Gas Analysis

Sample gas cooler

TC-MINI

Installation and Operation Instructions

Original instructions

BE440015 Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen

05/2021 Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20
E-Mail: [email protected]
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: [email protected]

Read this instruction carefully prior to installation and/or use. Pay at-
tention particularly to all advises and safety instructions to prevent in-
juries. Bühler Technologies can not be held responsible for misusing
the product or unreliable function due to unauthorised modifications.

All rights reserved. Bühler Technologies GmbH 2021

Document information
Document No.......................................................... BE440015
Version......................................................................... 05/2021
 TC-MINI

Contents
1 Introduction..................................................................................................................................................................................................................... 2
1.1 Intended use ......................................................................................................................................................................................................... 2
1.2 Types ....................................................................................................................................................................................................................... 2
1.3 Scope of delivery .................................................................................................................................................................................................. 2
1.4 Ordering instructions ........................................................................................................................................................................................ 2
2 Safety instructions......................................................................................................................................................................................................... 3
2.1 Important advice ................................................................................................................................................................................................. 3
2.2 General hazard warnings ................................................................................................................................................................................. 4
3 Transport and storage .................................................................................................................................................................................................. 5
4 Installation and connection ........................................................................................................................................................................................ 6
4.1 Installation site requirements......................................................................................................................................................................... 6
4.2 Installation ............................................................................................................................................................................................................ 6
4.2.1 Connecting the filter gas connections (optional) ....................................................................................................................... 7
4.2.2 Flow adapter connection (optional)................................................................................................................................................ 7
4.2.3 Connecting the moisture detector (option).................................................................................................................................. 7
4.3 Electrical connections ........................................................................................................................................................................................ 7
4.4 Settings................................................................................................................................................................................................................... 9
5 Operation and control ................................................................................................................................................................................................. 11
5.1 Status Signal via LEDs and Status Relay ...................................................................................................................................................... 11
5.2 Using the Digital Interface .............................................................................................................................................................................. 11
5.3 Modbus Configuration ..................................................................................................................................................................................... 11
5.4 Modbus Communication ................................................................................................................................................................................ 12
5.5 Modbus Register................................................................................................................................................................................................. 13
6 Maintenance................................................................................................................................................................................................................... 17
7 Service and repair......................................................................................................................................................................................................... 18
7.1 Troubleshooting ................................................................................................................................................................................................ 19
7.2 Safety instructions ........................................................................................................................................................................................... 20
7.3 Cleaning and removal of the heat exchanger.......................................................................................................................................... 20
7.4 Replacing the fuse of the cooler................................................................................................................................................................... 20
7.5 Replacing the filter element (option) .......................................................................................................................................................... 21
7.6 Drying of the moisture detector (option)................................................................................................................................................... 21
7.7 Spare parts and accessories ........................................................................................................................................................................... 21
7.7.1 Consumables and accessories ....................................................................................................................................................... 22
8 Disposal ........................................................................................................................................................................................................................... 23
9 Appendices..................................................................................................................................................................................................................... 24
9.1 Gas cooler technical data ................................................................................................................................................................................ 24
9.2 Technical Data - Options ................................................................................................................................................................................. 24
9.3 Dimensions (mm).............................................................................................................................................................................................. 25
9.4 Performance data.............................................................................................................................................................................................. 25
9.5 Heat exchanger.................................................................................................................................................................................................. 26
9.5.1 Heat exchanger description ........................................................................................................................................................... 26
9.5.2 Heat exchanger overview................................................................................................................................................................ 26
10 Attached documents ................................................................................................................................................................................................... 27

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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.
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 Types
The device is delivered with different configurations. The part number given on the type plate informs you about the specific
configuration of your device.

1.3 Scope of delivery

– Cooler
– Product documentation
– Connection-/mounting accessories (optional)

1.4 Ordering instructions

4496 1 1 1 X 0 4 X X X 0 0 X X X 0 0 0 0 Product Characteristics
Gas cooler models (with 1 heat exchanger)
1 TC-MINI 6111: moderate ambient temperature 40 °C
2 TC-MINI 6112: higher ambient temperature 50 °C
Certifications
0 Standard applications – CE
Supply voltage
4 24 V DC
Heat exchanger 1)
1 1 0 0 0 Stainless steel, MTS, metric
1 1 5 0 0 Stainless steel, MTS-I, US
1 2 0 0 0 Duran glass, MTG, metric
1 2 5 0 0 Duran glass, MTG, US
1 3 0 0 0 PVDF, MTV, metric
1 3 5 0 0 PVDF, MTV-I, US
1 6 0 0 0 Stainless steel, angle connector, MTS-WS, metric
1 6 5 0 0 Stainless steel, angle connector, MTS-I-WS, US
Moisture detector/filter
0 0 without filter, without moisture detector
0 1 without filter, 1 moisture detector with block
1 0 1 filter, without moisture detector
1 1 1 filter with built-in moisture detector
Signal outputs
1 0 0 0 0 Analog output, 4..20 mA, incl. status output
2 0 0 0 0 Modbus RTU digital output, incl. status output
1)
Moisture detector/filter screw-in fitting and tubes metric or US, accordingly

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2 Safety instructions

2.1 Important advice

Operation of the device is only valid if:
– the product is used under the conditions described in the installation- and operation instruction, the intended application
according to the type plate and the intended use. In case of unauthorized modifications done by the user Bühler Technolo-
gies GmbH can not be held responsible for any damage,
– when complying with the specifications and markings on the nameplates.
– the performance limits given in the datasheets and in the installation- and operation instruction are obeyed,
– monitoring devices and safety devices are installed properly,
– service and repair is carried out by Bühler Technologies GmbH,
– only original spare parts are used.
This manual is part of the equipment. The manufacturer keeps the right to modify specifications without advanced notice. Keep
this manual for later use.

Signal words for warnings

Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.
DANGER

Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not
WARNING
avoided.

Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property or
CAUTION
minor or medium injuries if not avoided.

Signal word for important information to the product.

NOTICE

Warning signs
These instructions use the following warning signs:

Warns of a general hazard 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

General information

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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,
– compliance with national installation regulations.
– the device is protected from mechanical loads.

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.
– Do not install damaged or defective spare part. If necessary, visually inspect prior to installation to determine any obvious
damage to the spare parts.
Always observe the applicable safety and operating regulations in the respective country of use when performing any type of
maintenance.

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 Potentially explosive atmosphere

Explosion hazard if used in hazardous areas.
The device is not suitable for operation in hazardous areas with potentially explosive at-
mospheres.
Do not expose the device to combustible or explosive gas mixtures.

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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 re-
commend aerating the cabinet or installing a fan to lower the inside temperature.
When wall mounting the sample gas cooler, be sure the wall or the cabinet provide adequate weight bearing and stability.

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, 11 LD V38, AK 20, AK 5.5 OR AK 5.2, 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 peri-
staltic pumps.

Connecting the condensate drains

Depending on the material, build a connecting line with fittings and tubing or hose between the heat exchanger and condens-
ate drain. For stainless steel the condensate drain can be suspended directly to 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 DN 8/10 (5/16”), with passive dis-
charge via traps or automatic condensate drains. Use screw joints with a minimum inner span of 7 mm, sold separately as ac-
cessories. The MTG heat exchanger in glass cannot be operated in conjunction with an automatic condensate drain.

Connecting the heat exchanger

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 con-
sists of a silicone ring with a PTFE sleeve. The PTFE side must face the glass thread.

Glass
PTFE

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4.2.1 Connecting the filter gas connections (optional)

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 option filter without Moisture detector, a bypass may be connected to the filter head.
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 filters limits the maximum approved operating pressure in the system!
Operating pressure ≤ 2 bar

4.2.2 Flow adapter connection (optional)

When ordering the cooler with the option moisture detector without filter, it will be factory installed inside a flow adapter.
The connection between the heat exchanger outlet and the flow adapter inlet does not have tubing included. The connection
G1/4 or NPT 1/4" (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.

4.2.3 Connecting the moisture detector (option)

When ordering the cooler with moisture detector option, it will be factory installed inside a flow adapter, or for the filter option
installed and connected in the filter head.

4.3 Electrical connections

NOTICE
The connection must be made by a trained professional.

CAUTION Wrong mains voltage

Wrong mains voltage may damage the device.
Regard the correct mains voltage as given on the type plate.

The sample gas cooler features plug-in connectors at the top for connecting the power supply and the status outputs.
The unit features an output for status messages. Please refer to the technical data for ratings.
An alarm is triggered 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.
When the moisture detector (optional) is installed, an alarm is activated if the moisture is still present in the prepared sample
gas. This is the same alarm output as for the temperature.

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X2.1 X2.5

X2.10
X2.6

X1.1

DIP Switch / Settings

LED green
LED red

Inputs/outputs Terminal Function Description

Moisture detector X1.1 FF.1 (white) Moisture detector
X1.2 FF.2 (brown)
X1.3 FE: Shield for moisture detector inlet
Status X2.1 Status NC (Alarm) Alarm/Status
X2.2 Status COM Changeover contact, potential-free,
X2.3 Status NO (ok) Ratings see technical data
24 V input X2.4 24 V DC - Power supply
X2.5 24 V DC +
Analog output X2.6 FE: Shield for analog output
X2.7 mA + Analog output
X2.8 mA - 4…20 mA, 0 - 80 °C
Digital output X2.6 FE: Shield for digital output
X2.7 Signal A Communication line for digital interface
X2.8 Signal B
24 V output * X2.9 24 V DC - Supply for optional add-on units
X2.10 24 V DC + maximum current, see technical data
* Add-on units, e.g. a pump, with 24 V supply can be connected to the output, switched via the status output. The 24 V supply
must then be configured appropriately (see data sheet).

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4.4 Settings
Remarks on outlet dew point
Not all applications require an outlet dew point of 5 °C. In some applications a higher dew point is sufficient. In other applica-
tions a stable outlet dew point doesn’t matter, it’s enough for the gas to be dry, so for the outlet dew point to have an adequate
difference in temperature below the ambient temperature.
The advantage of a higher outlet temperature is that at a given ambient temperature the Peltier cooler provides significantly
more cooling performance. So on the e.g. TC-MINI version model 6111, at an ambient temperature of 40 °C this means:

Outlet dew point: 5 °C 10 °C 15 °C

Available cooling capacity: 16 kJ/h 28 kJ/h 39 kJ/h

To fully utilize these advantages, the electronics feature several parameter settings:
1. Adjustable outlet dew point
An outlet dew point of 3, 5, 10 or 15 °C can be set to reach the specified values. Here it’s important the ambient temperature
is always ABOVE the outlet dew point setting, or condensation may form in the lines after the cooler. So the ambient tem-
perature range is limited.
2. Delta-T Control
Here the electronics measures the ambient temperature an regulates the outlet dew point to a an about 15 °C or 30 °C lower
value, but no less than the dew point set under 1. This extends the potential cooling capacity to the limits of the heat ex-
changer. Here it’s important to note the outlet dew point fluctuates along with the ambient temperature and a stable dew
point cannot be a prerequisite for the measurement.
As seen in the following graphics using the TC-MINI 6111 as an example, a difference of 15 °C from the ambient temperature
means the focus is on drying the sample gas. The stability of the dew point then takes a backseat to the high performance
which can be achieved.
At a difference of 30 °C, at a set outlet dew point of 10 °C this means the dew point remains stable up to an ambient temper-
ature of approx. 40 °C, and the safe drop is only preferred over the ambient temperature with ambient temperature peaks
over 40 °C.
Cooling capacity in kJ/h

10 °C
Output dew point

Ambient temperature in °C

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DIP switch
The unit is configured using four DIP switches at the front of the cooler.

1 ON switch
SW1 0 1
0 OFF switch
SW2 0 1
SW Switch, the following numbering of the SWs corresponds with the numbering on the DIP
SW3 0 1
switch.
SW4 0 1

SW1 / SW2 SW2 SW1 Gas output dew point

0 0 3 °C
0 1 5 °C (factory setting)
1 0 10 °C
1 1 15 °C

SW3 / SW4 SW3 SW4 Delta-T control/digital interface

0 0 Gas output dew point, fixed
0 1 Difference from ambient temperature approx. 15 °C
1 0 Difference from ambient temperature approx. 30 °C
1 1 Modbus option active (only with optional Modbus RTU digital output)

Using the Modbus RTU option

On devices with Modbus option, the DIP switches are set so the digital interface is active. With the interface active, it’s import-
ant the switch settings SW1 and SW2 are not relevant for the cooler function. In this case, the cooler uses the values in the re-
gisters.
When disabling the digital interface with the DIP switch, the settings apply based on the DIP switches again. The Modbus re-
gisters will not be overwritten.

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5 Operation and control

NOTICE
The device must not be operated beyond its specifications.

After switching on the supply voltage the cooler starts to cool the cooling block. When switched off the contact between X2.1 and
X2.2 is closed.
The target temperature is factory preset to 5 °C. The alarm limit is defined at +5/-2 K.
(Note deviating defaults with Modbus option enabled, see Modbus register table).

5.1 Status Signal via LEDs and Status Relay

LED LED Status Condition FF Temperature Description
green red internal
OFF OFF X2.1, X2.2 Unit off With the cooler switched off, the status out-
put corresponds error status.
ON OFF X2.1, X2.3 OK OK (*) OK Normal operation
OFF Flashing X2.1, X2.2 OK OK (*) Error Overload / temperature outside the target
f = 1 Hz range
OFF ON X2.1, X2.2 OK Error xxx Moisture penetration
OFF Flashing X2.1, X2.2 Error xxx xxx Various possible causes, contact Service.
f = 5 Hz

OK No error
Error Error present
xxx Status not defined
f =… LED flash frequency
X2.1, X2.2… Markings on terminals
(*) Also applies if no moisture detector connected
If the red LED lights up during operation, please refer to chapter ““.Troubleshooting [> page 19]“.

5.2 Using the Digital Interface

The digital interface on this device is a Modbus RTU protocol, which physically communicates via RS485 (2-wire). The cooler
therefore takes on the role of the slave in communication.
The Modbus interface enables direct access to process and diagnostic data and parameters during operation.

5.3 Modbus Configuration

The settings below are the defaults; the parameters can be adjusted if the interface is enabled.
1 start bit
8 data bits
1 parity bits (configurable)
1 stop bit (*)
Baudrate: 19200 bps (configurable)
Device ID: 10 (configurable)
(*) The length of a Modbus frame is always 11 bit, configuring the interface at 0 data bits automatically changes the number of
stop bits to 2.

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5.4 Modbus Communication

Communication via Modbus RTU is always imitated by the master (request). The slave (typically) responds to the request with a
response. A Modbus RTU frame for a request/response always has the following structure:

Address field (A) Function code (FC) Data CRC

1 byte 1 byte 1 … 252 bytes 2 bytes
Register addresses and data are transferred in Big Endian format.
Every register stands for a 16 bit value, with the information represented in various data types. The data type and required func-
tion code are assigned to the respective registers in the following tables.
To read/write data types with sizes larger than an individual register, multiple registers must be addressed.

Supported function codes:

Function code (FC) FC values

Read Holding Registers 3
Write Multiple Registers 16

Data types:

Description Number of bytes Number of registers

Float 4 2
Int16 2 1
Uint16 2 1
Int32 4 2
Uint32 4 2

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5.5 Modbus Register

TC-MINI
Bühler Technologies GmbH

Description FC Address Access Data type Default Min Max Selection Resolution Unit
Block temperature measurement 3 2000 R Float - - - - 0.5 °C
Block temperature status 3 2002 R Uint32 - - - 0 : = error
1..15 := reserved
16 := sensor not calibrated
17 := initialization / measurement invalid
18 := stabilization phase
19 := load limit reached
20 := measurement outside target range
21..31 := not used
Ambient temperature measurement 3 2004 R Float - - - - 0.5 °C
Ambient temperature status 3 2006 R Uint32 - - - 0 : = error
1..15 := reserved
16 := sensor not calibrated
17 := initialization / measurement invalid
18..31 := not used
Block temperature setpoint 3, 16 5000 R/W Float 5.0 3.0 15.0 - 0.5 °C
Positive alarm tolerance setpoint 3, 16 5002 R/W Float 3.0 1.0 7.0 - 1.0 K
Negative alarm tolerance setpoint 3, 16 5004 R/W Float -3.0 -3.0 -1.0 - 1.0 K
Temperature difference Delta-T 3, 16 5008 R/W Float -15.0 -30.0 0.0 - 1.0 K
Enable/disable Delta T 3, 16 9001 R/W Uint16 0 - - 0 := normal operation 1 -
1:= Delta-T control
Signal store 3, 16 9002 R/W Uint16 2 - - 1 := no 1 -
Moisture detector error 2 := yes
Signal store 3, 16 9003 R/W Uint16 1 - - 1 := no 1 -
Moisture alarm 2 := yes
Sensitivity moisture detector 1 3, 16 9004 R/W Uint16 0 - - 0 := sensitivity low
1 (with moisture detector) 1 := sensitivity high
2 (without moisture de- 2 := moisture detector inactive
tector)
Modbus Baudrate selection 3, 16 9009 R/W Uint16 3 - - 1 := 4800 - -
2 := 9600
3 := 19200
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4 := 38400
5 := 57600
6 := 115200
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Description FC Address Access Data type Default Min Max Selection Resolution Unit

TC-MINI
Modbus Parity selection 3, 16 9010 R/W Uint16 2 - - 0 := none 1 -
1 := odd
2 := even
Modbus Device address selection 3, 16 9011 R/W Uint16 10 1 247 - 1 -
TEST 3 9990 R Uint32 12648430 - -
TEST_UINT16 3, 16 9992 R/W Uint16 206 0 65535 - 1 -
TEST_INT16 3, 16 9993 R/W Int16 -206 -32768 32767 - 1 -
TEST_UINT32 3, 16 9994 R/W Uint32 2766 0 0xffffffff
TEST_INT32 3, 16 9996 R/W Int32 -2766 0x800 0x7fffffff
00000
TEST_Float 3, 16 9998 R/W Float -10.5
Status register overview 3 10000 R Uint16 0 - - Bit 0 := status information at
Register 10001
Bit n := status information at
Register 10000 + n + 1
Condition code register 1 3 10001 R Uint16 0 - - Bit 0 := device status - -
Bit 1 := device in error status
Bit 2 := set temperature range overrun
Bit 3 := set temperature range underrun
Bit 4 :=
Bit 5 :=
Bit 6 := moisture detector connected
Bit 7 :=
Condition code register 2 3 10002 R Uint16 0 - - Bit 0 := - -
Bit 1 :=
Bit 2 := initialization phase
Bit 3 := Delta-T active
Bit 4 :=
Bit 5 :=
Bit 6 := FF1 moisture alarm
Bit 7 :=
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Condition code register 3 3 10003 R Uint16 0 Bit 0 :=

Bit 1 :=
Bit 2 :=
Bit 3 :=
Bit 4 :=
Bit 5 :=
Bit 6 :=
Bit 7 :=
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Description FC Address Access Data type Default Min Max Selection Resolution Unit

TC-MINI
Condition code register 4 3 10004 R Uint16 0 Bit 0 :=
Bit 1 :=
Bit 2 :=
Bit 3 :=
Bit 4 :=
Bit 5 :=
Bit 6 :=
Bit 7 :=
Error register 1 3 10005 R Uint16 0 Bit 0 :=
Bit 1 := controller communication error
Bit 2 :=
Bit 3 := controller configuration error
Bit 4 :=
Bit 5 :=
Bit 6 :=
Bit 7 := gen. software error
Error register 2 3 10006 R Uint16 0 Bit 0 :=
Bit 1 :=
Bit 2 :=
Bit 3 :=
Bit 4 :=
Bit 5 :=
Bit 6 :=
Bit 7 :=
Error register 3 - moisture detector 1 3 10007 R Uint16 0 Bit 0 :=
Bit 1 :=
Bit 2 := cable break
Bit 3 :=
Bit 4 :=
Bit 5 :=
Bit 6 :=
Bit 7 :=
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Error register 5 - PT100.1 3 10009 R Uint16 0 - - Bit 0 := general error

Bit 1 := short-circuit / temperature low
Bit 2 := cable break / temperature high
Bit 3 := measurement fluctuation
Bit 4 :=
Bit 5 :=
Bit 6 :=
Bit 7 :=
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Description FC Address Access Data type Default Min Max Selection Resolution Unit

TC-MINI
Error register 6 - PT100.2 3 10010 R Uint16 0 - - Bit 0 := general error
Bit 1 := short-circuit / temperature low
Bit 2 := cable break / temperature high
Bit 3 := measurement fluctuation
Bit 4 :=
Bit 5 :=
Bit 6 :=
Bit 7 :=
Utilisation controller 1 3 10017 R Uint16 - 0 100 10 %
Device run time 3 10100 R Float - 0 - 6 min h
Device restart / device reset 16 11000 W Uint16 0 - - 86 := device restart
17:= factory reset
Reset moisture detector 1 16 11002 W Uint16 170 - - -

Example:
Register 5000 = 0x1388
Read block temperature set values

A FC Start register HI Start register LO No. register HI No. register LO CRC CRC
Request 0x0A (10) 0x03 (3) 0x13 0x88 0x00 (0) 0x02 (2) 0x41 0xDE
A FC No. of byte DATA 3 DATA 2 DATA 1 Data 0 CRC CRC
Response 0x0A (10) 0x03 (3) 0x04 0x40 0xA0 0x00 0x00 0x55 0x11
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6 Maintenance
The basic version of the cooler requires no special maintenance.
However, it may have different options depending on the configuration ordered. In this case the following routine maintenance
is required:
Filter option: Check filter element (see chapter Replacing the filter element (option) [> page 21].
During maintenance, remember:
– The equipment must be maintained by a professional familiar with the safety requirements and risks.
– Only perform maintenance work described in these operating and installation instructions.
– When performing maintenance of any type, observe the respective safety and operation regulations.

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.

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7 Service and repair

This chapter contains information on troubleshooting and correction should an error occur during operation.
Repairs to the unit must be performed by Bühler authorised personnel.
Please contact our Service Department with any questions:
Tel.: +49-(0)2102-498955 or your agent
If the equipment is not functioning properly after correcting any malfunctions and switching on the power, it must be inspected
by the manufacturer. Please send the equipment inside suitable packaging to:
Bühler Technologies GmbH
- Reparatur/Service -
Harkortstraße 29
40880 Ratingen
Germany
Please also attach the completed and signed RMA decontamination statement to the packaging. We will otherwise be unable to
process your repair order.
You will find the form in the appendix of these instructions, or simply request it by e-mail:
[email protected].

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7.1 Troubleshooting
Problem/malfunction Possible cause Action
No LED lights up – Mains voltage interrupted – Connect to mains; check the plug is cor-
rectly inserted
– Fuse defective – Check fuse and replace if necessary
– LED defective – Send in cooler
– Internal error – Send in cooler
Red LED flashing – Operating point not yet reached – Wait (max. 15 min)
(f = 1 Hz) – Cooling output too low despite the cooler – Ensure the vents are not covered (heat
Excess temperature running buildup)
Temperature low – Flow rate too high/dew point too high/gas – Maintain limits / install pre-separator
temperature too high
– Built-in fan stopped – Check and replace if necessary
– Controller defective – Send in cooler
– Short circuit – Temperature sensor failure: Send in cooler
– Broken wire – Temperature sensor failure: Send in cooler
Red LED flashing – Internal error – Send in cooler
(f = 5 Hz)
Steady red LED – Cooler overloaded flow rate too high/dew – Maintain limits/install pre-separator
Moisture in sample gas point/gas temperature too high
(If the moisture detector was – Cooling output too low despite the cooler – Ensure the vents are not covered (heat
triggered it will then need to running buildup); maintain limits
be dried) – Condensate trap full – Empty condensate trap
– Water entering from water bag – Observe delivery rate of peristaltic pumps
– Install condensate drain with downward
slope
– Cable break in the moisture detector con- – Check connection line and plug-in connec-
nection line tion
Condensate inside the gas out- – Condensate trap full – Empty condensate trap
put – Valve inside the automatic condensate – Flush in both directions
drain may be stuck
– Cooler overload – Maintain limits
Reduced gas flow rate – Gas circuit clogged – Remove and clean heat exchanger
– if necessary, replace filter element
– Condensate output iced over – Send in cooler
Modbus communication error – Bus connection fault – Check electrical connections
– Line termination fault – Check bus line
– Check bus configuration – Check/reset configurator

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7.2 Safety instructions

– The device must be operated within its specifications.
– All repairs must be carried out by Bühler authorised personnel only.
– Only perform modifications, servicing or mounting described in this manual.
– Only use original spare parts.

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.

CAUTION Health hazard if the heat exchanger leaks

The heat exchanger is charged with glycol-based coolant.
In the event of a heat exchanger leak:
a) Avoid contact with the skin and eyes.
b) In the event of a leak, do not restart the cooler under any circumstances The cooler
must be repaired by the manufacturer.

7.3 Cleaning and removal of the heat exchanger

Heat exchangers only need to be replaced or maintained if clogged or damaged. If they are clogged, we recommend checking if
using a filter will avoid future occurrences.
– Close gas supply.
– Switch off device and disconnect all plugs (e.g. status output connector, supply input, etc.).
– Disconnect gas connections and condensate drain.
– Pull the heat exchanger up and out.
– Clean cleaning nest (hole inside the cooler block), as the heat exchangers are installed with silicone grease.
– Flush the heat exchanger until all contaminants have been removed.
– Grease the cooled outside surface external surface with silicone grease.
– Reinsert the heat exchanger into the cooling nest with a rotating movement.
– Reconnect the gas supply and condensate drain. The gas inlet is marked red.
– Restore power/gas supply and wait for unit to be ready for operation.
– Open gas supply.

7.4 Replacing the fuse of the cooler

– Close the gas supply.
– Switch off and unplug the device.
– Loosen the screws on the cover.
– Carefully remove the cover.
– The fuse is located on the board under a plastic cap. Replace microfuse and put the cap back on. Please note the mains
voltage in order to select the correct microfuse.
– Reattach cover. Screw in mounting screws.
– Restore the power and gas supply.

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7.5 Replacing the filter element (option)

CAUTION Gas leakage
The filter should not be dismantled under pressure.
Don’t use damaged parts again.

– Close the gas supply.

– Switch off and unplug the device.
– Pull the bracket, holding on to the filter glass.
– Whilst holding the filter head, move the glass back and forth and carefully remove downward.
– Remove the filter element and insert a new one.
– Check for leaks and replace, if necessary.
– Whilst holding the filter head, move the glass back and forth and carefully reattach the filter head, attach the bracket, and
ensure it is seated securely.
– Restore the power and gas supply.
NOTICE! Please observe legal regulations when disposing of filter elements.

7.6 Drying of the moisture detector (option)

The moisture detector must be dried if moisture enters.
– Close the gas supply.
– Switch off and unplug the device.
– Loosen the swivel nut for the moisture detector connection line and disconnect the line.
– Unscrew the moisture detector counter-clockwise and remove.
– Dry moisture detector.
– Reinsert the moisture detector and carefully tighten the screw connection.
– Connect the connection line and tighten the swivel nut.
– Restore the power and gas supply.

7.7 Spare parts and accessories

Please also specify the model and serial number when ordering parts.
Upgrade and expansion parts can be found in our catalog.
Available spare parts:

Item no. Description

40 11 00 0 Flow adapter type G, PVDF G1/4
40 11 00 0 I Flow adapter type NPT, PVDF NPT 1/4"
41 11 10 0 Moisture detector FF-3-N, without cable
91 44 05 00 81 Moisture detector connection cable, 300 mm
91 44 05 00 82 Moisture detector connection cable, 450 mm
91 10 00 00 31 Sample gas cooler micro-fuse 24 VDC, 5 x 20 mm, 5 A, delayed action
55 30 00 09 93 2 Fan, 24 VDC

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7.7.1 Consumables and accessories

Item no. Description
91 12 00 00 39 24 V top-hat rail power supply
91 12 00 00 40 24 V top-hat rail power supply for using the 24 V output
45 10 008 Automatic condensate drain AK 5.2
45 10 028 Automatic condensate drain AK 5.5
44 10 004 Automatic condensate drain AK 20
44 10 001 Automatic condensate drain 11 LD V 38
41 03 00 50 Replacement filter element F2; 2 µm, Unit 5 count
43 81 045 Screw connection G1/4 - DN 8/12 for passive condensate connection MTS and MTV
43 81 048 Screw connection NPT 1/4" for passive condensate connection MTS and MTV

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8 Disposal
The heat exchanger is charged with glycol-based coolant.
In EU member states, as per Directive 2012/19/EU, device with electrical components must be recycled separately.
Dispose of parts so as not to endanger the health or environment. Follow the laws in the country of use for disposing of elec-
tronic components and devices as well as hazardous materials during disposal.
As an EU member state you have the option to return Bühler Technologies GmbH products to us. When returning the product,
the completed and signed RMA decontamination declaration must be attached to the packaging. You will find the form in the
appendix of these instructions, or simply request it by e-mail: [email protected].

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9 Appendices

9.1 Gas cooler technical data

Gas Cooler Technical Data
Ready for operation after max. 10 minutes
Ambient temperature 5 °C to 55 °C
Gas outlet dew temperature, preset: 5 °C
IP rating: IP 20
Housing Stainless steel, brushed
Packaging dimensions approx. 235 x 225 x 280 mm (without add-on filter)
Weight incl. heat exchanger approx. 3.5 kg
Power supply 24 VDC
24 V output max. 1 A
Power input max. 70 VA (plus max. 25 VA at 24 V output)
Status output switching capacity 33 VAC / 70 VDC, 1 A
Electrical connections, Phoenix plug
standard applications

9.2 Technical Data - Options

A moisture detector may be connected to the control. The moisture detector can be mounted to the cooler using a block or by in-
stalling it into the optional filter.

Technical Data FF-3-N Moisture Detector

Ambient temperature 3 °C to 50 °C
max. operating pressure with FF-3-N 2 bar
Material PVDF, PTFE, epoxy resin, stainless steel 1.4571, 1.4576

AGF-PV-30-F2 Filter Technical Data

Ambient temperature 3 °C to 100 °C
max. operating pressure with filter 4 bar
Filter surface 60 cm2
Filter fineness 2 µm
Dead volume 57 ml
Materials
Filter: PVDF, Duran glass (parts in contact with media)
Seal: Viton
Filter element: sintered PTFE

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9.3 Dimensions (mm)

Sample gas Air
IN/OUT OUT

Air
OUT
Condensate
OUT

approx.

Optional filter
Air
IN

9.4 Performance data

Cooling capacity in kJ/h

A selected outlet dew point of 10 or 15 °C shifts the curves 5 or

10 °C to the right.

The MTV and MTG limits apply to a normal operating point of τe

= 40 °C and ϑG = 70 °C.
Ambient temperature in °C

6111 with MTS 6112 with MTS

Limit for MTV Limit for MTG

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9.5 Heat exchanger

9.5.1 Heat exchanger description

The energy content of the sample gas and the required cooling capacity of the gas cooler is determined by three parameters: gas
temperature ϑG, dew point τe (moisture content) and volume flow v. The outlet dew point rises with increasing energy content of
the gas. The following limits for the maximum flow are specified for a standard operating point of τe = 40 °C and ϑG = 70 °C. The
maximum flow vmax in Nl/h of cooled air indicated, so after moisture has condensed. Values may differ for other dew points and
gas inlet temperatures. However, the physical facts are so vast we decided to omit the illustration. Please contact our experts for
clarification or refer to our calculation programme.

9.5.2 Heat exchanger overview

Heat exchanger MTS 3) MTG 3) MTV 3)
MTS-I 2) 3) MTG 3) MTV-I 2) 3)
Version / Material Stainless steel Glass PVDF
Flow rate vmax 1) 300 Nl/h 210 Nl/h 190 Nl/h
Inlet dew point τe max 1) 65 °C 65 °C 65 °C
Gas inlet temperature ϑG,max 1) 140 °C 140 °C 140 °C
Max. Cooling capacity Qmax 95 kJ/h 80 kJ/h 65 kJ/h
Gas pressure pmax 25 bar 3 bar 2 bar
Pressure drop Δp (v = 150 L/h) 20 mbar 19 mbar 18 mbar
Dead volume Vtot 19 ml 18 ml 17 ml
4)
Gas connections (metric) 6 mm tube GL14 (6 mm) DN 4/6
Gas connections (US) 1/4" tube GL14 (1/4")4) 1/4"-1/6"
Condensate out connections (metric) G1/4 GL18 (8 mm) 4) G1/4
Condensate out connections (US) NPT 1/4" GL18 (8 mm) 4) NPT 1/4"

1)
Max. cooling capacity of the cooler must be considered.
2)
Models marked I have NPT threads or US tubes, respectively.
3)
Passive discharge via automatic condensate drains or traps not applicable for MTG heat exchanger. For passive discharge on
the MTS and MTV heat exchangers, use a screw connection with a clearance of at least 7 mm (see accessories).
4)
Gasket inside diameter

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10 Attached documents
– Declaration of conformity: KX 440005
– RMA - Decontamination Statement

BE440015 ◦ 05/2021 Bühler Technologies GmbH 27

RMA-Formular und Erklärung über Dekontaminierung
RMA-Form and explanation for decontamination
RMA-Nr./ RMA-No.
Die RMA-Nummer bekommen Sie von Ihrem Ansprechpartner im Vertrieb oder Service./ You may obtain the RMA
number from your sales or service representative.
Zu diesem Rücksendeschein gehört eine Dekontaminierungserklärung. Die gesetzlichen Vorschriften schreiben vor,
dass Sie uns diese Dekontaminierungserklärung ausgefüllt und unterschrieben zurücksenden müssen. Bitte füllen Sie
auch diese im Sinne der Gesundheit unserer Mitarbeiter vollständig aus./ This return form includes a decontamination
statement. The law requires you to submit this completed and signed decontamination statement to us. Please com-
plete the entire form, also in the interest of our employee health.

Firma/ Company Ansprechpartner/ Person in charge

Firma/ Company Name/ Name

Straße/ Street Abt./ Dept.
PLZ, Ort/ Zip, City Tel./ Phone
Land/ Country E-Mail

Gerät/ Device Serien-Nr./ Serial No.

Anzahl/ Quantity Artikel-Nr./ Item No.

Auftragsnr./ Order No.

Grund der Rücksendung/ Reason for return bitte spezifizieren/ please specify

Kalibrierung/ Calibration Modifikation/ Modification

Reklamation/ Claim Reparatur/ Repair
andere/ other
Ist das Gerät möglicherweise kontaminiert?/ Could the equipment be contaminated?
Nein, da das Gerät nicht mit gesundheitsgefährdenden Stoffen betrieben wurde./ No, because the device was not operated with
hazardous substances.
Nein, da das Gerät ordnungsgemäß gereinigt und dekontaminiert wurde./ No, because the device has been properly cleaned and
decontaminated.
Ja, kontaminiert mit:/ Yes, contaminated with:

explosiv/ entzündlich/ brandfördernd/ komprimierte ätzend/ giftig, gesundheitsge- gesund- umweltge-

explosive flammable oxidizing Gase/ caustic Lebensgefahr/ fährdend/ heitsschädlich/ fährdend/
compressed poisonous, risk harmful to health hazard environmental
gases of death health hazard
Bitte Sicherheitsdatenblatt beilegen!/ Please enclose safety data sheet!

Das Gerät wurde gespült mit:/ The equipment was purged with:
Diese Erklärung wurde korrekt und vollständig ausgefüllt und von einer This declaration has been filled out correctly and completely, and signed by
dazu befugten Person unterschrieben. Der Versand der (dekontaminier- an authorized person. The dispatch of the (decontaminated) devices and
ten) Geräte und Komponenten erfolgt gemäß den gesetzlichen Bestim- components takes place according to the legal regulations.
mungen.

Falls die Ware nicht gereinigt, also kontaminiert bei uns eintrifft, muss die Should the goods not arrive clean, but contaminated, Bühler reserves the
Firma Bühler sich vorbehalten, diese durch einen externen Dienstleister right, to comission an external service provider to clean the goods and in-
reinigen zu lassen und Ihnen dies in Rechnung zu stellen. voice it to your account.

Firmenstempel/ Company Sign Datum/ Date

rechtsverbindliche Unterschrift/ Legally binding signature

DE000011 Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen

01/2019 Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20
E-Mail: [email protected]
Internet: www.buehler-technologies.com
 Dekontaminierungserklärung

Die Analyse defekter Baugruppen ist ein wesentlicher Bestandteil der Qualitätssicherung der Firma
Bühler Technologies.

Um eine aussagekräftige Analyse zu gewährleisten muss die Ware möglichst unverändert untersucht
werden. Es dürfen keine Veränderungen oder weitere Beschädigungen auftreten, die Ursachen ver-
decken oder eine Analyse unmöglich machen.

Bei elektronischen Baugruppen kann es sich um elektrostatisch sensible Baugruppen handeln. Es ist
darauf zu achten, diese Baugruppen ESD-gerecht zu behandeln. Nach Möglichkeit sollten die Baugrup-
pen an einem ESD-gerechten Arbeitsplatz getauscht werden. Ist dies nicht möglich sollten ESD-
gerechte Maßnahmen beim Austausch getroffen werden. Der Transport darf nur in ESD-gerechten Be-
hältnissen durchgeführt werden. Die Verpackung der Baugruppen muss ESD-konform sein. Verwenden
Sie nach Möglichkeit die Verpackung des Ersatzteils oder wählen Sie selber eine ESD-gerechte Ver-
packung.

Beachten Sie beim Einbau des Ersatzteils die gleichen Vorgaben wie oben beschrieben. Achten Sie auf
die ordnungsgemäße Montage des Bauteils und aller Komponenten. Versetzen Sie vor der Inbetrieb-
nahme die Verkabelung wieder in den ursprünglichen Zustand. Fragen Sie im Zweifel beim Hersteller
nach weiteren Informationen.

Analysing defective assemblies is an essential part of quality assurance at Bühler Technologies.

To ensure conclusive analysis the goods must be inspected unaltered, if possible. Modifications or
other damages which may hide the cause or render it impossible to analyse are prohibited.

Electronic assemblies may be sensitive to static electricity. Be sure to handle these assemblies in an
ESD-safe manner. Where possible, the assembles should be replaced in an ESD-safe location. If un-
able to do so, take ESD-safe precautions when replacing these. Must be transported in ESD-safe con-
tainers. The packaging of the assemblies must be ESD-safe. If possible, use the packaging of the spare
part or use ESD-safe packaging.

Observe the above specifications when installing the spare part. Ensure the part and all components
are properly installed. Return the cables to the original state before putting into service. When in doubt,
contact the manufacturer for additional information.

DE000011 Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen

01/2019 Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20
E-Mail: [email protected]
Internet: www.buehler-technologies.com