M&C CSS Series User manual

Gas Conditioning Unit Series CSS®
CSS-M/W wall mount
Instruction Manual
Version 1.02.01

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Dear customer,
Thank you for buying our product. In this instruction manual you will find all necessary information
about this M&C product. The information in the instruction manual is fast and easy to find, so you can
start using your M&C product right after you have read the manual.
If you have any question regarding the product or the application, please don’t hesitate to contact M&C
or your M&C authorized distributor. You will find all the addresses in the appendix of this manual.
For additional information about our products and our company, please go to M&C’s website
www.mc-techgroup.com. There you will find the data sheets and manuals of our products in German
and English.
This Operating Manual does not claim completeness and may be
subject to technical modifications.
© 03/2022 M&C TechGroup Germany GmbH. Reproduction of this
document or its content is not allowed without permission from M&C.
CSS®is a registered trade mark.
Version: 1.02.01

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Contents
1General information....................................................................................................................... 5
2Declaration of conformity ............................................................................................................. 5
3Safety instructions......................................................................................................................... 6
3.1Intended use ............................................................................................................................. 6
4Warranty ......................................................................................................................................... 7
5Used terms and signal indications............................................................................................... 7
6Introduction .................................................................................................................................... 9
7Application ..................................................................................................................................... 9
8Technical Data.............................................................................................................................. 10
9Description ................................................................................................................................... 11
10Receipt of marchendise and storage .....................................................................................12
11Installation instructions.......................................................................................................... 12
12Supply connections ................................................................................................................. 13
12.1Hose connections ................................................................................................................... 13
12.2Electrical connections ............................................................................................................. 14
13Starting...................................................................................................................................... 15
13.1Cooler regulation .................................................................................................................... 16
13.2New pump switch since 06/2007 ............................................................................................ 16
14Closing down............................................................................................................................ 18
15Maintenance..............................................................................................................................18
15.1Replacement of the filter element and the O-Ring.................................................................. 19
15.2Dismounting the sample gas pump for examination or maintenance ..................................... 20
15.3Maintenance of the integrated peristaltic pump type SR25.2 ................................................. 20
15.3.1Mounting instructions for peristaltic pump ....................................................................... 21
15.3.2Changing the pump tubing .............................................................................................. 22
15.3.3Changing contact pulleys and springs............................................................................. 23
15.3.4Reassembly of the driver................................................................................................. 25
15.3.5Cleaning the pump head ................................................................................................. 25
15.3.6Repair information for integrated peristaltic pump type SR25.2 ...................................... 25
16Operating of the built-in electronic temperature controller ................................................. 26
16.1Temperature controller version until march 2022 ................................................................... 26
16.1.1Changing the set value.................................................................................................... 26
16.2Temperature controller version starting april 2022 .................................................................26
16.2.1Changing the set value.................................................................................................... 27
17Trouble shooting ...................................................................................................................... 27
18Proper disposal of the device .................................................................................................28
19Spare part list ........................................................................................................................... 29
20Appendix ................................................................................................................................... 30

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List of Illustrations
Figure 1Scheme of gas flow ..............................................................................................................9
Figure 2Dimensions CSS-M/W........................................................................................................11
Figure 3Hose connections CSS-M/W..............................................................................................13
Figure 4Electronic board CSS-M.....................................................................................................17
Figure 5Replacement of the filter element and the O-ring...............................................................19
Figure 6SR25.2: Mounting distance between front panel and pump motor ....................................21
Figure 7Changing the pump tubing .................................................................................................22
Figure 8Different pump tube sizes...................................................................................................23
Figure 9Disassembly of pump head and driver ...............................................................................23
Figure 10Check of axes and rolls ..................................................................................................24
Figure 11Front view of the temperature controller version until 03.2022.......................................26
Figure 12Front view of the temperature controller version starting 04.2022..................................26
Figure 13Circuit diagram CSS-M/W................................................................................................31

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Head Office
M&C TechGroup Germany GmbH Rehhecke 79 40885 Ratingen Germany
Telephone: 02102 / 935 - 0
Fax: 02102 / 935 - 111
E - mail: [e-mail]
www.mc-techgroup.com
1 GENERAL INFORMATION
The product described in this manual has been built and tested in our production facility.
All M&C products are packed to be shipped safely. To ensure the safe operation and to maintain the
safe condition, all instructions and regulations stated in this manual need to be followed. This manual
includes all information regarding proper transportation, storage, installation, operation and
maintenance of this product by qualified personnel.
Please follow all instructions and warnings closely.
Please read this manual carefully before commissioning and operating the device. If you have any
questions regarding the product or the application, please don’t hesitate to contact M&C or your M&C
authorized distributor.
2 DECLARATION OF CONFORMITY
CE - Certification
The product described in this operating manual complies with the following EU directives:
EMC-Instruction
The requirements of the EU directive 2014/30/EU “Electromagnetic compatibility“ are met.
RoHS Directive
The requirements of the RoHS2 (‘Restriction of Hazardous Substances 2’) directive 2011/65/EU and
its annexes are met.
Low Voltage Directive
The requirement of the EU directive 2014/35/EU “Low Voltage Directive“ are met.
The compliance with this EU directive has been examined according to DIN EN 61010.
Declaration of conformity
The EU Declaration of conformity can be downloaded from the M&C homepage or directly requested
from M&C.

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3 SAFETY INSTRUCTIONS
Follow these safety directions and instructions regarding installation, commissioning and
operation of the device:
Read this manual before commissioning and operating the product. Make sure to follow all safety
instructions.
Installation and commissioning of electrical devices must be carried out only by qualified skilled
personnel in compliance with the current regulations.
The installation and commissioning of the device must conform to the requirements of VDE 0100
‘Regulations on the Installation of Power Circuits with Nominal Voltages below 1000 V’ and must be in
compliance with all relevant regulations and standards.
Make sure to compare the supply voltage with the specified voltage on the product label before
connecting the device.
Protection against damages caused by high voltages:
Disconnect the power supply before opening the device for access. Make sure that all extern power
supplies are disconnected.
Operate the device only in the permitted temperature and pressure ranges. For details please refer to
the technical data sheet or manual.
Install the device only in protected areas, sheltered from rain and moisture. The product should not be
exposure to the elements.
This device is NOT certified to be installed or operated in explosive hazardous areas.
Installation, maintenance, inspections and any repairs of the devices must be carried out only by
qualified skilled personnel in compliance with the current regulations.
3.1INTENDED USE
The CSS-MW gas conditioning unit is intended for use in general purpose areas (non-hazardous
environments). The CSS-M/W can only be operated in compliance with the information in chapter 8
Technical Data. You must meet the requirements of the ambient temperature and pressure
characteristics in particular.
Do not use this product for any other purpose. Improper use and handling can create hazards and
cause damage. For more information, please refer to the safety information in this instruction manual.

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4 WARRANTY
In case of a device failure, please contact immediately M&C or your M&C authorized distributor.
We have a warranty period of 12 months from the delivery date. The warranty covers only
appropriately used products and does not cover the consumable parts. Please find the complete
warranty conditions in our terms and conditions.
The warranty includes a free-of-charge repair in our production facility or the free replacement of the
device. If you return a device to M&C, please be sure that it is properly packaged and shipped with
protective packaging. The repaired or replaced device will be shipped free of delivery charges to the
point of use.
5 USED TERMS AND SIGNAL INDICATIONS
Danger
DANGER indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
Warning
WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Caution
CAUTION indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Attention ATTENTION is used to address practices not related to physical
injury.
Note
These are important information about the product or parts of the
operating manual which require user’s attention.
Qualified Personnel ‘Qualified personnel’ are experts who are familiar with the
installation, mounting, commissioning and operation of these
types of products.
High voltages!
Protect yourself and others against damages which might be
caused by high voltages.
Toxic!
Acute toxicity (oral, dermal, inhalation)! Toxic when in contact with
skin, swallowed or inhaled.
Corrosive!
These substances destroy living tissue and equipment upon
contact.
Do not breathe vapors; avoid contact with skin and eyes.

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Contains gas under pressure. Do not open container!
Check pressure before opening container, and adjust pressure to
atmospheric pressure.
Wear protective gloves!
Working with chemicals, sharp objects or extremely high
temperatures requires wearing protective gloves.
Wear safety glasses!
Protect your eyes while working with chemicals or sharp objects.
Wear safety glasses to avoid getting something in your eyes.
Wear protective clothes!
Working with chemicals, sharp objects or extremely high
temperatures requires wearing protective clothes.

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6 INTRODUCTION
The gas conditioning unit CSS-M/W for wall mounting is a completely pre-assembled compact gas
conditioning system working continuously and delivering a sample gas quantity of max. 70 Nl/h.
The entire gas conditioning unit is housed in a compact and robust steel sheet case which ensures
that the gas analyzes can be carried out quickly, safely and with a minimum amount of maintenance.
The gas conditioning unit CSS-M/W for wall mounting must not be used for sampling of explosive
gas/air or gas/oxygen mixtures, for sampling of combustible gases which may result in an explosive
mixture in combination with air or oxygen nor in explosive atmospheres and hazardous areas.
7 APPLICATION
The gas conditioning unit CSS-M/W for wall mounting has been developed for continuous operation.
The components integrated in the system CSS-M/W are intended for „standard use“.




Figure 1 Scheme of gas flow
Gas cooler ECP
Front panel filter FPF-2-0,3GF, 0.3 µm porosity with integrated liquid alarm
Sample gas pump N3 KPE
Flowmeter FM40
Peristaltic pump SR25.2 for continuous automatic condensate removal

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8 TECHNICAL DATA
Gas Conditioning Unit Type CSS-M/W
Sample outlet dew point Range of adjustment: +2 to +15 °C [35.6 to 59 °F], factory
setting: +5 °C [41 °F]
Dew point stability At constant conditions < ± 0.1 °C [± 0.18 °F]
Sample inlet temperature **Max. 80 °C [176 °F]
Gas inlet water vapor saturation **Max. 50 °C [122 °F]
Gas flow rate **Max. 70 Nl/h
Ambient temperature **+10 to +45 °C [50 to 113 °F]
Air humidity 75 % year’s average, rare and slight dewing of 95 % on 30
days per year admissible
Storage temperature -25 to +65 °C [-13 to +149 °F]
Pressure 0.7 bar to 1.4 bar abs.*
Total cooling capacity Max. 40 kJ/h
Number of gas inlets 1
Number of gas outlets 1*
Number of condensate outlets 1
Sample gas connections Tube connection 4/6 mm
Material medium-touched parts Glass, PVDF, PVC, Novoprene, Viton®, PPH
Ready for operation Approx. 10 min
Mains power supply 230 V 50 Hz ± 10 % or 115 V 60 Hz ± 10 %
Power consumption Max. 240 VA
Fuse protection 4 A, time-lag, 5 x 20 mm
Electrical mains supply Mains cable 3 x 1 mm2, signal cable 3 x 0.5 mm2,
3 m [≈9.84 ft] length
Status alarm, 1 change over
contact, potential free
Contact rating 250 VAC, 2 A, summary alarm for gas flow, liquid
and cooler temperature
Case protection IP20 EN 60529
Housing version Sheet steel case, lacquered, RAL 7035
Case dimensions (H x W x D) 177 x 263 x 372.5 mm [≈6.97” x 10.4” x 14.7”]
Weight Approx. 11 kg [≈24.3 lbs]
PVDF=Polyvinylidenefluoride
PVC=Polyvinyl chloride
FPM=Fluor caoutchouc
PPH=Polypropylene hard
Specifications for components see appendix
* Standard
** Maximum values in technical data must be rated in consideration of total cooling capacity at 25 °C
[77 °F] ambient temperature and an outlet dew point of 5 °C [41 °F].
Please note: Nl/h and Nl/min refer to the German standard DIN 1343 and are based on these standard
conditions: 0 °C [32 °F], 1013 mbar.

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9 DESCRIPTION
Figure 2 shows the dimensions and construction of the CSS-M/W.
5
,
0
24
6
710
101,5
37,75






177
2
63
15
Netzkabel
372,5
300
2
5
47,5
Signalkabel
Kondensat
A
us
Figure 2 Dimensions CSS-M/W
Fine filter FPF-2-0,3GF
Electronic controller
Flow meter FM40 with sample gas outlet
Peristaltic pump SR25.2 with condensate outlet
Pump switch
LED indication condensate alarm red
Sample gas inlet
All components of the gas conditioning unit are mounted in a compact sheet steel case. Filter and
peristaltic pump are placed into the front panel and thus assure a very easy maintenance.
The minimum flow rate is determined by the sample gas pump (see also chapter 13). If the required
minimum total flow rate of 30 Nl/h is not reached, excessive overpressure can lead to premature
destruction of the pump diaphragm.
The gas cooler is equipped with a heat exchanger made of Duran glass.
The fine filter FPF-2-0,3GF (0.3 µm filter porosity) installed in front of the sample gas pump
N3 KPE ensures the necessary removal of solid particles.
The instrument contains a temperature alarm contact that is activated in case the temperature differs
more than ±3 °C [±5.4 °F] from the set value (5 °C [41 °F]) adjusted at the factory.
The temperature alarm contact of the cooler (+8 °C or +2 °C) [+46.4 °F or +35.6 °F] controls
automatically the switching on and off of the sample gas pump provided the switch “Pump on” has
been actuated (green light is on). The condensate occurred is removed continuously via the peristaltic
pump type SR25.2.
The DN4/6 mm hose connections for the condensate and sample gas outlet are located on the front
panel, the DN4/6 mm sample gas inlet is located on the back side on the case.
The ventilation grids in the sidewalls ensure that the equipment is sufficiently ventilated.
A liquid alarm sensor is integrated in the filter FPF-2-0,3GF to protect the downward analyzers against
liquid irruptions and to increase the operating safety of the whole system. In case of liquid inrush, the
internal electronic of the sample gas pump is automatically switched off.

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10 RECEIPT OF MARCHENDISE AND STORAGE
The gas sampling system CSS-M/W is a completely pre-installed unit. The scope of delivery includes
furthermore:
25 x Filter elements (1 package)
1 x Connection cable
1 x Instruction Manual
Please take the CSS-M/W and possible special accessories carefully out of the packaging material
immediately after arrival, and compare the goods with the items listed on the delivery note;
Check the goods for any damage caused during delivery and, if necessary, notify your transport
insurance company without delay of any damage discovered.
Note
The gas conditioning system should be stored in a protected frost-free area!
11 INSTALLATION INSTRUCTIONS
Note
In order to ensure that the case is safe and stable when being used, it should be
placed on a horizontal surface free from vibrations. Only then, the perfect
functioning of the separation and drainage procedures of the condensate inside
the heat exchanger of the cooler will only be guaranteed.
The gas conditioning system should be kept away from heat sources and be freely
ventilated in order to prevent an accumulation of heat.
When the equipment is being used outside, ample protection against the effects of
direct sunlight and dampness must be provided. In winter, the equipment must
only be used in frost-free areas; pay attention to the type of the equipment
protection.
Please avoid temperature variations, strong airflow as well as aggressive
atmospheres at the instalment location.
In order to guarantee the operational safety of the gas conditioning system and the
downstream analyzers, and to avoid false alarms, the gas conditioning unit should
not be used at temperatures other than those specified. Furthermore, it must be
protected against dust deposits and penetrating dust.
It is of great importance that the analyzers connected downstream are used at
temperatures well above the specified gas outlet dew point of +5 °C [+41 °F]. This
prevents the gas in the connector lines to the analyzers from subsequent
condensing.
Unheated gas sample lines must be installed with slope up to the cooler. In this
case, a preliminary condensate separation is not required.

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12 SUPPLY CONNECTIONS
12.1 HOSE CONNECTIONS
Condensate out DN3,2/6,4
Mains cable Signal cable
350mm
3000mm 3000mm
Sample gas inlet DN4/6 Sample gas outlet DN4/6
Figure 3 Hose connections CSS-M/W
Note
Do not mix up the hose connections; the connections are marked according to
Figure 3.
After having connected all lines, please check the seals.
All tube connections are DN4/6 mm sealing ring threaded hose couplings out of PVDF/PPH as
standard. They are suitable for gas inlet temperatures of maximum 80 °C [176 °F] (see chapter 8).
Follow these steps to mount the sample gas and condensate tubes:
1.Remove the union nut from the sealing ring couplings by turning it anti-clockwise. Be sure to
remove the union nut carefully from the fitting. There is a loose clamp ring inside the union nut.
2.Place the union nut over the connecting tube.
3.Push the sealing ring over the connecting tube with the thicker bulge facing the nut.
4.Place the tube over the nipple on the thread.
Note
The tightness of the connections can only be guaranteed if the connecting hose
has a straight edge (use a hose cutter).
5.Hand-tighten the nut. The tube is now slip-proof and pressure-tight mounted to the hose
connection fitting.
6.The tubes are to be removed in the reverse order.

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Warning
Aggressive condensate is possible.
Chemical burns caused by aggressive media possible!
Wear protective gloves and protective glasses!
Wear proper protective clothing!
12.2 ELECTRICAL CONNECTIONS
Warning
False supply voltage can damage the equipment. When connecting the
equipment, please ensure that the supply voltage is identical with the
information provided on the model type plate!
Note
For the assembly of power installations with rated voltages up to 1000 V,
the requirements of VDE 0100 and relevant standards and specifications
must be observed!
The main circuit is equipped with a fuse corresponding to the nominal
current (over current protection); for electrical details see technical data.
The gas conditioning unit CSS-M/W is available with either 230 V/50 Hz or 115 V/60 Hz (for circuit
diagram see Appendix). A 4 A fuse is used on all models as fuse protection. The fuse is located on the
electronic board inside the steel sheet case.
The electrical connection is made via the mains cable of 3 x 1 mm2on the back side of the case.
Brown = L
Blue =N
Green/yellow = PE
Connection of the signal lines:
The signal cables, 3 m [≈9.84 ft] long, 3 x 0,5 mm2are numbered from 1 – 3 (Status signals of the
condensate controller, the cooling temperature and the optional flow alarm sensor).
1 = NC
2 = MC
3 = NO
Please install the signal lines separated from the power supply lines. The contact rating for the alarm
contact is max. 250 V AC 2 A.

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13 STARTING
Before starting the gas conditioning system, pay attention to the site-oriented and process-oriented
precautions. Please check once again that the operating voltage (see type plate) corresponds to the
supply voltage!
Note
Before connecting the equipment to the mains voltage, the main switch must be in
position “0“.
The following steps have to be done before starting up for the first time:
1.Place the cold appliance plug, which is delivered with the mains supply cable, into the cold
appliance plug socket;
2.Connect the mains plug to the mains;
3.Turn the main switch to the position “I”.
After the starting time (LED K1 on the controller is on), the gas conditioning system is ready for use,
and the sample gas pump is switched on, if the key is activated (green light is on).
The sample gas must not be fed before the starting time of the sample gas cooler is finished, i.e. if the
sample gas outlet temperature does not exceed the limits adjusted at works (LED K1 on the controller
is on).
Note
The request for a maximum pressure load of the sample gas pump N3 KPE of 1.4
bar abs. results in the following minimal gas flow rate:
N 3 KPE min. 30 Nl/h air,
Premature damage can be caused to the pump membrane due to excess pressure
if less than the minimal total amount of flow is extracted.
In case of long-term measurements with a high level of dust, it is necessary to
utilise a suitable sample gas probe in order to protect the sample leads from
clogging-up.

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13.1 COOLER REGULATION
Indication LED K1 LED K2
After starting up > 8 °C [46.4 °F]
(Ambient temp.)
Off (Status alarm and pump
off)
Yellow light is
permanently on
(cooling)
After approx. 10 min. 7.5 °C
[45.5 °F]
Yellow light is on.
In case no condensate alarm
is given and the pump switch
is activated (green light is on),
the pump will be switched on.
Sample gas is lifted.
Yellow light is
permanently on
(cooling)
Normal operation 5 °C [41 °F] Yellow light is on Yellow light is flashing
(cooler control)
13.2 NEW PUMP SWITCH SINCE 06/2007
In the past time, it happened repeatedly that the pump switch of the gas conditioning system CSS-M
failed. For that reason, we changed the switch in 06/2007 into a key button. The effect is that the
switch status of the pump in case of a voltage loss does not exist anymore.
In order to keep the switch status, there is a jumper JP1 on the board by which you can determine
whether the pump shall restart automatically after a voltage loss or not.
With the bridge 2-3 (on), the pump restarts automatically.
With the bridge 1-2 (off), the pump does not restart again.
When delivered, the bridge is made between 1-2 (off), i.e. the pump does not restart after a voltage
loss.

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Figure 4 Electronic board CSS-M..

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14 CLOSING DOWN
Note
The location for the gas conditioning unit must remain frost-free, even if the unit
has been switched off.
There are no special regulations to be observed if the gas conditioning unit CSS-M/W is to be closed
down for a short period of time.
In case of a long-term closing down, for example after a series of measurements has been completed,
it is recommended to purge the gas conditioning system with ambient air or inert gas. Under normal
conditions, the equipment needs only to be purged for 3 to 5 minutes. Condensate residues should
also be removed from the system.
Warning
Aggressive condensate is possible.
Chemical burns caused by aggressive media possible!
When disassembling, repairing or cleaning, wear safety glasses and
proper protective clothing!
15 MAINTENANCE
Before carrying out any maintenance work, the specific safety instructions referring to the instalment
and the process must be observed!
Warning
Dangerous voltage. Before any maintenance work is carried out on the
gas conditioning system, put the main switch of the instrument into
position “0” and tear the mains plug off!
The frequency of the maintenance work depends on the operational process and can therefore only be
determined in each individual case.
All parts which require maintenance work are easily accessible and are installed on the front side of
the gas conditioning unit CSS-M/W. Only for any work on the gas sample pump, the case has to be
opened:
Replace the filter element of the fine filter FPF-2-0,3 GF in case the flow rate is to low or after
visible control.

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Note
In order to protect downstream analyzers, the wet filter element must
always be replaced in the event of a condensate ingress.
The hose of the condensate pump SR25.2 should be checked every six months and, if necessary,
replaced (see chapter 15.3.1).
The diaphragm of the sample gas pump N3 KPE should be checked every six months and, if
necessary, replaced.
15.1 REPLACEMENT OF THE FILTER ELEMENT AND THE O-RING
Note
In any case you open the filter, the filter element must be changed.
For changing the filter element and the O-ring:
1. Disconnect the mains voltage.
2. Unscrew the filter housing cover.
3. Exchange the filter element and/or O-ring. Pay attention to the correct insertion of the filter
element and the O-ring (the structural surface of the filter element must show to the front!).
4. Screw down the filter housing cover again.
O-ring
Filter element
Figure 5 Replacement of the filter element and the O-ring

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15.2 DISMOUNTING THE SAMPLE GAS PUMP FOR EXAMINATION OR MAINTENANCE
For dismounting the sample gas pump N3 KPE:
Warning
Dangerous voltage. Before any maintenance work is carried out on the
gas conditioning system, disconnect the unit from the mains!
1. Disconnect the gas conditioning system from the mains voltage.
2. Unscrew the front panel and put it beside without detaching the piping and the wiring.
3. Loosen the 4 fastening screws of the mounting angle on which the pump is mounted.
4. Pull out the pump with mounting angle.
5. Examination and maintenance of the pump N3 KPE.
6. After examination and maintenance screw down the mounting angle again and mount the
front panel.
15.3 MAINTENANCE OF THE INTEGRATED PERISTALTIC PUMP TYPE SR25.2
Before starting any maintenance work, make sure that any work done on the device is in compliance
with all relevant regulations and standards.
Warning
Inhalation hazard possible, if using toxic or asphyxiant gases!
Purge peristaltic pump with inert gas or air before opening! If the pump
is used for toxic gas or asphyxiant (oxygen-displacing) gas, it needs to
be purged with inert gas or air before opening. Follow closely all
relevant occupational safety regulations during operation.
Warning
Disconnect power supply before opening the device for access.
Make sure that all external power supplies are disconnected.
Aggressive condensate possible!
Media residues in tubing!
Chemical burns caused by aggressive media possible!
Wear protective gloves and protective glasses!
Wear proper protective clothing!