M&C CSS Series User manual

Gas Conditioning Unit Series CSS®
CSS-V1 and CSS-V2
19“ housing or wall mounting
Instruction Manual
Version 1.01.02

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Dear customer,
Thank you for buying our product. In this manual you will find all necessary information about this M&C
product. The information in the 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 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 to be complete and may be
subject to technical modifications.
© 03/2019 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: 1.01.02

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List of Contents
1General information.................................................................................................................... 5
2Declaration of conformity........................................................................................................... 5
3Safety instructions...................................................................................................................... 6
4Warranty...................................................................................................................................... 6
5Used terms and signal indications ............................................................................................ 7
6Introduction................................................................................................................................. 9
7Application .................................................................................................................................10
8Technical Data............................................................................................................................12
8.1 Options.................................................................................................................................13
9Description.................................................................................................................................14
10 Receiving and storing............................................................................................................16
11 Installation instructions.........................................................................................................16
11.1 Retrofitting of the wall mount housing to a 19“-housing.........................................................17
12 Supply connections ...............................................................................................................17
12.1 Hose connections .................................................................................................................17
12.2 Relocate the connections to the back of the housing ............................................................18
12.3 Electrical connections ...........................................................................................................19
12.3.1 Connecting signal lines..................................................................................................20
13 Commissioning ......................................................................................................................21
13.1 Cooler control .......................................................................................................................21
14 Closing down..........................................................................................................................22
15 Maintenance............................................................................................................................22
15.1 Replacement of the filter element and the O-Ring.................................................................23
15.2 Dismounting the sample gas pump for examination or maintenance.....................................24
15.3 Maintenance of the integrated peristaltic pump type SR 25.2................................................25
15.3.1 Changing the pump tubing.............................................................................................26
15.3.2 Changing contact pulleys and springs............................................................................27
15.3.3 Reassembly of the driver ...............................................................................................28
15.3.4 Cleaning the pump head................................................................................................29
15.3.5 Repair information..........................................................................................................29
15.4 Cleaning the cooling fins of the compressor cooler...............................................................29
16 Operating of the integrated electronic temperature regulator ............................................30
16.1 Changing the set value .........................................................................................................30
17 Trouble shooting....................................................................................................................31
18 Spare part list .........................................................................................................................33
19 Appendix.................................................................................................................................35

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List of Figures
Figure 1 Gas flow diagram CSS-V1.............................................................................................10
Figure 2 Gas flow diagram CSS-V2.............................................................................................11
Figure 3 Design CSS-V2............................................................................................................. 14
Figure 4 Dimensions CSS-V1 and CSS-V2.................................................................................15
Figure 5 Hose connections CSS-V1............................................................................................17
Figure 6 Connecting the collective alarm..................................................................................... 20
Figure 7 Replacing the filter element and the O-ring ...................................................................23
Figure 8 Dismounting the sample gas pump ............................................................................... 24
Figure 9 Changing the pump tubing ............................................................................................26
Figure 10 Different pump tube sizes.............................................................................................. 27
Figure 11 Disassembly of pump head and driver ..........................................................................27
Figure 12 Check of axes and rolls.................................................................................................28
Figure 13 Front view of the temperature regulator......................................................................... 30
Figure 14 Connecting conductors board CSS-V............................................................................36

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Headquarters
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.
Follow all instructions and warnings closely.
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 operate 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.
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.

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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.
NOTICE!
NOTICE 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 andothers against damages which might becaused
by high voltages.
Toxic!
Acute toxicity (oral, dermal, inhalation)! Toxic when in contact with
skin, swollowed or inhaled.
Corrosive!
These substances destroy living tissue and equipment upon contact.
Do not breathe vapors; avoid contact with skin and eyes.
Contains gas under pressure. Do not open container!
Check pressure before opening container, and adjust pressure to
atmosheric pressure.
Wear protective gloves!
Working with chemicals, sharpe objects or extremly high
temperatures requires wearing protective gloves.

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Wear safety glasses!
Protect your eyes while working with chemicals or sharpe objects.
Wear safety glasses to avoid getting something in your eyes.
Wear protective clothes!
Working with chemicals, sharpe objects or extremly high
temperatures requires wearing protective clothes.

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6 INTRODUCTION
The gas conditioning units CSS-V1 and CSS-V2, optionally for 19" or wall mounting, are complete pre-
assembled compact continuously operating gas conditioning systems, which, depending on the version,
can deliver a sample gas quantity of max. 2 x 150 Nl/h or 1 x 250 Nl/h. Due to a large number of
additional options, the samplegas preparation can be adaptedto the various requirements of continuous
gas analysis technology.
The entire gas conditioning system is housed in a compact and robust sheet steel housing so that gas
analyses can be carried out quickly, with low maintenance and reliably without any major assembly
work.
The CSS-V1 and CSS-V2 gas conditioning units must not be used for sampling flammable gas/air or
gas/oxygen mixtures, for sampling flammable gas which can form an flammable mixture in combination
with air or oxygen, or in explosive atmospheres or in hazardous areas.

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7 APPLICATION
The CSS-V1 and CSS-V2 are completely pre-installed sample gas conditioning systems for
continuous use, which can be excellently integrated into analytical systems due to their individual
configurability. The compact design only requires a small amount of space. The preparations are
ready for operation within a few minutes. The usual time-consuming procurement of individual
components and small parts and their assembly is no longer necessary.





Figure 1 Gas flow diagram CSS-V1
Gas cooler ECM-1
Front panel filter FPF-2-0,3GF, 0.3 µm porosity with integrated liquid alarm sensor (optional)
Sample gas pump N3/5/9 KPE (optional)
Flowmeter FM40 with option flow alarm FM-20mo (optional)
Peristaltic pump SR25.2 for continuous automatic condensate removal (optional)
•Sample gas line, material: PTFE.
•Condensate line, material: Novopren®.
•At the heat exchanger the sample gas inlet and outlet are marked with arrows.

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








Figure 2 Gas flow diagram CSS-V2
Gas cooler ECM-2
2 x Front panel filter FPF-2-0,3GF, 0.3 µm porosity with integrated liquid alarm sensor (optional)
2 x Sample gas pump N3/5/9 KPE (optional)
2 x Flowmeter FM40 with 2 x flow alarm FM-20mo (optional)
2 x Peristaltic pump SR25.2 for continuous automatic condensate removal (optional)
•Sample gas line, material: PTFE.
•Condensate line, material: Novopren®.
•To distinguish the sample gas lines, sample gas line 2 is marked with a black O-ring at the sample
gas inlet and outlet of the heat exchanger 2.
•At the heat exchanger, sample gas inlet and outlet are marked with arrows.
Marking with
black O-ring
Marking with
black O-ring

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8 TECHNICAL DATA
Gas Conditioning Unit Type
CSS-V1
CSS-V2
Part No. 230 V/50 Hz
01G6010
01G6020
Part No. 115 V/50 to 60 Hz
01G6010a
01G6020a
Sample outlet dew point
Adjustment range 2 to 7 °C [35.6 to 44.6 °F], factory setting
+5 °C [41 °F]
Dew point stability
At constant conditions < ±0.1 °C [±0.18 °F]
Sample inlet temperature
Max. 180 °C** [356 °F**]
Gas inlet water vapor saturation
Max. +80 °C** [176 °F**]
Gas flow rate
**Max. 250 Nl/h
**Max. 2 x 150 Nl/h
Ambient temperature
+10 to +40 °C** [50 to 104 °F**]
Storage temperature
-25 to +65 °C [approx. -13 to 149 °F]
Pressure
0.7 bar to 1.4 bar abs.*
Total cooling capacity
Max. 144 kJ/h
Number of gas inlets
1
2
Number of gas outlets
1
2
Number of condensate outlets
1
2
Sample gas connections
Tube connection 4/6 mm
Material of sample contacting parts
PVDF, PVC, Novoprene®, FPM, PPH, PTFE
Ready for operation
Approx. 10 min.
Mains power supply
230 V 50 to 60 Hz ±10 % or 115 V 50 to 60 Hz ±10 %
(115 V/50 Hz not with option sample pump)
Power consumption
Max. 220 VA + max: 300 VA for the sample gas pumps
Fuse protection
6.3 A, time-lag, 5 x 20 mm
Electrical mains supply
Cold appliance plug with 2 m [6.56 ft] cable
Case protection
IP20 EN 60529
Housing version
Sheet steel case for 19”- or wall mounting, lacquered
RAL 7035
Case dimensions (W x H x D)
483 x 267.5 x 301.5 mm [19” x 10.5” x 11.9”]
Weight
Approx. 22 kg [48.5 lbs]
PVDF = Polyvinylidenefluoride
PVC = Polyvinyl chloride
FPM = Fluor caoutchouc
PPH = Polypropylene hard
PTFE = Polytetraflourethylene
* Standard
** Maximum values in technical data must be rated in consideration of total cooling capacity at 25 °C
[77 °F] ambient temperature and 5 °C [41 °F] outlet dewpoint.

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8.1OPTIONS
Part No.
Description
93K0140
Extra charge for heat exchanger ECM- 1, material: glass
93K0170
Extra charge for heat exchanger ECM- 1 material: stainless steel SS 316Ti
93K0160
Extra charge for heat exchanger ECM- 1 material: PVDF
97K0100
Extra charge for heat exchanger ECM- 2 material: glass
97K0110
Extra charge for heat exchanger ECM- 2 material: stainless steel SS 316Ti
97K0115
Extra charge for heat exchanger ECM- 1 material: PVDF
01G6125
Extra charge for mounting a sample gas pump N3 KPE
(additionally electronic controller 01G6150 necessary)
01G6130
Extra charge for mounting a sample gas pump N5 KPE
(additionally electronic controller 01G6150 necessary)
01G6135
Extra charge for mounting a sample gas pump N9 KPE
(additionally electronic controller 01G6150 necessary)
01G6120
Extra charge for mounting a sample gas filter FPF-2-0,3GF with integrated liquid
alarm sensor
09F4000
Extra charge for mounting a flow meter FM40 7 to 70 Nl/h
09F4005
Extra charge for mounting a flow meter FM40 15 to 150 Nl/h
09F4010
Extra charge for mounting a flow meter FM40 25 to 250 Nl/h
02E3500
Extra charge for mounting a flow alarm sensor FA-20mo
01G6150
Extra charge for mounting a control electronic for max. 2 liquid alarm sensors and
max. 2 flow alarm sensors
01P9125
Extra charge for mounting a peristaltic pump SR25.2 for condensate removal, with
complete tubing

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9 DESCRIPTION
Figure 3 Design CSS-V2
Fine filter FPF-2-0,3GF
Electronic controller
Flow meter FM40 with flow alarm sensor FA-20mo
Peristaltic pump SR25.2 with condensate outlet
Cold appliance socket
Connection for collective alarm
Sample gas outlets
Condensate outlet directly at the peristaltic pump
Sample gas inlet directly at the heat exchanger
All components of the gas conditioning unit are mounted inside a compact sheet steel case. Filter and
peristaltic pump are mounted to the front panel to ensure easy maintenance.
The minimum flow is determined by the gas sample pump (see also chapter 8) Premature damage can
be caused to the pump membrane if less than the minimal total amount of flow is extracted as a result
of excess pressure.
The gas cooler is equipped with a heat exchanger made of Duran glass, stainless steel SS 316Ti or
PVDF.
The FPF-2-0.3GF fine filter (0.3 µm filter porosity) installed upstream of the N3/5/9 KPE sample gas
pump ensures the necessary solids separation.

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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 and switches off the
sample gas pump if existing. 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.
The condensate occurred is removed continuously via the peristaltic pump type SR25.2.
The DN4/6 mm hose connections for the sample gas outlet as well as the electrical connections in the
top of the gas conditioning unit can, in dependence on the installation conditions, also be mounted in
the back of the unit very easily.
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 analysers against
liquid irruptions and to increase the operating safety of the whole system. In case of liquid inrush, the
sample gas pump, if existing, is switched off automatically.
Figure 4 Dimensions CSS-V1 and CSS-V2

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10 RECEIVING AND STORING
The gas sampling systems CSS-V1 and CSS-V2 are completely pre-installed unit. The scope of delivery
includes furthermore:
•25 x Filter elements (1 package)
•1 x Connection cable
•1 x 6-pole connection box
•1 x Instruction Manual
Please remove the CSS-V1 or CSS-V2 carefully from the packaging. Check the scope of the delivery
specified on the delivery note. Please make sure that you have received all items stated on the delivery
note.
Please check the unit for any transport damages after receipt and report any complaints to the transport
company immediately.
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 place of installation.
In order to guarantee the operational safety of the gas conditioning system
and the downstream analysers, 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 analysers 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 analysers from subsequent
condensing.
Unheated gas sample lines must be installed with slope up to the cooler.

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11.1 RETROFITTING OF THE WALL MOUNT HOUSING TO A 19“-HOUSING
The gas conditioning units CSS-V1 and CSS-V2 are delivered with a wall mounting housing.
If a 19”-housing is needed, the gas conditioning unit can be retrofitted very easy by installing the
mounting brackets from the back to the front:
•Remove two fixing screws per bracket,
•Align the angle with the 19" mounting holes facing the front,
•Fix the mounting bracket flush with the front panel at the housing by using the two fixing screws.
12 SUPPLY CONNECTIONS
12.1 HOSE CONNECTIONS
Figure 5 Hose connections CSS-V1
NOTE!
Do not mix up the hose connections.
Check the seals after connecting all lines.
Contrary to Figure 5, version CSS-V2 has two sample gas outlets.
The condensate connections are carried out directly at the peristaltic pump.
All tube connections areDN 4/6 mm sealingring threaded hosecouplings out of PVDF/PPHas standard.
They are suitable for gas inlet temperatures of maximum 80 °C [176 °F] (see chapter 8).

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Follow these steps to mount the sample gas and condensate tubes:
•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.
•Place the union nut over the connecting tube.
•Push the sealing ring over the connecting tube with the thicker bulge facing the nut.
•Place the tube over the nipple on the thread.
NOTE!
The tightness of the connections can only be guaranteed if the connecting
tube has a straight edge (use a hose cutter).
•Hand-tighten the nut.
The tube is now slip-proof and pressure-tight mounted to the hose connection fitting.
The tubes are to be removed in the reverse order.
WARNING!
Aggressive condensate is possible.
Chemical burns caused by aggressive media possible!
Wear protective gloves and protective glasses!
Wear proper protective clothing!
12.2 RELOCATE THE CONNECTIONS TO THE BACK OF THE HOUSING
If the installation conditions require to relocate the connections to the back of the housing, follow these
steps:
•Remove connection sheet fixing screws (see Figure 5)
•Remove cover angle fixing srews at the back of the unit
•Attach connection sheet with 2 fixing screws at the back of the unit
•Attach cover angle with 2 fixing screws at the top of the housing

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12.3 ELECTRICAL CONNECTIONS
WARNING!
Wrong 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 (chapter 8).
The gas conditioning units CSS-V1 and CSS-V2 are available with either 230 V/50 Hz or 115 V/50 to
60 Hz (for circuit diagram see appendix). 6.3 A time-lag fuses are used on all models as fuse protection.
The fuses are located inside of the cold appliance socket.
The electrical connection is made via the 2 m [6.56 ft] mains cable with cold appliance plug optionally at
the back side or the top of the housing.

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12.3.1 CONNECTING SIGNAL LINES
The electrical connection of the collective alarm (cooler, liquid and flow) is a 6-pole male connector,
which is located at the back or top of the housing.
The matching 6-pole female connector is part of the scope of delivery.
The male connector is connected as follows:
Figure 6 Connecting the collective alarm
For CSS-V1 the collective alarm of the lower channel is connected (4, 5, 6).
For CSS-V2 both channels are connected with the cooler alarm and with one liquid and one flow alarm
each.
NOTE!
Please install the signal lines separated from the power supply
lines.
1
2
3
4
5
6
Intern
Extern
Status Alarm
Kontaktbelastung
Contact rating
24 V AC/DC 0.5 A
Stecker/male connector Typ Phoenix MSTB
2,5/6-STF 5,08
Oberer Kanal
Unterer Kanal
Buchse/Female X2
Lower channel
Upper channel