Buhler TC-Standard (+) X2 Installation And Operation Instructions Manual
Gas Analysis
Sample gas cooler
TC-Standard (+) X2
Installation and Operation Instructions
Original instructions
BE440023
10/2018
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20
E-Mail: analyse@buehler-technologies.com
Internet: www.buehler-technologies.com
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20
Internet: www.buehler-technologies.com
E-Mail: analyse@buehler-technologies.com
Read this instruction carefully prior to installation and/or use. Pay attention particularly to all advises and safety instructions to prevent injuries. Bühler Technologies can not be held responsible for misusing
the product or unreliable function due to unauthorised modifications.
All rights reserved. Bühler Technologies GmbH 2019
Document information
Document No..........................................................BE440023
Version..........................................................................10/2018
TC-Standard (+) X2
Contents
1 Introduction..................................................................................................................................................................................................................... 3
1.1 Intended use .........................................................................................................................................................................................................3
1.2 Overview ................................................................................................................................................................................................................3
1.3 Type plate ..............................................................................................................................................................................................................4
1.4 Scope of delivery.................................................................................................................................................................................................. 4
1.5 Ordering instructions ........................................................................................................................................................................................ 5
1.5.1 Gas cooler models with one heat exchanger ...............................................................................................................................5
1.5.2 Gas cooler models with two heat exchangers ............................................................................................................................ 6
1.5.3 Gas cooler model with two heat exchangers in series ..............................................................................................................7
2 Safety instructions.........................................................................................................................................................................................................8
2.1 Important notices................................................................................................................................................................................................8
2.2 General hazard warnings .................................................................................................................................................................................9
3 Transport and storage .................................................................................................................................................................................................11
4 Installation and connection.......................................................................................................................................................................................12
4.1 Installation site requirements....................................................................................................................................................................... 12
4.2 Installation .......................................................................................................................................................................................................... 12
4.2.1 Connecting the filter gas connections (optional) ..................................................................................................................... 12
4.2.2 Flow adapter connection (optional).............................................................................................................................................. 12
4.2.3 Connecting the moisture detector (option)................................................................................................................................12
4.2.4 Peristaltic pump connector (optional) ......................................................................................................................................... 13
4.2.5 Connecting the heat exchanger .....................................................................................................................................................13
4.3 Electrical connections ...................................................................................................................................................................................... 14
4.4 Signal outputs.....................................................................................................................................................................................................15
5 Operation and control .................................................................................................................................................................................................17
5.1 Description of functions...................................................................................................................................................................................17
5.2 Delta T control option .......................................................................................................................................................................................17
5.3 Use of menu functions .................................................................................................................................................................................... 18
5.3.1 Lock Menu.............................................................................................................................................................................................18
5.3.2 Menu navigation overview..............................................................................................................................................................19
5.4 Description of menu functions ..................................................................................................................................................................... 21
5.4.1 Main menu ...........................................................................................................................................................................................21
5.4.2 Submenu 1 ............................................................................................................................................................................................ 21
5.4.3 Submenu 1 (global settings)........................................................................................................................................................... 22
5.4.4 Set favourite menu ............................................................................................................................................................................25
6 Maintenance..................................................................................................................................................................................................................26
7 Service and repair......................................................................................................................................................................................................... 27
7.1 Troubleshooting ................................................................................................................................................................................................ 27
7.1.1 Error messages on the display....................................................................................................................................................... 28
7.2 Safety instructions ............................................................................................................................................................................................29
7.3 Cleaning and removal of the heat exchanger...........................................................................................................................................30
7.4 Replacing the hoses of the peristaltic pump (option) ............................................................................................................................30
7.5 Replacing the filter element (option)..........................................................................................................................................................30
7.6 Drying of the moisture detector (option)....................................................................................................................................................31
7.7 Calibration of the moisture detector (option)...........................................................................................................................................31
7.8 Spare parts and accessories ............................................................................................................................................................................31
7.8.1 Consumables and accessories ........................................................................................................................................................32
8 Disposal........................................................................................................................................................................................................................... 33
9 Appendices.....................................................................................................................................................................................................................34
9.1 Gas cooler technical data ................................................................................................................................................................................34
9.2 Technical Data - Options .................................................................................................................................................................................35
9.3 Flow diagrams....................................................................................................................................................................................................36
9.4 Performance curves.......................................................................................................................................................................................... 37
9.5 Heat exchanger ..................................................................................................................................................................................................38
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TC-Standard (+) X2
9.5.1 Heat exchanger description ........................................................................................................................................................... 38
9.5.2 Heat exchanger overview................................................................................................................................................................ 39
9.6 Dimensions (mm)............................................................................................................................................................................................. 40
10 Attached documents................................................................................................................................................................................................... 41
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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.
This device may be operated in a zone 2, explosion class IIC (ATEX & IECEx), explosive gas atmosphere which is rarely and only
temporarily explosive and in Class I, Division 2 (US & Canada).
Optional mounting of various add-on units may limit the area of application of this device.
Cooler with certificate Canada and IECEx
The equipment shall be mounted within a tool-secured IP54 enclosure.
Cooler with certificate USA
The equipment shall be mounted within a tool-secured IP54 enclosure which is capable of accepting one or more of the
ClassIDivision2 wiring methods per the National Electric Code (ANSI/NFPA70).
Cooler with certificate ATEX
The equipment shall be mounted within a IP54 enclosure in accordance with EN60079-15, and in a tool-secured enclosure which
meets the requirements of EN60079-0 and EN60079-15.
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-StandardX2 series was designed specifically for high cooling capacities and high ambient temperatures.
The TC-Standard+X2 series was designed specifically for the requirements in so-called automated measuring systems(AMS) according to EN15267-3. The series connection of the heat exchangers will cool in two cycles to minimise wash out effects.
The Peltier cooler is distinguished by two types according to cooling capacity or operation temperature. This classification is reflected in the type designation. The exact item number of the model defined by you is determined by the model code in the category ordering information.
Application Standard applications
Operation temperature 40 °C 50 °C
1 heat exchanger TC-Standard 6111 X2 TC-Standard 6112 X2 3rd digit=1
2 heat exchangers TC-Standard 6121 X2 TC-Standard 6122 X2 3rd digit=2
2 heat exchangers in series TC-Standard+ 6121 X2 TC-Standard+ 6122 X2 3rd digit=2
4th digit=1 4th digit=2
Additional components which every conditioning system should feature can optionally be integrated:
– Peristaltic pump for condensate separation,
– Filter,
– Moisture detector.
This allows for various configurations of cooler and options. Here the approach is to simplify creating a complete system in a
cost-efficient way through pre-installed components with hoses connected. We further paid attention to easy access to wear
parts and consumables.
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Manufacturer and address
Type designation and voltage
Serial no., Item no.
Blast protection markings
(Atex, IECex and US/Canada)
Description
Year of manufacture
TC-Standard 230 V, 50/60Hz, 130W
101001081115 449621112412510011010
FM18ATEX0012X II 3 G Ex ec nC IIC T4 Gc
IECEx FMG 18.0005X Ex ec nC IIC T4 Gc
USA/Canada: CL I DIV 2 GP ABCD
Tamb: 0°C to 50°C
Year: 2018 Manual doc.no.: BX440023
1.3 Type plate
Example:
1.4 Scope of delivery
– Cooler
– Product documentation
– Connection-/mounting accessories (optional)
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1.5 Ordering instructions
1.5.1 Gas cooler models with one heat exchanger
The item number is a code for the configuration of your unit. Please use the following model code:
4496 2 1 1 X 2 X 1 X X X 0 X X X 0 X 0 Product characteristic
Gas cooler models (with 1 heat exchanger)
1 TC-Standard 6111 X2: Ambient temperature 40 °C
2 TC-Standard 6112 X2: Ambient temperature 50 °C
Certifications
2 for explosive areas
Supply voltage
1 115 VAC, 50/60 Hz
2 230 V AC, 50/60 Hz
4 24 VDC
Heat exchanger
1 1 0 Stainless steel, PTS, metric
1 1 5 Stainless steel, PTS-I, US fitting
1 2 0 Duran glass, PTG, metric
1 2 5 Duran glass, PTG, US fitting
1 3 0 PVDF, PTV, metric
1 3 5 PVDF, PTV-I, US fitting
Peristaltic Pumps *
0 0 without peristaltic pump
1 0 CPsingle X2 with hose nipple, angled
3 0 CPsingle X2 with screw connection
Moisture detector / filter
0 0 without filter, without moisture detector
0 1 without filter, 1 moisture detector with adapter
1 0 1 filter, without moisture detector
1 1 1 filter with built-in moisture detector
Status Outputs
0 0 status output only
1 0 Analog output option, add-on
Delta T-control
0 0 without Delta T-control
1 0 Delta T-control option
* 24 V DC version not available
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1.5.2 Gas cooler models with two heat exchangers
The item number is a code for the configuration of your unit. Please use the following model code:
4496 2 1 2 X 2 X 2 X X X 0 X X X 0 X 0 Product characteristic
Gas cooler models (with 2 heat exchangers)
1 TC-Standard 6121 X2: Ambient temperature 40 °C
2 TC-Standard 6122 X2: Ambient temperature 50 °C
Certifications
2 for explosive areas
Supply voltage
1 115 VAC, 50/60 Hz
2 230 V AC, 50/60 Hz
4 24 VDC
Heat exchanger
2 1 0 Stainless steel, 2 MTS, metric
2 1 5 Stainless steel, 2 MTS-I, US fitting
2 2 0 Duran glass, 2 MTG, metric
2 2 5 Duran glass, 2 MTG, US fitting
2 3 0 PVDF, 2 MTV, metric
2 3 5 PVDF, 2 MTV-I, US fitting
Peristaltic Pumps *
0 0 without peristaltic pump
2 0 CPdouble X2 with hose nipple, angled
4 0 CPdouble X2 with screw connection
Moisture detector / filter
0 0 without filter, without moisture detector
0 1 without filter, 1 moisture detector with adapter
0 2 without filter, 2 moisture detectors with adapter
1 0 1 filter, without moisture detector
1 1 1 filter with built-in moisture detector
2 0 2 filters, without moisture detector
2 1 2 filters, 1 moisture detector
2 2 2 filters, 2 moisture detectors
Status Outputs
0 0 status output only
1 0 Analog output option, add-on
Delta T-control
0 0 without Delta T-control
1 0 Delta T-control option
* 24 V DC version not available
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1.5.3 Gas cooler model with two heat exchangers in series
The item number is a code for the configuration of your unit. Please use the following model key:
4496 2 1 2 X 2 X 2 X X X 0 X X X 0 X 0 Product characteristic
Gas cooler models (with 2 heat exchangers in series)
1 TC-Standard+ 6121 X2: Ambient temperature 40 °C
2 TC-Standard+ 6122 X2: Ambient temperature 50 °C
Certifications
2 for explosive areas
Supply voltage
1 115 V AC, 50/60 Hz
2 230 V AC, 50/60 Hz
4 24 V DC
Heat exchanger
2 2 2 Duran glass, 2x MTG-2, metric
2 2 7 Duran glass, 2x MTG-2, US fitting
2 3 2 PVDF, 2x MTV-2, metric
2 3 7 PVDF, 2x MTV-2-I, US fitting
Peristaltic Pumps
0 0 without peristaltic pump
2 0 CPdouble X2 with hose nipple, angled
4 0 CPdouble X2 with screw connection
Moisture detector / filter
0 0 without filter, without moisture detector
0 1 without filter, 1 moisture detector with adapter
1 0 1 filter, without moisture detector
1 1 1 filter with built-in moisture detector
Status outputs
0 0 status output only
1 0 Analog output option, add-on
*
* 24 V DC version not available
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TC-Standard (+) X2
DANGER
WARNING
CAUTION
NOTICE
2 Safety instructions
2.1 Important notices
NOTICE
The device is suitable for hazardous areas.
This unit may only be used if:
– The product is being used under the conditions described in the operating- and installation instructions, used according to
the nameplate and for applications for which it is intended. Any unauthorized modifications to the unit will void the warranty provided by Bühler Technologies GmbH,
– The specifications and markings in the type plate must be observed,
– The threshold values in the data sheet and the instructions must be observed,
– Monitoring equipment / protection devices must be connected correctly,
– Service and repair work not described in these instructions are performed by Bühler Technologies GmbH,
– Genuine replacement parts must be used.
Erecting electrical systems in explosive areas requires compliance with the following national regulations:
– IEC/EN60079-14
– National electric code (NEC)
– Canadian electric code (CEC)
Additional national regulations pertaining to initial operation, operation, maintenance, repairs and disposal must be observed.
These operating instructions are a part of the equipment. The manufacturer reserves the right to change performance-, specification- or technical data without prior notice. Please keep these instructions for future reference.
Signal words for warnings
Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.
Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not
avoided.
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.
Signal word for important information to the product.
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Warning signs
These instructions use the following warning signs:
Warns of a general hazard General notice
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
Warns of hot surfaces
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.
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.
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.
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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 Explosion hazard
Life and explosion risk may result from gas leakage due to improper use.
a) Use the devices only as described in this manual.
b) Regard the process conditions.
c) Check tubes and hoses for leakage.
WARNING Risk of breakage
a) Protect the equipment against being hit.
b) Protect the device against falling objects.
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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 recommend aerating the cabinet or installing a fan to lower the inside temperature.
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, 11LDV38, AK20, AK5.5 OR AK5.2, 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 peristaltic pumps.
Connecting the condensate drain
Depending on the material, build a connecting line with fittings and tubing or hose between the heat exchanger and condensate drain. For stainless steel the condensate drain can be hung directly from 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 6 mm (1/4").
The MTG heat exchanger (in coolers with 2 heat exchangers) can only be operated with peristaltic pumps.
4.2.1 Connecting the filter gas connections (optional)
The connection between the heat exchanger outlet and the filter inlet already has tubing. 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
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
Operating pressure ≤ 2 bar
option filter without Moisture detector
filters
limits the maximum approved
, a bypass may be connected to the filter head.
operating pressure
in the system!
4.2.2 Flow adapter connection (optional)
When ordering the cooler with the
The connection between the heat exchanger outlet and the flow adapter inlet does not have tubing included. The connection
G1/4 or NPT1/4" (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.
option moisture detector without filter
, it will be factory installed inside a flow adapter.
4.2.3 Connecting the moisture detector (option)
When ordering the cooler with
installed and connected in the filter head.
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moisture detector option
, it will be factory installed inside a flow adapter, or for the
filter option
TC-Standard (+) X2
gas out
gas in
gas out
gas in
condensate out
condensate out
Heat exchanger 1
Heat exchanger 2
Gas cooler
(two single heat exchangers)
gas out
gas in
gas out
gas in
condensate out
condensate out
Heat exchanger 1
Heat exchanger 2
Gas cooler +
(two heat exchangers in series)
4.2.4 Peristaltic pump connector (optional)
Coolers ordered with attached peristaltic pump already have it installed and wired. Heat exchangers ordered at the same time
are already installed and connected to the peristaltic pump.
The ø6mm (0.24inch) hose nipple for the pump’s condensate outlet must be carefully and properly connected with a suitable
hose and hose clamp.
Versions with screw connections DN4/6 or 1/6”-1/4” are supplied with ferrule and knurled nut and must be carefully sealed
with appropriate hose.
NOTICE
Installing peristaltic
ating pressure
Operating pressure ≤ 1 bar
pumps
in the system!
CPsingle / CPdouble limits the maximum permissible
oper-
4.2.5 Connecting the heat exchanger
The picture on the left shows the schematics for connecting two separate heat exchangers.
To minimise gas wash out in the cooler, the two (identical) heat exchangers must be operated in series (right picture). This
should be done as follows:
1. Gas inlet line to red gas inlet on heat exchanger 2 (pre-cooling).
2. Connection between gas outlet on heat exchanger 2 and the red gas inlet on heat exchanger 1 (after-cooling).
3. Attaching the final gas output line to the gas outlet on heat exchanger 1.
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 consists of a silicone ring with a PTFE sleeve. The PTFE side must face the glass thread.
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Glass
PTFE
4.3 Electrical connections
The operator must install an external separator for the device which is clearly assigned to this device.
This separator
– must be located near the device,
– must be easy for the operator to reach,
– must comply with IEC 60947-1 and IEC 60947-3,
– must separate all live conductors and the status output, and
– must not be attached to the power feed.
The mains supply of the device must be fused according to the specifications under technical data.
Potential equalization/static charge
Static charges can result in incendive sparking. Avoid static charges. Any conductive parts of the cooler must be grounded!
The housing has a connection for an earth/equipotential bonding conductor. Ensure the housing is adequately earthed (minimum conductor cross-section 4 mm2).
Particularly observe the requirements of EN 60079-14!
WARNING Hazardous electrical voltage
The device must be installed by trained staff only.
CAUTION Wrong mains voltage
Wrong mains voltage may damage the device.
Regard the correct mains voltage as given on the type plate.
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TC-Standard (+) X2
Plug numbering
Electric supply S1
115/230 V (24 V DC)
Alarm contact S2 *
Analogue output S3
1 - N/C
2 - N/C
3 - GND
4 - 4-20 mA out
5 - shield
(+24 V)
(-24 V)
*
Connection via plug
The device is equipped with connectors according to EN 175301-803 for mains and status output. If the cables are mounted properly, they cannot be interchanged. Please make sure that the connectors are remounted correctly after connecting the cable. The
following figures show the pin assignment with respect to the numbers printed on the connector.
The supply line cross-sections must be suitable for the rated current. Use a maximum line cross-section of 1.5mm² (AWG16) and
a cable diameter of 8-10mm (0.31-0.39 inch).
* When using an alarm contact connect to ≥33VAC or ≥70VDC PE voltage.
The clamping area has a diameter of 8-10mm (0.31–0.39 inch).
4.4 Signal outputs
The device provides different status signals. The maximum switching load of the alarm outputs is limited to 250VAC/150VDC,
2A, 50VA each.
An alarm is triggered by the alarm contact/status output (S2) 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.
The front film has three LEDs:
Colour Marking Function
Red S2 High/low temperature, device error
Yellow S1 --Green OP Normal operation
The LEDs OP and S2 indicate the device status similar to S2.
If the option “temperature signal” is built in, the unit has a signal output via the analogue output to indicate the actual cooler
temperature.
When the moisture detector (optional) is installed, an alarm is activated by the alarm contact/status output (S2) if the moisture
is still present in the prepared sample gas. Thereby, no distinction is made between the alarm/cable break triggered by moisture
detector 1 or 2. This information is displayed by an error message instead.
The temperature signal can be read via the panel plug (S3) using the M12x1 connector. This plug is located next to the moisture
detector connectors at the top of the cooler.
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Description of signal outputs
Function / contact
type
Regarding S2) internal changeover
contact: max.
250VAC / 150VDC,
2A, 50VA
Regarding S3) 4-20mA analogue
output
(R
<500Ω)
Load
Description
the following device statuses can
be indicated via two switching
outputs:
Signalling of actual temperature
(please use shielded cables)
Contact between 3 and 2 closed (alarm)
– No mains voltage and/or actual temperature out-
side the alarm thresholds
Contact between 3 and 1 closed (ok)
– Mains voltage attached + actual temperature
within the alarm thresholds
With moisture detector option
Contact between 3 and 2 closed (alarm)
– The moisture detector registers residual humidity
in the sample gas or cable break: Error message
Contact between 1 and 3 closed (ok)
– no residual moisture in measuring gas / no cable
break
With temperature signal option
T
= -20°C ≙ (-4°F) -> 4mA/ 2 V
Cooler
T
= 5°C ≙ (41°F) -> 9mA/ 4,5 V
Cooler
T
= 60°C ≙ (140°F) -> 20mA/ 10 V
Cooler
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