Buhler TC-MINI Owner's manual

Gas Analysis
Installation and Operation Instructions
Original instructions
Sample gas cooler
TC-MINI
BE440015
04/2023
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 2023
Document information
Document No.......................................................... BE440015
Version.........................................................................04/2023

TC-MINI
Contents
1 Introduction.....................................................................................................................................................................................................................2
1.1 Intended use .........................................................................................................................................................................................................2
1.2 Types........................................................................................................................................................................................................................2
1.3 Scope of delivery ..................................................................................................................................................................................................2
1.4 Ordering instructions.........................................................................................................................................................................................2
2 Safety instructions ......................................................................................................................................................................................................... 3
2.1 Important advice ................................................................................................................................................................................................. 3
2.2 General hazard warnings .................................................................................................................................................................................4
3 Transport and storage .................................................................................................................................................................................................. 5
4 Installation and connection ........................................................................................................................................................................................6
4.1 Installation site requirements.........................................................................................................................................................................6
4.2 Installation ............................................................................................................................................................................................................6
4.2.1 Connecting the filter gas connections (optional) ....................................................................................................................... 7
4.2.2 Flow adapter connection (optional) ............................................................................................................................................... 7
4.2.3 Connecting the moisture detector (option) ................................................................................................................................. 7
4.3 Electrical connections......................................................................................................................................................................................... 7
4.4 Settings...................................................................................................................................................................................................................9
5 Operation and control .................................................................................................................................................................................................11
5.1 Status Signal via LEDs and Status Relay ......................................................................................................................................................11
5.2 Using the Digital Interface...............................................................................................................................................................................11
5.3 Modbus Configuration .....................................................................................................................................................................................11
5.4 Modbus Communication................................................................................................................................................................................ 12
5.5 Modbus Register................................................................................................................................................................................................ 13
6 Maintenance...................................................................................................................................................................................................................17
7 Service and repair......................................................................................................................................................................................................... 18
7.1 Troubleshooting ................................................................................................................................................................................................ 19
7.2 Safety instructions ........................................................................................................................................................................................... 20
7.3 Cleaning and removal of the heat exchanger.......................................................................................................................................... 20
7.4 Replacing the fuse of the cooler................................................................................................................................................................... 20
7.5 Replacing the filter element (option) .......................................................................................................................................................... 21
7.6 Drying of the moisture detector (option)................................................................................................................................................... 21
7.7 Spare parts .......................................................................................................................................................................................................... 21
7.7.1 Consumables and accessories ........................................................................................................................................................22
8 Disposal ...........................................................................................................................................................................................................................23
9 Appendices .....................................................................................................................................................................................................................24
9.1 Gas cooler technical data................................................................................................................................................................................24
9.2 Technical Data - Options .................................................................................................................................................................................24
9.3 Dimensions (mm)..............................................................................................................................................................................................25
9.4 Performance data..............................................................................................................................................................................................25
9.5 Heat exchanger..................................................................................................................................................................................................26
9.5.1 Heat exchanger description............................................................................................................................................................26
9.5.2 Heat exchanger overview ................................................................................................................................................................26
10 Attached documents ...................................................................................................................................................................................................27
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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 Types
The device is delivered with different configurations. The part number given on the type plate informs you about the specific
configuration of your device.
1.3 Scope of delivery
– Cooler
– Product documentation
– Connection-/mounting accessories (optional)
1.4 Ordering instructions
4496 1 1 1 X 0 4 X X X 0 0 X X X 0 0 0 0 Product Characteristics
Gas cooler models (with 1 heat exchanger)
1 TC-MINI 6111: moderate ambient temperature 40°C
2 TC-MINI 6112: higher ambient temperature 50°C
Certifications
0 Standard applications – CE
Supply voltage
4 24 V DC
Heat exchanger 1)
1 1 0 0 0 Stainless steel, MTS, metric
1 1 5 0 0 Stainless steel, MTS-I, US
1 2 0 0 0 Duran glass, MTG, metric
1 2 5 0 0 Duran glass, MTG, US
1 3 0 0 0 PVDF, MTV, metric
1 3 5 0 0 PVDF, MTV-I, US
1 6 0 0 0 Stainless steel, angle connector, MTS-WS, metric
1 6 5 0 0 Stainless steel, angle connector, MTS-I-WS, US
Moisture detector/filter
0 0 without filter, without moisture detector
0 1 without filter, 1 moisture detector with block
1 0 1 filter, without moisture detector
1 1 1 filter with built-in moisture detector
Signal outputs
1 0 0 0 0 Analog output, 4..20 mA, incl. status output
2 0 0 0 0 Modbus RTU digital output, incl. status output
1) Moisture detector/filter screw-in fitting and tubes metric or US, accordingly
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2 Safety instructions
2.1 Important advice
Operation of the device is only permitted 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 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
General information
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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 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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4 Installation and connection
4.1 Installation site requirements
The unit is only intended for wall-mounted use in enclosed areas. Adequate protection from the weather must be provided
when 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 have
enough 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 Installation
Run 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. Our
condensate 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 drains
Depending 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 condensate
drain 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 exchanger
The 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
Pay attention to the appropriate spanner size when selecting fittings for stainless steel heat exchangers.
TS/TS-I gas connections: SW 17
TS/TS-I condensate out connections: SW 22
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4.2.1 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 a
suitable 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 screw
in a suitable screw connection. Pay attention to leaks.
NOTICE
Installing filters limits the maximum approved operating pressure in the system!
Operating pressure ≤ 2 bar
4.2.2 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 connection
G1/4 or NPT1/4" (flow adapter marked NPT) for the gas inlet/outlet must be carefully and properly connected using a suitable
screw 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 option
installed and connected in the filter head.
4.3 Electrical connections
NOTICE
The connection must be made by a trained professional.
CAUTION Wrong mains voltage
Wrong 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. Please refer to the technical data for ratings.
An alarm is triggered if the temperature of the cooler is outside the specified limits. It does not indicate if the alarm was
triggered 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 sample
gas. This is the same alarm output as for the temperature.
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X2.5X2.1
X2.10
X2.6
X1.1
DIP Switch / Settings
LED green
LED red
Inputs/outputs Terminal Function Description
Moisture detector X1.1 FF.1 (white) Moisture detector
X1.2 FF.2 (brown)
X1.3 FE: Shield for moisture detector inlet
Status X2.1 Status NC (Alarm) Alarm/Status
Changeover contact, potential-free,
Ratings see technical data
X2.2 Status COM
X2.3 Status NO (ok)
24 V input X2.4 24 V DC - Power supply
X2.5 24 V DC +
Analog output X2.6 FE: Shield for analog output
X2.7 mA + Analog output
4…20 mA, 0 - 80 °C
X2.8 mA -
Digital output X2.6 FE: Shield for digital output
X2.7 Signal A Communication line for digital interface
X2.8 Signal B
24 V output * X2.9 24 V DC - Supply for optional add-on units
maximum current, see technical data
X2.10 24 V DC +
* Add-on units, e.g. a pump, with 24 V supply can be connected to the output, switched via the status output. The 24 V supply
must then be configured appropriately (see data sheet).
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