M&C TechGroup CSS Operator's manual
Operating Manual
19 Inch Rack Mounting Gas Conditioning Unit
series CSS
®
(incl. the new temperature controller type 70304)
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2
List of contents
1 General information ................................................................................................................... 5
2 Declaration of conformity .......................................................................................................... 5
3 Safety instructions ..................................................................................................................... 6
4 Warranty ...................................................................................................................................... 6
5 Used terms and signal indications ........................................................................................... 7
6 Introduction ................................................................................................................................. 8
6.1 Serial number ........................................................................................................................... 8
6.2 Power supply ............................................................................................................................ 8
7 Technical Data ............................................................................................................................ 9
8 Description ................................................................................................................................ 10
9 Function .................................................................................................................................... 16
10 Electrical Connections ............................................................................................................. 18
10.1 Electrical junction box X1 ....................................................................................................... 18
10.2 Sub-D-plug X2 ........................................................................................................................ 19
10.2.1 Status contacts ................................................................................................................. 19
10.2.2 Local control ..................................................................................................................... 20
10.2.3 External Control ................................................................................................................ 21
10.3 Liquid- and flow alarm card LFC-2 ......................................................................................... 22
11 Description of the optional temperature controller 70304 for heated sample lines ........... 24
12 Operating principle of the controller 70304 ........................................................................... 24
12.1 Parameter of the user level with factory setting ...................................................................... 24
13 Change of parameters .............................................................................................................. 25
13.1 Removing and activating the level inhibit ............................................................................... 25
13.2 Menue structure...................................................................................................................... 26
13.3 Time Out ................................................................................................................................. 26
14 Receipt Of Goods and storage ................................................................................................ 27
15 Installation instructions ........................................................................................................... 27
16 Supply connections ................................................................................................................. 28
16.1 Hose connection ..................................................................................................................... 28
16.2 Electrical connections ............................................................................................................. 28
17 Starting ...................................................................................................................................... 29
17.1 Measure.................................................................................................................................. 29
17.2 Check/Calibration ................................................................................................................... 30
17.3 Self-optimising (PID-Function) of the controlled system ......................................................... 31
18 Closing down ............................................................................................................................ 31
19 Maintenance .............................................................................................................................. 32
20 Dismounting the flow components sub panel ....................................................................... 32
21 Alarms and elimination ............................................................................................................ 33
21.1 Voltage loss ............................................................................................................................ 33
21.2 Cooler alarm/temperature controller alarm ............................................................................. 34
21.3 Flow alarm .............................................................................................................................. 34
21.4 Liquid alarm ............................................................................................................................ 35
22 Spare part lists .......................................................................................................................... 36
23 Appendix ................................................................................................................................... 38
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List of illustrations
Figure 1 Front view of the CSS ...................................................................................................... 10
Figure 2 Operation and control board............................................................................................. 11
Figure 3 Plan view of the components mounted on the Flow components sub panel .................... 13
Figure 4 Components mounted in the 19“ rack housing ................................................................. 14
Figure 5 Back-panel of the 19" rack housing .................................................................................. 15
Figure 6 Gas flow schematic .......................................................................................................... 16
Figure 7 Electrical junction box X1 (B) ........................................................................................... 18
Figure 8 Status contacts ................................................................................................................. 19
Figure 9 Plan of terminal connections in the Sub-D-Plug X2 (A) for local control of the
CSS... and CSS.../C ......................................................................................................... 20
Figure 10 Plan of terminal connections in the Sub-D-Plug X2 (A) for external control of
the CSS... and CSS.../C ................................................................................................... 21
Figure 11 Circuit diagram LFC-2 ...................................................................................................... 23
Figure 12 Display/control elements .................................................................................................. 24
Figure 13 Menue structure ............................................................................................................... 26
Figure 14 Pin assignment for external drive of the CSS ................................................................... 39
Figure 15 Circuit diagram gas conditioning CSS .............................................................................. 40
Figure 16 CSS with 4 x span solenoid valves .................................................................................. 41
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This Operating Manual does not claim completeness and may be subject to technical modifications.
© 10/1996 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.
4th Edition: 02/2008
Dear customer,
we have made up this operating manual in such a way that all necessary information about the product can be found and understood quickly and easily.
Should you still have any question, please do not hesitate to contact M&C directly or go through your
appointed dealer. Respective contact addresses are to be found in the annexe to this operating manual.
Please also contact our homepage www.mc-techgroup.com for further information about our products. There, you can read or download the data sheets and operating manuals of all M&C products as
well as further information in German, English and French.
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Head Office
M&C TechGroup GmbH Rehhecke 79 40885 Ratingen Germany
Telephone: 02102 / 935 - 0
Fax: 02102 / 935 - 111
E - mail: info@mc-techgroup.com
www.mc-techgroup.com
1 GENERAL INFORMATION
The product described in this operating manual has been examined before delivery and left our works
in perfect condition related to safety regulations. In order to keep this condition and to guarantee a
safe operation, it is important to heed the notes and prescriptions made in this operating manual. Furthermore, attention must be paid to appropriate transportation, correct storage, as well as professional
installation and maintenance work.
All necessary information a skilled staff will need for appropriate use of this product are given in this
operating manual.
2 DECLARATION OF CONFORMITY
CE - Certification
The product described in this operating manual complies with the following EC directives:
EMV-Instruction
The requirements of the EC directive 2004/108/EC “Electromagnetic compatibility“ are met.
Low Voltage Directive
The requirement of the EC directive 2006/95/EC “Low Voltage Directive“ are met.
The compliance with this EC 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
Please take care of the following basic safety procedures when mounting, starting up or operating this equipment:
Read this operating manual before starting up and use of the equipment. The information and warnings given in this operating manual must be heeded.
Any work on electrical equipment is only to be carried out by trained specialists as per the regulations
currently in force.
Attention must be paid to the requirements of VDE 0100 (IEC 364) when setting high-power electrical
units with nominal voltages of up to 1000 V, together with the associated standards and stipulations.
Check the details on the type plate to ensure that the equipment is connected to the correct mains
voltage.
Protection against touching dangerously high electrical voltages:
Before opening the equipment, it must be switched off and hold no voltages. This also applies to any
external control circuits that are connected.
The device is only to be used within the permitted range of temperatures and pressures.
Check that the location is weather-protected. It should not be subject to either direct rain or moisture.
The device must not be used in hazardous areas.
Installation, maintenance, monitoring and any repairs may only be done by authorized personnel with
respect to the relevant stipulations.
4 WARRANTY
If the equipment fails, please contact M&C directly or else go through your M&C authorised dealer.
We offer a one year warranty as of the day of delivery as per our normal terms and conditions of sale,
and assuming technically correct operation of the unit. Consumables are hereby excluded. The terms
of the warranty cover repair at the factory at no cost or the replacement at no cost of the equipment
free ex user location. Reshipments must be send in a sufficient and proper protective packaging.
Gas sampling and gas conditioning technology 4-1.1-ME
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DANGER!
This means that death, severe physical injuries and/or important
material damages will occur in case the respective safety measures are not fulfilled.
W ARNIN G!
This means that death, severe physical injuries and/or important
material damages may occur in case the respective safety measures are not fulfilled.
CARE!
This means that minor physical injuries may occur in case the
respective safety measures are not fulfilled.
CARE!
Without the warning triangle means that a material damage may
occur in case the respective safety measures are not met.
AT TE NTION !
This means that an unintentional situation or an unintentional
status may occur in case the respective note is not respected.
NOTE!
These are important information about the product or parts of the
operating manual which require user’s attention.
SKILLED STAFF
These are persons with necessary qualification who are familiar
with installation, use and maintenance of the product.
5 USED TERMS AND SIGNAL INDICATIONS
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Part number
Type
Cooler - gas flow [l/h]
Power supply
03 G 1000
CSS 230V
ECP 1000 - 140l/h
230V 50/60Hz
03 G 1000a
CSS 115V
ECP 1000 - 140l/h
115V 60Hz
03 G 1100
CSS/C* 230V
ECP 1000 - 140l/h
230V 50/60Hz
03 G 1100a
CSS/C* 115V
ECP 1000 - 140l/h
115V 60Hz
03 G 2000
CSS-2 230V
ECP 2000 - 2 x 140l/h
230V 50/60Hz
03 G 2000a
CSS-2 115V
ECP 2000 - 2 x 140l/h
115V 60Hz
03 G 3000
CSS-3 230V
ECP 3000 - 350l/h
230V 50/60Hz
03 G 3000a
CSS-3 115V
ECP 3000 - 350l/h
115V 60Hz
03 G 3100
CSS-3/C* 230V
ECP 3000 - 350l/h
230V 50/60Hz
03 G 3100a
CSS-3/C* 115V
ECP 3000 - 350l/h
115V 60Hz
Options
03 G 9000
Extra charge for CSS... with integr. temp. controller 70304 f. heated sample line
03 G 9020(a)
Extra charge for CSS... with altogether 3 check valves
03 G 9025(a)
Extra charge for CSS... with altogether 4 check valves
03 G 9030(a)
Extra charge for CSS... with altogether 5 check valves
6 INTRODUCTION
This M&C unit provides completely pre-installed sample gas conditioning for continuous use and can
be excellently integrated within analysis systems. It is equipped with:
1 sample gas inlet;
Electric gas cooler;
Sample gas pump;
Condensation pump;
Micro fine filter with glass-fibre element (0,1µm);
External or manual switching for testing with zero or span gas by 3-way and 2-way
solenoid valves;
Status alarm with display for cooler temperature, flow alarm and liquid alarm;
2 sample gas outlets with flow meters incl. needle valve (70 l/h or rather 250 l/h);
PTFE hosing;
Optional: electronic temperature controller for heated sample lines.
Its compact construction means that it takes up little space. The CSS unit is ready for use within a
matter of a few minutes. This at last makes the usual time consuming procurement of individual components and assembly superfluous.
6.1 SERIAL NUMBER
The type plates bearing the serial number are located on the back panel of the 19“-rack-housing.
Always quote the device’s serial number when making inquiries and ordering spare parts.
6.2 POWER SUPPLY
Depending on the version, the CSS is operated with 115 or 230 V AC.
Precise details can be found on the device's type plate.
In dependence of the cooler type, the power supply and the version .../C -test gas to the probe- the
following types of the CSS can be distinguished:
* Version CSS.../C: test gas to sample probe
(a) : 115V-Version
Gas sampling and gas conditioning technology 4-1.1-ME
7 TECHNICAL DATA
Gas flow rate**
CSS(/C) : max. 140l/h
CSS-2 : max. 2 x 140l/h
CSS-3(/C) : max. 350l/h
Flow meter
CSS(/C), CSS-2: 2 x with needle valve, adjustable to 70l/h,
flow meter FM1 with flow alarm sensor
CSS-3(/C) : 2 x with needle valve, adjustable to 250l/h,
flow meter FM1 with flow alarm sensor
Gas pressure
0,7bar to 1,4bar abs.
Sample inlet temperature**
max. 150°C
Sample inlet dew point**
max. 80°C
Sample outlet dew point
range of adjustment: +2 °C ..... +15 °C, factory setting: +5 °C
Dew point stability
at constant conditions < ± 0,1 °C
Gas filter F-0,1GF50
Glass fiber, retention rate 99,99% for particles > 0,1µm
Ambient temperature**
+5°C to +45°C
Storage temperature
-25°C to +65°C
Relative humidity
< 80%
Housing
19"-rack housing mounting 6 U, depth 350mm
Degree of protection
IP20, DIN40050
Weight
CSS(/C) : approx. 15kg
CSS-2, CSS-3(/C): approx. 16,5kg
Connections
G 1/4 i* - DIN ISO 228/1
Power supply
230V 50/60Hz or 115V 60Hz, CSS : 150VA
CSS-2/3: 250VA
Electrical connection
Power terminals max. 4 mm2 (4 x PG 13,5)
Alarm-/Control signal 15 pin Sub-D-Connector
Warm up time
approx. 10 min.
Material of sample contacting
parts
PVDF, glass, Viton, Novoprene, PTFE
Status signal for
Measure/Check, cooler temperature, liquid alarm, flow alarm:
potential free change over contact, max. 24V/1A
Test gas inlet - 2 x
solenoid valve actuated by manual or external switch
Option:
Electronic PID temperature controller for heated sample lines
front panel mounting
control range : 0°C to 200°C
sensor inlet : PT 100 and Fe-CuNi
controlling outlet : 10A solid state relay #
status alarm : integrated into the status signal
parameter : free adjustable
Electrical equipment standard
EN 60204-1 (DIN VDE 0113 Teil 1/02.86)
9
* other connections on request
** Maximum values in technical datas must be rated in consideration of total cooling capacity at 25 °C ambient temperature and an outlet dew
point of 5 °C.
#
standard for max. 20m heated sample line at 110W/m
Gas sampling and gas conditioning technology 4-1.1-ME
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Pumpe EinPumpe Aus
Sampling-Sy stem
Temp. controller
Nullgas
Zero gas
Meßgas
Sample gas
Messen
Measure
Pump off
Temp. Regler
CSS
Pump on
Prüfen
Check
Prüfgas
Test gas
Endgas
Span gas
LS/LA
Steuerung Intern
Extern-rt
Intern-gn
A-
A-
A±
Status
control intern
Ein
2
1
FA-1,bi
Sensor
Open
Auf
FPF-0,1
M&C
190,5
266
465
483
(1.4) 1 (1.2)
optional tempreature controller
(1.3)
1.2.1
1.2.4
1.2.5
1.2.3 1.2.2
1.2.6
A
A
(1.1)
8 DESCRIPTION
The components of the M&C gas conditioning sampling system type CSS are mounted in a 19" rack
housing. The CSS may also be configured with an optional wall-mounting-bracket (Part-No.
03G9005).
Figure 1 Front view of the CSS
The front plate (1) displays the following components:
(1.1) operation and control board;
(1.2) flow components sub panel;
(1.3) option*- temperature controller for heated sample line (Part No. 03G9000);
(1.4) handles.
*
If the temperature controller option is not chosen a plastic plate will cover the opening.
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Figure 2 shows the operation and control board (1.1). The different functions are selected by toggle
switches and indicated with LED’s. The internal or external function is configured through the wiring in
the Sub-D-Plug (see 4.1) and indicated by a dual coloured LED on the operation and control board.
Figure 2 Operation and control board
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Function
Description
Switch
LED
l
r
Local Control
(intern)
control of the CSS with operation and control board;
link between pin 1 and 9 (connector X2, s. 10.2.2);
control power supply;
(dual col-
oured)
green
External Control
(extern)
external control with Sub-D-Plug X2 (s. 10.2.3),
switches of the operation and control board out of
function; control power supply after switching the CSS
on ;
(dual col-
oured)
red
On
internal control activated;
X green*
Off
switches CSS off
X no LED
Status
no alarm: CSS ready for operation;
alarm : cooler-/temperature-controller alarm;
flow alarm;
liquid alarm.
green*
red*
Cooler- Alarm
no alarm: CSS ready for operation;
alarm : CSS not ready for operation,
temperature of cooler <2°C or >8°C,
or optional temperature-controller:
controller not in range
green*
red*
FlowAlarm
no alarm: CSS in operation;
alarm : no gas flow (i.e. inlet or outlet
is blocked),
sample gas pump not in operation,
liquid alarm,
cooler-/temperature-controller alarm;
green*
red*
LiquidAlarm
no alarm: CSS ready for operation
alarm : condensate alarm;
green*
red*
Pump Off
sample gas pump off;
X red
Pump On
sample gas pump on;
X green*
Measure
CSS in sample mode,
signal contact available;
X yellow*
Check
CSS in test mode,
signal contact available;
X yellow*
Sample Gas
3-way solenoid valve open for sample mode;
X yellow*
Test Gas
3-way solenoid valve open for test mode;
X yellow*
Zero Gas
2-way solenoid valve open for Zero Gas;
X yellow*
Span Gas
2-way solenoid valve open for Span Gas;
X yellow*
The following chart describes the functions of the operation and control board.
* LED display also for external control
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175
1.2.7 1.2.8
152
48
1.2.1 1.2.21.2.61.2.31.2.41.2.5
All of the maintenance components are mounted on the flow components sub panel (1.2) (s. Fig. 1
and 3) and are easily accessed by removing front panel mounting screws. These are:
(1.2.1) Gas-Filter FPF-0,1GF;
(1.2.2) Peristaltic pump SR25.1;
(1.2.3) Liquid-Alarm-Sensor LA1 with Flow-Chamber LS;
(1.2.4) Flow-Meter 1 FM40, measuring range 7-70l or 25-250l**
(1.2.5) Optical bi stable Flow-Alarm-Sensor FA-1,bi;
(1.2.6) Flow-Meter 2 FM40, measuring range 7-70l or 25-250l**;
(1.2.7) Gas Pump N3 KPE or N9 KPE**;
(1.2.8) Terminal X8
(** with version CSS-3... and CSS-3/C...)
Figure 3 Plan view of the components mounted on the Flow components sub panel
For maintenance it is possible to pull out the rack housing (1.2), without dismounting the complete
unit.
Gas sampling and gas conditioning technology 4-1.1-ME
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