M&C CSS Series Instruction Manual
Gas conditioning unit, 19“, wall mount or portable in carrying case with software version 1.6
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- Page 1 Gas Conditioning Unit Series CSS ® CSS-VC1, CSS-VC2 19“, wall mount or portable in carrying case with software version 1.6 Instruction Manual Version 1.01.03...
- Page 2 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.
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Page 3: Table Of Contents
Contents General information ........................5 Declaration of conformity ......................5 Safety ............................6 Intended Use ..........................6 Warranty .............................6 Used Terms and Signal Indications ..................7 Introduction ..........................9 Application ..........................10 Technical specifications ......................11 Technical specifications for the expansion modules .............12 Options ..........................13 Description ..........................16 Goods receiving and storage ....................17 Installation instructions ......................18 11.1 Conversion to wall mounted or 19"... - Page 4 18.2 Maintenance of the sample gas pump(s) ................43 18.2.1 Remove pump head Type N 3/5/9 KPE ................45 18.2.2 Replacing the diaphragm Type N 3/5/9 KPE ..............45 18.2.3 Valve plate change Type N 3/5/9 KPE ................45 18.2.4 Mount pump head type N 3/5/9 KPE ................
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Page 5: General Information
Headquarters M&C TechGroup Germany GmbH Rehhecke 79 40885 Ratingen Germany Tel: 02102 / 935 - 0 Fax: 02102 / 935 - 111 e-mail: info@mc-techgroup.com www.mc-techgroup.com GENERAL INFORMATION The product described in this manual has been supplied in a safe and tested condition. For safe operation and to maintain this condition, the information and instructions in this manual must be followed. -
Page 6: Safety
SAFETY Note the following safety precautions when installing, commissioning and operating the device: Before operation and use of the equipment, read the operating manual. The instructions and warnings listed in the operating manual must be followed. Work on electrical equipment must only be performed by qualified personnel in accordance with the regulations currently in force. -
Page 7: Used Terms And Signal Indications
USED TERMS AND SIGNAL INDICATIONS means that death, serious personal injury and/or substantial property damage will result if proper precautions are not taken. Danger indicates that death, serious personal injury and/or substantial property damage might occur if proper precautions are not taken. Warning means that minor personal injury may result if proper precautions are not taken. - Page 8 Wear safety glasses! Protect your eyes while working with chemicals or sharp objects. Wear safety glasses to avoid getting something in your eyes. Wear protective clothes! Working with chemicals, sharp objects or extremely high temperatures requires wearing protective clothes. CSS-VC-1.6 | 1.01.03 www.mc-techgroup.com...
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Page 9: Introduction
INTRODUCTION The gas conditioning CSS-VC unit, either for 19 "- or wall mounting or as a portable unit in carrying case, is a fully pre-assembled compact continuously-operating gas purification system, which, depending on the design, can supply a sample gas volume of max. 1 x 250 Nl/h (CSS VC1) or 2 x 150 Nl/h (CSS- VC2). -
Page 10: Application
APPLICATION With the CSS-VC, fully pre-installed gas conditioning systems are created for continuous use, which can be integrated perfectly into analytical systems. The compact design makes few demands on space. The gas conditioning systems are operational within minutes. This renders time-consuming and expensive procurement of individual components and small parts and their assembly unnecessary. -
Page 11: Technical Specifications
TECHNICAL SPECIFICATIONS Gas conditioning series CSS ® Version CSS-VC1 Version CSS-VC2 Article number 230 V 50 Hz 01G6050 01G6055 Article number 115 V / 50-60 Hz 01G6050a 01G6055a Setting range: + 2 °C ..+ 7 °C [35.6 … 44.6 °F], Gas outlet dew point factory setting: + 5 °C [41 °F] Dew point stability... -
Page 12: Technical Specifications For The Expansion Modules
TECHNICAL SPECIFICATIONS FOR THE EXPANSION MODULES Module Communication module Status module Temperature control module Backflush module Part No. 91B8620 91B8630 91B8640 91B8650 Power supply 24 V DC ±20 % internal Earthing L < 3 m [≈ 9.84 ft] L < 3 m [≈ 9.84 ft] M&C system bus (RJ-45) Communication L <... -
Page 13: Options
OPTIONS Beyond the standard scope of options of this for the CSS-VC, other customised options are possible that cannot be listed in this manual. Description Part No. Extra charge for gas connections directly to a heat exchanger 01G6062 Extra charge for glass heat exchanger ECM-1 for CSS-VC1, sample gas connections on the 93K0140 heat exchanger Extra charge for stainless steel heat exchanger ECM-1 for CSS-VC1, sample gas connections... - Page 14 Description Part No. Peristaltic pumps for condensate disposal (max. 2 pcs.) Extra charge for mounting a peristaltic pump SR25.2 for condensate disposal, with hoses pre- 01G6140 installed (one required for each gas line) Filter (max. 2 pcs. Front-installed filters and 2 pcs. Universal or aerosol filters) and liquid alarm (max. 2 pcs.) Extra charge for installation of a sample gas filter FPF-0, 1GF 04F1000...
- Page 15 Description Part No. External expansion modules (only with electronic evaluation system 01G6175) Extra charge for communication module (one-time necessity for all expansion modules of the 01B8620 TCU) Extra charge for temperature control module (2 additional thermostats in TCU with 4 relays for 01B8640 high or low temperature monitoring) for controlling solid-state relays Extra charge for status module for group alarm via 1 changeover relay and 1 solid-state relay for...
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Page 16: Description
DESCRIPTION Figure 2 Dimensions and possible construction CSS-VC.. Fine filter FPF-0, 1GF Flow meter FM40 with and without forked light barrier FA-20mo Multifunctional expandable controller unit TCU Peristaltic pumps SR25.2 with condensate output at the pump ... -
Page 17: Goods Receiving And Storage
or faults, plain text information appears on the display and is also indicated by LEDs (e.g. cooler within the setpoint range and no other alarms - green LED, flow alarm (option) - yellow LED, temperature ±3° C [±5.4 °F] from the setpoint and humidity alarm (option) - red LED). The fine filter downstream of the cooler (different filter types available) provides for the necessary separation of solids. -
Page 18: Installation Instructions
INSTALLATION INSTRUCTIONS So that the unit is safe and operates reliably, it should be mounted horizontally and without vibration. Only then is proper separation and drainage of the condensate in the heat exchanger of the cooler ensured. Notice The mounting of the gas conditioning unit should take place away from heat sources and be freely ventilated so that there can be no disruptive accumulation of heat. -
Page 19: Supply Connections
SUPPLY CONNECTIONS Figure 3 Connections in the connection panel of the CSS-VC.. Depending on the version of the CSS-VC, instead of the 11 and 12-pin connector for single alarms, mA output cooler temperature and external sample gas pump control, a 6-pin connector may also be present for group alarm (see Figure 4 ). -
Page 20: Hose Connections
12.1 HOSE CONNECTIONS The connection of the sample gas input, depending on the connection type, is directly on the heat exchanger or on the clamping plate. Do not confuse the hose connections. They are marked appropriately. After connecting all the lines, they should be checked to ensure there are no leaks. -
Page 21: Lay The Connectors On The Rear Panel
12.2 LAY THE CONNECTORS ON THE REAR PANEL If, for example with the 19" mounting, mounting conditions require the connections to be moved up in the connection panel onto the back of the device, this is quite possible: Remove the connection-panel mounting screws (see Figure 3) •... -
Page 22: Electrical Connections
12.4 ELECTRICAL CONNECTIONS Incorrect voltage can destroy the device. On connection, ensure the Warning correct mains voltage in accordance with the rating plate! For the erection of power installations with nominal voltages up to 1000 V the requirements of VDE 0100 and relevant standards and regulations must be complied with! Notice The CSS-VC.. -
Page 23: Connection Of Individual Alarms, External Pump Control And External Cooler Temperature Display (Part No. 01G6175)
Figure 7 Upper and lower channel of CSS-VC2 12.4.2 CONNECTION OF INDIVIDUAL ALARMS, EXTERNAL PUMP CONTROL AND EXTERNAL COOLER TEMPERATURE DISPLAY (PART NO. 01G6175) The electrical connection of the individual alarms is via two connectors, depending on the mounting of the connection plate, either on the back or in the lid of the housing. -
Page 24: Figure 9 Connection Examples For Alarm Outputs
For the alarm relays „safety first“ is valid, i.e. contacts are open currentless and in case of alarm. For external pump control potential free contacts have to be used! Notice Switch open => pump off Switch closed => pump on On X2 connector pin 10-12, external switches can be connected for controlling the sample gas pumps (internal or external). -
Page 25: Connection Of Heated Line For Portable Version (Part No. 01G6190)
12.4.3 CONNECTION OF HEATED LINE FOR PORTABLE VERSION (PART NO. 01G6190) If, for the portable version in a carrying case, the option temperature controller for heated line (Part No. 01G6190) is selected, on the rear of the housing of the CSS-VC.. there is a 7-pin connector for connection of heated lines type PSP and PSP 4M and PSP 4M-W. -
Page 26: Cooler Controller
The following steps are to be carried out before initial commissioning: Plug the cold-device connector of the supplied mains connection cable into the cold-device socket • for gas conditioning; • Connect power cord to the network; Switch on power supply. •... -
Page 27: Decommissioning
DECOMMISSIONING The location of the compact conditioning unit must remain frost-free, even during periods when the unit is switched off. Notice On short-term decommissioning of the gas conditioning unit CSS-VC.. no special measures need to be taken. For long-term decommissioning, it is recommended to flush the gas conditioning unit with ambient air or inert gas. -
Page 28: Properties Of The Tcu
15.2 PROPERTIES OF THE TCU • Menu navigation with 3 language selections (German, English, French) • Error history (32 messages) Detailed status indicators: Group alarm or individual alarm (cooler temperature, liquid flow), • warnings, OK condition, control temperature, temperature gradient, total running time after service, error-free time Configuration options: Service interval, language, pump control, temperature control and backflush •... -
Page 29: The Temperature Control Module
Figure 11 Electrical connections communication module 15.3.2 THE TEMPERATURE CONTROL MODULE If the CSS-VC.. is purchased with an external thermostat module, it must be specified at the time of ordering which devices should be regulated (2 probes or 2 heated lines or 1 probe and 1 heated line) so that the controller can be Notice configured accordingly. -
Page 30: The Status Module
Figure 12 Electrical connections temperature control module 15.3.3 THE STATUS MODULE On the status module, by the group alarm message of the TCU a changeover relay and a solid-state relay are connected. These can be used for alarm indication. In addition, external sample gas pumps can be switched off via two further solid-state relays e.g. -
Page 31: The Backflush Module
15.3.4 THE BACKFLUSH MODULE With the backflush module, on the TCU a backflush programme can be set for gas sampling probes (duration of a backflush pulse, number of backflush pulses, time between backflush pulses, timing of backflush). The programme switches with time delay two solid-state relays with which in turn solenoid valves can be switched, which accordingly release purging air to the gas sampling probe. -
Page 32: Operation Of The Multifunctional Control Unit Tcu
OPERATION OF THE MULTIFUNCTIONAL CONTROL UNIT TCU In normal fault-free operation, the TCU display shows the current cooling temperature and the green LED is lit constantly when the cooler temperature is within the alarm limits. The bottom line of the display shows "status: OK"... -
Page 33: Display Of Control Temperatures Or Cooling Temperature Curve
16.1 DISPLAY OF CONTROL TEMPERATURES OR COOLING TEMPERATURE CURVE By 1 x pressing of the arrow button, the following screen will appear on the CSS-VC.. without an external temperature control module: If the external temperature control module was purchased with the CSS-VC.., there is a choice as to which display will appear here after the PRG key has been pressed once. -
Page 34: Configure The Switching On And Off Of The Sample Pumps
16.2 CONFIGURE THE SWITCHING ON AND OFF OF THE SAMPLE PUMPS By 2 x pressing of the arrow key and then 1 x pressing of the PRG key, the following view appears: Here it is visible whether the pump is working or not. Using the arrow keys, the pump to be configured can be selected. -
Page 35: Configure Backflushing
16.3 CONFIGURE BACKFLUSHING By 3 x pressing of the arrow key, then 1 x pressing of the PRG key, the following view appears when the backflush module is connected: Using the arrow keys, the parameters to be changed can be selected. By pressing the PRG key, the parameter can now be changed with the arrow keys and then confirmed with the PRG key discarded with the ESC key... -
Page 36: Display Of Events
Parameters: Default setting Info Start in: 0 d 0 h 0 m Max.: 9 T 23 h 59 m Flushing time T1 30 s Max.: 99 m 59 s ����2 = 2 ∗ ����1 + ���������������� ���� ���� ���� ���� + 1 ���� Dead time 60 s 0-120s... -
Page 37: Operating Data
16.5 OPERATING DATA By 5 x pressing (4 x without backflush module) of the arrow (or 1 x pressing of the arrow key ) the following view appears: Here the actual device temperature, the period until the next service warning, the service interval, the software version and serial number are displayed. -
Page 38: Setting Service Interval, Language, Control Temperatures And Temperature Sensor Types
16.7 SETTING SERVICE INTERVAL, LANGUAGE, CONTROL TEMPERATURES AND TEMPERATURE SENSOR TYPES To change service interval, language, control temperatures and temperature sensor types: Disconnect the device from the mains. • Hold the PRG key down and switch the device back on until the message to release the key •... - Page 39 To discard the changed settings, keep the ESC key pressed for 5 seconds • After saving or discarding the settings, you will automatically return to the start screen. If the unit is disconnected from the mains voltage while it is in user setup, all changes made are also rejected.
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Page 40: Alarms And Faults
LA-Reset = (x = reset necessary, ----- = no reset necessary) A thermocouple type must be set only when the temperature control module is connected in conjunction with equipment which do not use a PT100 as a temperature sensor. Notice If a thermocouple type is set, on warming up, an internal check is made whether a heating rate of +3 °C [+5.4 °F]/minute is being reached. -
Page 41: Temperature Alarms From Cooler And Temperature Control Module
17.2 TEMPERATURE ALARMS FROM COOLER AND TEMPERATURE CONTROL MODULE Error message Alarm Warning Error Lowtemp.: 1 Low temperature cooler Hightemp: 1 High temperature cooler T> Max: 1 Temperature sensor range exceeded => sensor defective T <min:1 Temperature sensor measuring range fallen below =>... -
Page 42: Other Fault And Alarm Messages
This prevents liquid pumped along to the analyser and thus damaging ! The triggered alarm (red LED) must be acknowledged by pressing any key. If the error is not corrected, the error screen comes back after 60 s. 17.4 OTHER FAULT AND ALARM MESSAGES Error message Alarm Warning Error... -
Page 43: Change The Filter Elements And O Rings
All serviceable parts are mounted in an easily accessible location in the front of the compact gas conditioning unit CSS-VC... Change filter elements of the dust and aerosol filters (FPF-0,1GF/FPF+/universal filter/aerosol filter) • when there is too little flow or after visual inspection (see Section 18.1); In order to protect downstream analysers, in the event of a condensate breakthrough, the wet filter element must always be changed. -
Page 44: Figure 17 Maintenance Of Sample Gas Pump(S)
Figure 17 Maintenance of sample gas pump(s) Loosen hoses on the pump head; mount [sic] any existing flow chamber(s) with mounting plate • from the stud bolts. N9 KPE N3/5 KPE Figure 18 Sectional drawing N3/5 KPE and N9 KPE CSS-VC-1.6 | 1.01.03 www.mc-techgroup.com... -
Page 45: Remove Pump Head Type N 3/5/9 Kpe
Valve plates, diaphragms and seals should always be replaced at the same time. Notice The changing of diaphragm(s), valve plates and sealing rings is to be carried out in the following order: Remove pump head • Change the diaphragm • •... -
Page 46: Mount Pump Head Type N 3/5/9 Kpe
18.2.4 MOUNT PUMP HEAD TYPE N 3/5/9 KPE • Move structure diaphragm via fan wheel into top dead centre (dead point) position. • Place intermediate plate 2 on the housing with valve plates 7 and 8 as well as head cover 3 in accordance with the marks (M). -
Page 47: Maintenance Of The Built-In Peristaltic Pump Type Sr 25.2
18.3 MAINTENANCE OF THE BUILT-IN PERISTALTIC PUMP TYPE SR 25.2 Pump hose, belt, pressure rollers and springs are the only wear parts of the pump. They are easy to change. Figure 19 Components of the peristaltic pump SR25.2 www.mc-techgroup.com CSS-VC-1.6 | 1.01.03... -
Page 48: Mounting Instructions For Peristaltic Pump
18.3.1 MOUNTING INSTRUCTIONS FOR PERISTALTIC PUMP Make sure to mount the pump to the front of the cooler with a minimum distance of 3.5 mm [≈ 0.138”] and a maximum distance of 5.5 mm [≈ 0.216”] between the pump motor and the front panel. The minimum distance avoids damages to the pump motor and the maximum distance prevents the motor shaft from getting loose. -
Page 49: Figure 21 Replacing The Pump Hose
Figure 21 Replacing the pump hose Unplug gas conditioning unit from the mains; • Remove hose connections on the pump; • Squeeze belt using the handles and turn the S-latch clockwise until it stops; • • Remove the belt and pull the old pump tubing on the slip fittings out of the guides; Squeeze the pressure rollers and see if spring tension exists;... -
Page 50: Change Of Contact Pulleys And Springs
18.3.3 CHANGE OF CONTACT PULLEYS AND SPRINGS • Switch off the mains; • Unscrew nuts of the pump head (wrench size 5.5) and remove snap ring from motor shaft; Figure 22 Disassembly of pump head and driver Draw the pump head out of the motor shaft •... -
Page 51: Cleaning The Pump Head
At first delivery two different types of springs are mounted in the driver (right and left springs). When spare springs are ordered, for simplified storage only one type will be delivered (right spring) that can be replaced without any problems Note and guarantees full functionality when all four springs are replaced. -
Page 52: Cleaning Of The Cooling Fins Of The Compressor Cooler
18.4 CLEANING OF THE COOLING FINS OF THE COMPRESSOR COOLER In order to prevent reduction in cooling performance, the cooling fins of the compressor cooler must be cleaned of dust regularly. To do this, blow compressed air on the right side in the housing into the ventilation grille. -
Page 53: Spare Parts Lists
SPARE PARTS LISTS The wear and spare part requirements depend on specific operating conditions. The recommended quantities are based on experience and are not binding. They refer to the version of CSS-VC.. with a gas line. Gas conditioning version CSS-VC.. (C) Consumable parts, (R) Recommended spare parts (S) Spare parts... - Page 54 Gas conditioning unit version CSS-VC.. (C) Consumable parts, (R) Recommended spare parts (S) Spare parts Recommended quantity in operation [years] Article No. Description C/R/S Aerosol filter CLF5 90F2005 Filter element type CLF-5 for liquid particulate filters CLF and CLF-5. 90F0040 O-ring (26) for the filter head.
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Page 55: Proper Disposal Of The Device
PROPER DISPOSAL OF THE DEVICE At the end of the life cycle of our products, it is important to take care of the appropriate disposal of obsolete electrical and non-electrical devices. To help protect our environment, please follow the rules and regulations of your country regarding recycling and waste management. - Page 56 Messages that may appear in the list of events and their meanings: Alarms Event message Significance Everything OK Everything OK T1 alarm Cooler temp. too high T2 alarm Temp. channel 2 is too high T3 alarm Temp. channel 3 is too high T1 low alarm T1 under the alarm hysteresis LA1 cable br.
- Page 57 Cancellation of alarms Event message Significance T1 OK T1 is in the control range or PT100 is OK T2 OK T2 is in the control range or PT100 is OK T3 OK T3 is in the control range or PT100 is OK LA1 OK Humidity sensor 1 is OK or has no humidity LA2 OK...
- Page 58 Error and status messages Message Significance SysError General internal error. Consult with M&C service department. Sys OK General error cancelled Comm. error Communication with expansion module is missing Comm. OK Communication with expansion module is back P1 man. On Pump 1 is set to On P1 man.
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Page 59: Figure 24 Tcu Menu
Figure 24 TCU menu www.mc-techgroup.com CSS-VC-1.6 | 1.01.03...