double 6112: Ambient temperature 60 °C
Certifications
0 Standard applications – CE
Supply voltage
1 115 V AC, 50/60 Hz
2 230 V AC, 50/60 Hz
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
Condensate drain 1)
0 without condensate drain
2 CPdouble with hose nipple, angled
4 CPdouble with screw connection 2)
Sample gas pumps 1) 3)
0 without sample gas pump
1 P1, PVDF
2 P1, with bypass valve
Moisture detector/filter 1) 2)
0 0 without filter, without moisture detector
0 1 without filter, 1 moisture detector with PVDF adapter 4)
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, incl. status output
2 0 Modbus RTU digital output, incl. status output
1) With this option, the maximum ambient temperature is limited to 50°C.
2) Metric or US connection, per heat exchanger.
3) Factory installed tubing for suction operation.
4) Also available in stainless steel.
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1.4.2 TC-Double+
The item number is a code for the configuration of your unit. Please use the following model code:
4496 6 1 1 X 0 X 1 X X X X X X X 0 0 0 Product Characteristics
Gas cooler type
1 TC-Double+ 6111: Ambient temperature 40 °C
2 TC-Double+ 6112: Ambient temperature 60 °C
Certifications
0 Standard applications – CE
Supply voltage
1 115 V AC, 50/60 Hz
2 230 V AC, 50/60 Hz
Heat exchanger
1 2 2 Duran glass, PTG-2, metric
1 2 7 Duran glass, PTG-2-I, US
1 3 2 PVDF, PTV-2, metric
1 3 7 PVDF, PTV-2-I, US
Condensate drain 1)
0 without condensate drain
2 CPdouble with hose nipple, angled
4 CPdouble with screw connection 2)
Sample gas pumps 1) 3)
0 without sample gas pump
1 P1, PVDF
2 P1, with bypass valve
Moisture detector/filter 1) 2)
0 0 without filter, without moisture detector
0 1 without filter, 1 moisture detector with PVDF adapter 4)
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, incl. status output
2 0 Modbus RTU digital output, incl. status output
1) With this option, the maximum ambient temperature is limited to 50°C.
2) Metric or US connection, per heat exchanger.
3) Factory installed tubing for suction operation.
4) 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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3 Transport and storage
Only 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-free
room at a temperature of -20 °C to 60 °C (-4 °F to 140 °F).
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