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Buhler RC 1 Series Installation And Operation Instruction Manual

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Gas Analysis
Sample gas cooler
Series RC 1.x
Installation and Operation Instructions
Original instructions
BE450028
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
03/2024
Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20
E-Mail: analyse@buehler-technologies.com
Internet: www.buehler-technologies.com

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  • Page 1 Gas Analysis Sample gas cooler Series RC 1.x Installation and Operation Instructions Original instructions BE450028 Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen 03/2024 Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20 E-Mail: analyse@buehler-technologies.com Internet: www.buehler-technologies.com...
  • Page 2 Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20 Internet: www.buehler-technologies.com E-Mail: analyse@buehler-technologies.com Read this instruction carefully prior to installation and/or use. Pay at- tention particularly to all advises and safety instructions to prevent in- juries.

  • Page 3: Table Of Contents

    Series RC 1.x Contents Introduction .............................................  3 Intended use .........................................  3 Overview .......................................... 3 Scope of delivery ........................................ 3 Ordering Instructions...................................... 4 Safety instructions ......................................... 6 Important advice ......................................... 6 General Hazard Warnings .................................... 7 Transport and storage ........................................ 8 4 Installation and connection ...................................... 9 Installation site requirements.................................. 9 Installation .......................................... 9 4.2.1...
  • Page 4 Series RC 1.x Performance curves ...................................... 38 Flow diagrams ........................................ 39 9.4.1 Diagram typical installation ................................ 39 9.4.2 Cooler flow diagrams .................................. 40 Heat exchanger .........................................  40 9.5.1 Heat exchanger description................................ 40 9.5.2 Heat exchanger overview ................................ 41 Dimensions (mm)...................................... 43 10 Attached Documents........................................ 46 Bühler Technologies GmbH BE450028 ◦...

  • Page 5: Introduction

    Series RC 1.x 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. Sample gas coolers with the option for high-purity oxygen (suffix -O2) are optimised especially for use with increased oxygen concentrations with regard to the parts in contact with the medium.

  • Page 6: Ordering Instructions

    Series RC 1.x 1.4 Ordering Instructions RC 1.1 The item number is a code for the configuration of your unit. Please use the following model code: 4596 2 1 1 0 X X X X X 0 X X X 0 0 0 0 0 Product Characteristics Voltage 115 V, 60 Hz 230 V, 50/60 Hz...
  • Page 7 Series RC 1.x RC 1.1 with -H2/-O2 heat exchanger The item number is a code for the configuration of your unit. Please use the following model code: 4596 2 1 1 0 X X X X 0 0 0 X 0 0 0 0 0 X Product Characteristics Supply voltage 115 V, 60 Hz...

  • Page 8: Safety Instructions

    Series RC 1.x 2 Safety instructions 2.1 Important advice Operation of the device is only permitted 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, –...

  • Page 9: General Hazard Warnings

    Series RC 1.x 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.

  • Page 10: Transport And Storage

    Series RC 1.x 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).

  • Page 11: Installation And Connection

    Series RC 1.x 4 Installation and connection 4.1 Installation site requirements The unit is intended for wall-mounted or table-top 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.

  • Page 12: Connecting The Moisture Detector (Option)

    Series RC 1.x 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. 4.2.4 Peristaltic pump connector (optional) Coolers ordered with built-in peristaltic pumps already have these installed and wired.

  • Page 13: Adapter Plate Connection

    Series RC 1.x 4.2.7 Adapter plate connection The adapter plate is intended to easily replace the cooler with an existing bore pattern of the predecessor EGK 1/2. It is first inser- ted from behind with the threaded bolts through the bores of the RC 1.x and locked in place with the included nuts. The cooler with adapter plate can then be fastened to the existing bore pattern.

  • Page 14: Signal Outputs

    Series RC 1.x Plug numbering Electric supply S1 Analogue output S3 Alarm contact S2 1 - N/C 2 - N/C 3 - GND 4 - 4-20 mA out 5 - shield Digital output S4 1 - not used 2 - RS485 A 3 - GND/Common 4 - RS485 B 5 - Shielding...

  • Page 15: Operation And Control

    Series RC 1.x Description of signal outputs Function/contact type Description Regard- internal changeover con- the following device statuses Contact between 3 and 2 closed (alarm) ing S2) tact: max. 250 VAC/ can be indicated via two – No mains voltage and/or actual temperature outside 150 VDC, 2 A, 50 VA switching outputs: the alarm thresholds...

  • Page 16: Use Of Menu Functions

    Series RC 1.x The status output can e.g. be used to control the sample gas pump to allow for the gas flow to only be switched on once the per- missible cooling range has been reached or shut off the pump in the event of a moisture detector alarm. The separated condensate can be drained via connected peristaltic pumps or add-on automatic condensate drains.

  • Page 17: Menu Navigation Overview

    Series RC 1.x 5.2.2 Menu navigation overview When pressing the OK button in normal mode, the display will show the prompt code if the menu is locked. Use the ▲ and ▼ buttons to enter the correct code and press OK. If an incorrect code or no code is entered, the menu will not be unlocked and you will not be able to access all menu items.
  • Page 18 Series RC 1.x Display Main menu Submenu 1 Submenu 2 Parameter tEmP 5 °C Display RC 1 Temperature Input Temperature CH1 Device designation Target temp. Cooling block 3 . . . 20 °C Settings menu A hi 3 °C oper Input Display Hour meter...

  • Page 19: Description Of Menu Functions

    Series RC 1.x 5.3 Description of menu functions 5.3.1 Display Menu Block temperature display Display → Depending on the device state, the temperature will be displayed as a constant, flashing, or alternat- ing with a status message. Operating hours /runtime display Display →...

  • Page 20: Submenu 1

    Series RC 1.x Heat exchanger material selection Display → h. c hn Heat exchanger material selection Parameter range: (Steel), (Glass), (PVDF) Factory setting: (cooler without heat exchanger), or respective material per configuration Exit main menu Display → Selecting this will return you to display mode. 5.3.3 Submenu 1 Target temperature Display →...

  • Page 21: Submenu 1 (Global Settings)

    Series RC 1.x 5.3.4 Submenu 1 (global settings) Temperature unit Display → → unit Used to select the temperature display unit. Parameter range: °C, °F Factory setting: °C Analog output Display → → This submenu is used to specify the settings for analog output 1, see chapter Submenu 2 (Analog Output 1) [>...
  • Page 22 Series RC 1.x Moisture detector: error cleared automatically after cable break Display → → bLtc (bLtc = broken wire latch). The setting applies to all connected moisture detectors. Determines whether the cable break alarm must be reset manually or will automatically clear on valid measuring signal.
  • Page 23 Series RC 1.x Modbus RTU parity The default parity is even/odd, options are odd parity, no parity. The number of stop bits is automatically set based on the re- spective setting. No parity uses two stop bits, otherwise it is one. The properties of the digital interface are not affected when re- setting the device to its factory settings! This menu item is only available on devices with "Digital output Modbus RTU"...
  • Page 24 Series RC 1.x Exit submenu 1 Display → Submenu → Selecting this will return you to the main menu. 5.3.4.1 Submenu 2 (Analog Output 1) The analog output will display the actual cooler temperature. The menu items for the analog output are no available on devices with "Digital output Modbus RTU"...

  • Page 25: Set Favourite Menu

    Series RC 1.x 5.3.5 Set favourite menu Use the F or Func (function) key to set a favourite menu to later open it with just the push of a button. – Open the menu you wish to set as the favourite. This menu can also be a lockable menu. –...

  • Page 26: Modbus Register

    5.7 Modbus Register Description Address Access Data Default Selection Resolution Unit type Block temperature measurement 2000 Float °C Block temperature status 2002 Uint32 Bit 0 := Error Bit 1..15 := Reserved Bit 16:= Sensor not calibrated Bit 17:= Initialization/measurement invalid Bit 18 := Stabilisation phase Bit 19:= Load limit reached Bit 20:= Measurement outside target range...
  • Page 27 Description Address Access Data Default Selection Resolution Unit type Modbus Parity selection 3, 16 9010 Uint16 0 := None 1 := Odd 2 := Even Modbus Device address selection 3, 16 9011 Uint16 Lock menu 3, 16 9012 Uint16 9999 TEST 9990 Uint32...
  • Page 28 Description Address Access Data Default Selection Resolution Unit type Condition code register 4 10004 Uint16 Error register 1 10005 Uint16 Bit 0 := Display communication error Bit 1 := Controller communication error Bit 2 := Bit 3 := Controller configuration error Bit 4 := EEPROM regulator error Bit 5 := Bit 6 :=...
  • Page 29 Description Address Access Data Default Selection Resolution Unit type Utilisation controller 1 10017 Unit16 Device run time 10100 Float 6 min Restart/ 11000 Unit16 0x00 86 := Restart device reset device 17:= Factory reset Reset moisture detector 1 11002 Uint16 0xAA Reset moisture detector 2 11003...

  • Page 30: Service

    Series RC 1.x 6 Service The base version of the cooler requires no special maintenance. However, it may have different options depending on the cooler model. In this case the following routine maintenance is re- quired: – Option peristaltic pump: Checking hoses (see chapter Replacing the hoses of the peristaltic pump (option)) –...

  • Page 31: Service And Repair

    Series RC 1.x 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 For more information on your custom maintenance and startup services, please visit: https://www.buehler-technologies.com/ service...

  • Page 32: Error Messages In The Display

    Series RC 1.x 7.1.1 Error Messages in the Display If an error occurs, the display will read "Err". Press the " " button to show the error number(s). Error messages will appear until the unit has been restarted or the error is cleared using the "Func" button. It can only be cleared if the cause for the error has been corrected.

  • Page 33: Safety Instructions

    Series RC 1.x 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. For sample gas coolers with stainless steel heat exchangers for O applications (suffix -O2), there are special requirements for avoiding contamination when carrying out maintenance and repair work:...

  • Page 34: Cleaning And Removal Of The Heat Exchanger

    Series RC 1.x 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 whether using a filter will prevent this in future. For applications with high-purity acid or hydrogen, we recommend cleaning in accordance with current application-specific standards or using an original replacement heat exchanger.

  • Page 35: Drying Of The Moisture Detector (Option)

    Series RC 1.x 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. –...

  • Page 36: Spare Parts And Accessories

    Series RC 1.x 7.8.1 Spare Parts and Accessories Item no. Description 41020050 Filter element F2-L; unit 2 count (for type RC 1.1) 41030050 Filter element F2; unit 5 count (for type RC 1.2+) 4410001 Automatic condensate drain 11 LD V 38 4410004 Automatic condensate drain AK 20, PVDF 4410005...

  • Page 37: Disposal

    Series RC 1.x 8 Disposal The refrigerant circuit of the cooler contains R134a refrigerant. The heat exchanger is charged with glycol-based coolant. The applicable national laws must be observed when disposing of the products. Disposal must not result in a danger to health and environment.

  • Page 38: Appendices

    Series RC 1.x 9 Appendices 9.1 Gas Cooler Technical Data RC 1.1 (with -H2/-O2 heat exchanger) Gas cooler technical data Ready for operation after max. 15 minutes Rated cooling capacity (at 25 °C) 360 kJ/h ambient temperature 5 °C to 50 °C Gas outlet dew point preset: 5 °C adjustable:...

  • Page 39: Technical Data - Options

    Series RC 1.x 9.2 Technical Data - Options Technical Data Peristaltic Pumps CPsingle / CPdouble Ambient temperature 0 °C to 60 °C Flow rate 0.3 L/h (50 Hz) / 0.36 L/h (60 Hz) with standard hose Vacuum inlet max. 0.8 bar Pressure inlet max.

  • Page 40: Performance Curves

    Series RC 1.x 9.3 Performance curves RC 1.1 Ambient temperature (°C) Note: The limit curves for the heat exchangers exchanger apply to a dew point of 65 °C. RC 1.1 with -H2/-O2 heat exchanger Ambient temperature (°C) TS, DTS Note: The limit curves for the heat exchangers exchanger apply to a dew point of 65 °C. Bühler Technologies GmbH BE450028 ◦...

  • Page 41: Flow Diagrams

    Series RC 1.x RC 1.2+ Ambient temperature (°C) 2xSTG-2 ( : 70°C) 2xSTG-2 ( : 55°C) 2xSTV-2 ( : 70°C) 2xSTV-2 ( : 55°C) Note: The limit curves of the heat exchangers apply to different dew points ( ), see legend. 9.4 Flow diagrams 9.4.1 Diagram typical installation Sample gas/calibrating gas...

  • Page 42: Cooler Flow Diagrams

    Series RC 1.x 9.4.2 Cooler flow diagrams RC 1.1 1 gas path: 1 Cooler 2 Moisture detector (option) 3 Filter (optional) 4 Condensate pump (optional) RC 1.2+ 1 in-line gas path: 1 Cooler 2 Moisture detector (option) 3 Filter (optional) 4 Condensate pump (optional) 9.5 Heat exchanger 9.5.1 Heat exchanger description RC 1.1...

  • Page 43: Heat Exchanger Overview

    Series RC 1.x 9.5.2 Heat exchanger overview RC 1.1 Heat exchanger DTS (DTS-6 2) 3) TS-I TV-I DTS-I (DTS-6-I DTV-I Materials in contact with media Stainless steel Glass PVDF Stainless steel Glass PVDF PTFE PTFE Flow rate v 530 L/h 280 L/h 155 L/h 2 x 250 L/h 2 x 140 L/h...
  • Page 44 Series RC 1.x RC 1.2+ Heat exchanger 2x STG-2 2x STV-2 Materials in contact with media Glass PVDF PTFE Flow rate v 320 L/h 300 L/h Inlet dew point τ 70 °C 70 °C e,max Gas inlet temperature ϑ 140 °C 140 °C G,max Gas pressure p...

  • Page 45: Dimensions (Mm)

    Series RC 1.x 9.6 Dimensions (mm) RC 1.1 102.75 Filter Filter (optional) (optional) Ø7x10 94.5 S1 = Electric supply S2 = Alarm contact S3/S4 S1 S2 S3/S4 = Analog/digital output (optional) BE450028 ◦ 03/2024 Bühler Technologies GmbH...
  • Page 46 Series RC 1.x RC 1.1 with -H2/-O2 heat exchanger Ø7x10 94,5 S1 = Electric supply S3/S4 S2 = Alarm contact S1 S2 S3 = Analog/digital output (optional) 44 Bühler Technologies GmbH BE450028 ◦ 03/2024...
  • Page 47 Series RC 1.x RC 1.2+ 79.5 Filter (optional) approx. 88 Ø7x10 S1 = Electric supply S3/S4 S2 = Alarm contact S1 S2 S3/S4 = Analog/digital output (optional) BE450028 ◦ 03/2024 Bühler Technologies GmbH...

  • Page 48: Attached Documents

    Series RC 1.x 10 Attached Documents – Declaration of Conformity KX450017 – O declaration (heat exchanger) – RMA – Decontamination Statement 46 Bühler Technologies GmbH BE450028 ◦ 03/2024...
  • Page 51 Heat exchanger optimized for use with high-purity oxygen Gas Analysis Applications with oxygen: Free from particles, oil and grease For use with high-purity oxygen, the product requires special cleaning to ensure that it is free from oil and grease, as oxygen is a strong oxidising agent. Under unfavourable conditions, oxy- gen can cause spontaneous combustion of organic substances such as particles, oils and fats, and generally promotes the combustion of substances.
  • Page 52 RMA-Formular und Erklärung über Dekontaminierung RMA-Form and explanation for decontamination RMA-Nr./ RMA-No. Die RMA-Nr. bekommen Sie von Ihrem Ansprechpartner im Vertrieb oder Service. Bei Rücksendung eines Altgeräts zur Entsorgung tragen Sie bitte in das Feld der RMA-Nr. "WEEE" ein./ You may obtain the RMA number from your sales or ser- vice representative.
  • Page 53 Dekontaminierungserklärung DE000011 Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen 12/2022 Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20 E-Mail: service@buehler-technologies.com Internet: www.buehler-technologies.com...

This manual is also suitable for:

Rc 1.2+Rc 1.1

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