M&C TechGroup CSS-V2 Operator's manual
Operating Manual
Gas conditioning unit Series CSS
®
Version CSS-V1 and CSS-V2
for 19“- or wall mounting
Gas sampling and gas conditioning technology 4-1.2-ME
List of Contents
1 General information ....................................................................................................................... 4
2 Declaration of conformity .............................................................................................................. 4
3 Safety instructions ......................................................................................................................... 5
4 Warranty .......................................................................................................................................... 5
5 Used terms and signal indications ............................................................................................... 6
6 Introduction .................................................................................................................................... 7
7 Application ...................................................................................................................................... 8
8 Technical Data .............................................................................................................................. 10
8.1 Options .................................................................................................................................... 11
9 Description ................................................................................................................................... 12
10 Receipt of marchendise and storage ...................................................................................... 14
11 Installation instructions .......................................................................................................... 14
11.1 Retrofitting of the wall mounting housing to a 19“-housing ..................................................... 15
12 Supply connections ................................................................................................................. 15
12.1 Hose connections ................................................................................................................... 15
12.2 Displace the connections to the back of the housing .............................................................. 16
12.3 Electrical connections ............................................................................................................. 16
13 Starting ...................................................................................................................................... 18
13.1 Cooler regulation ..................................................................................................................... 18
14 Closing down ............................................................................................................................ 19
15 Maintenance .............................................................................................................................. 19
15.1 Replacement of the filter element and the O-Ring .................................................................. 20
15.2 Dismountage of the sample gas pump for examination or maintenance ................................ 21
15.3 Maintenance of the integrated peristaltic pump type SR 25.2 ................................................ 21
15.4 Cleaning the cooling fins of the compressor cooler ................................................................ 24
16 Operating of the integrated electronic temperature regulator ............................................. 25
16.1 Changing the set value ........................................................................................................... 25
17 Trouble shooting ...................................................................................................................... 26
18 Spare part list ............................................................................................................................ 28
19 Appendix ................................................................................................................................... 30
List of Illustrations
Figure 1 Scheme of gas flow CSS-V1.. ............................................................................................ 8
Figure 2 Scheme of gas flow CSS-V2.. ............................................................................................ 9
Figure 3 Design CSS-V2.. .............................................................................................................. 12
Figure 4 Dimensions CSS-V.. ........................................................................................................ 13
Figure 5 Hose connections CSS-V ................................................................................................ 15
Figure 6 Plug connections summery alarm .................................................................................... 17
Figure 7 Replacement of the filter element and the O-ring ............................................................ 20
Figure 8 Dismountage of the sample gas pump ............................................................................ 21
Figure 9 Replacement of the pump hose ....................................................................................... 22
Figure 10 Disassembly of pump head and driver ............................................................................. 23
Figure 11 Check of axes and rolls .................................................................................................... 23
Figure 12 Front view of the temperature regulator ........................................................................... 25
Figure 13 Connecting conductors board CSS-V .............................................................................. 31
2 Gas sampling and gas conditioning technology 4-1.2-ME
This Operating Manual does not claim completeness and may be
subject to technical modifications.
© 12/2008 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.
3rd Edition: 05/2013
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.
4-1.2-ME Gas sampling and gas conditioning technology 3
Head Office
M&C TechGroup Germany 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.
4 Gas sampling and gas conditioning technology 4-1.2-ME
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 gas conditioning unit CSS-V.. 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.
4-1.2-ME Gas sampling and gas conditioning technology 5
DANGER!
This means that death, severe physical injuries and/or important
material damages will occur in case the respective safety
measures are not fulfilled.
WARNING!
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.
ATTENT I O N !
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
6 Gas sampling and gas conditioning technology 4-1.2-ME
6 INTRODUCTION
The gas conditioning unit CSS-V.. for wall- or 19”-mounting is a completely pre-assembled compact
gas conditioning system, working continuously and delivering a sample gas quantity of max. 2 x
150Nl/hr resp. 1 x 250Nl/hr. A big variety of additional options guarantees an adaption to the different
requirements of continuous gas analysis technique.
The entire gas conditioning unit is housed in a compact and robust steel plate case which ensures that
the gas analyses can be carried out quickly, safely and with a minimum amount of maintenance.
The gas conditioning unit CSS-V.. 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.
4-1.2-ME Gas sampling and gas conditioning technology 7
7 APPLICATION
The units CSS-V.. provide completely pre-installed sample gas conditioning for continuous use and
can excellently be integrated into gas analysis systems. Its compact construction means that it takes
up only little space. The CSS-V.. units are ready for use within a few minutes. This, at last, makes the
usual time-consuming procurement of individual components and assembly superfluous.
Figure 1 Scheme of gas flow CSS-V1..
Gas cooler ECM-1
Front panel filter FPF-2-0,3GF, 0,3µm porosity with integrated liquid alarm
Sample gas pump N3/5/9 KPE
Flowmeter FM40 with option flow alarm FM-20mo
Peristaltic pump SR25.2 for continuous automatic condensate removal
Way of sample gas tubed in PTFE.
Way of condensate tubed in Novopren®.
At the heat exchanger sample gas inlet and outlet are marked with arrows.
8 Gas sampling and gas conditioning technology 4-1.2-ME
Marking with
black o-ring
Marking with
black o-ring
Figure 2 Scheme of gas flow CSS-V2..
Gas cooler ECM-2
2 x Front panel filter FPF-2-0,3GF, 0,3µm porosity with integrated liquid alarm
2 x Sample gas pump N3/5/9 KPE
2 x Flowmeter FM40 with option flow alarm FM-20mo
2 x Peristaltic pump SR25.2 for continuous automatic condensate removal
Way of sample gas tubed in PTFE.
Way of condensate tubed in Novopren®.
For differentiation the way of sample gas 2 is marked with a black o-ring at the sample gas inlet of the
heat exchanger 2 and sample gas outlet 2.
At the heat exchanger sample gas inlet and outlet are marked with arrows.
4-1.2-ME Gas sampling and gas conditioning technology 9
Gas Conditioning Unit Type
CSS-V1
CSS-V2
Part No. 230V/50Hz
01G6010
01G6020
Part No. 115V/50-60Hz
01G6010a
01G6020a
Sample outlet dew point
Range of adjustment 2 … 7°C, factory setting +5°C
Dew point stability
at constant conditions < ±0,1 °C
Sample inlet temperature
**max. 180°C**
Gas inlet water vapour saturation
**max. +80°C
Gas flow rate
**max. 250l/h
**max. 2 x 150l/h
Ambient temperature
**+10°C to +40°C
Storage temperature
-25°C to +65°C
Pressure
0,7bar to 1,4bar abs.*
Total cooling capacity
max. 144kJ/h
Number of gas inlets
1
2
Number of gas outlets
1
2
Number of condensate outlets
1
2
Sample gas connections
Hose connection 4/6 mm
Material medium-touched parts
PVDF, PVC, Novoprene®, FPM, PPH, PTFE
Ready for operation
Approx. 10 min.
Mains power supply
230V 50-60Hz ± 10% or 115V 50-60Hz ± 10%
(115V/50Hz not with option sample pump)
Power consumption
max. 220VA + max: 300VA for the sample gas pumps
Fuse protection
4A, time-lag, 5x20mm
Electrical mains supply
Cold appliance plug with 2m cable
Case protection
IP20 (EN 60529)
Housing version
Sheet steel case foe 19”- or wall mounting, lacquered
RAL 7035
Case dimensions (H x W x D)
267,5mm x 483mm x 301,5mm
Weight
Approx. 22kg
8 TECHNICAL DATA
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
ambient temperature and 5°C outlet dewpoint.
10 Gas sampling and gas conditioning technology 4-1.2-ME
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