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Bühler technologies RC 1.2 Rack Series Assembly, Installation And Operation Instructions

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Gas Analysis
Sample gas cooler
Series RC 1.2 Rack
Installation and Operation Instructions
Original instructions
BE450040
Bühler Technologies GmbH, Harkortstr. 29, 40880 Ratingen
07/2025
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 1.2 Rack Installation and Operation Instructions Original instructions BE450040 Bühler Technologies GmbH, Harkortstr. 29, 40880 Ratingen 07/2025 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: Document Information

    Bühler Technologies GmbH, Harkortstr. 29, 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 1.2 Rack Contents Introduction .............................................  3 Intended use .........................................  3 Overview .......................................... 3 Scope of delivery ........................................ 3 Ordering instructions...................................... 4 1.4.1 Gas cooler with one or two heat exchangers .......................... 4 1.4.2 Gas cooler with two heat exchangers in series ...........................  5 Safety instructions ......................................... 6 Important advice ......................................... 6 General Hazard Warnings ....................................
  • Page 4 Series RC 1.2 Rack 7.1.11 Calibration of the moisture detector (option) ........................... 36 Troubleshooting ........................................  37 7.2.1 Error Messages in the Display ................................ 38 Spare parts .......................................... 39 7.3.1 Spare parts and accessories ................................ 39 8 Disposal ............................................ 40 9 Appendices .............................................  41 Gas Cooler Technical Data .................................... 41 Technical Data - Options .................................... 43 Performance curves ......................................

  • Page 5: Introduction

    Series RC 1.2 Rack 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.

  • Page 6: Ordering Instructions

    Series RC 1.2 Rack 1.4 Ordering instructions 1.4.1 Gas cooler with one or two heat exchangers The item number is a code for the configuration of your unit. Please use the following model code: 4596 3 X 2 0 X X X X X 0 X X X 0 0 0 0 0 Product characteristic Housing type 19”...

  • Page 7: Gas Cooler With Two Heat Exchangers In Series

    Series RC 1.2 Rack 1.4.2 Gas cooler with two heat exchangers in series The item number is a code for the configuration of your unit. Please use the following model code: 4596 3 X 2 0 X 1 X X X 0 X X X 0 0 0 0 0 Product characteristic Housing type 19”...

  • Page 8: Safety Instructions

    Series RC 1.2 Rack 2 Safety instructions 2.1 Important advice The device may only be operated if: – the product is used under the conditions described in the operating and installation manual, in accordance with the type la- bel, and for the intended applications; Any unauthorised modifications to the device will void the warranty provided by Bühler Technologies GmbH, –...

  • Page 9: General Hazard Warnings

    Series RC 1.2 Rack 2.2 General Hazard Warnings The device may only be installed by qualified specialist personnel who are familiar with the safety requirements and associated risks. Qualified personnel within the meaning of this operating manual are electrically skilled persons who are familiar with installa- tion, assembly, commissioning, repair, and operation as well as the associated hazards.
  • Page 10 Series RC 1.2 Rack 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.

  • Page 11: Transport And Storage

    Series RC 1.2 Rack 3 Transport and storage The products should only be transported in their original packaging or a suitable replacement. Sample gas coolers with flammable refrigerant are marked on their original packaging and must be stored and transported in accordance with national regulations.

  • Page 12: Installation And Connection

    Series RC 1.2 Rack 4 Installation and connection 4.1 Installation site requirements The device is intended for indoor use, either in a 19" rack-mount enclosure or for wall mounting. The maximum installation alti- tude is suitable for elevations up to 2000 m. Wall mounting: The device must be fixed at the designated mounting points.

  • Page 13: Peristaltic Pump Connector (Optional)

    Series RC 1.2 Rack 4.2.4 Peristaltic pump connector (optional) Coolers ordered with attached peristaltic pump already have it installed and wired. Heat exchangers ordered at the same time are already installed and connected to the peristaltic pump. The ø6 mm (0.24 inch) hose nipple for the pump’s condensate outlet must be carefully and properly connected with a suitable hose and hose clamp.

  • Page 14: Condensate Drain Connection

    Series RC 1.2 Rack Glass PTFE Pay attention to the appropriate spanner size when selecting fittings for stainless steel heat exchangers. PTS/PTS-I gas connections: SW 14 or 9/16” PTS/PTS-I condensate out connections: SW 22 4.2.6 Condensate drain connection Depending on the material, build a connecting line with fittings and tubing or hose between the heat exchanger and condens- ate drain.

  • Page 15: Insulation Test

    Series RC 1.2 Rack Insulation test The device is equipped with extensive EMC protection. If insulation tests are carried out the electronic filter devices will be dam- aged. All necessary tests have been carried out for all concerned groups of components at the factory (test voltage 1 kV or 1.5 kV respectively, depending on the device).

  • Page 16: Humidity Status Output (A)

    Series RC 1.2 Rack 4.4.2 Humidity status output (A) The maximum switching capacity of the status output is 30 V AC / 60 V DC, 1 A. The status output (S2, A) indicates when residual moisture is still present in the conditioned sample gas or if a cable break is de- tected at the humidity sensor.

  • Page 17: Operation And Control

    Series RC 1.2 Rack 5 Operation and control NOTICE The device must not be started or operated outside the specifications! Before commissioning, the device should be left to stand quietly and upright for at least 1 hour after transport, positioning, or installation.

  • Page 18: Use Of Menu Functions

    Series RC 1.2 Rack 5.2 Use of menu functions Brief description of the operating principle: The unit is operated using 5 keys. Their functions are: Button Section Functions Display – Switches from the measurement display to the main menu Menu –...

  • Page 19: Menu Navigation Overview

    Series RC 1.2 Rack 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 20 Series RC 1.2 Rack Display Main menu Submenu 1 Submenu 2 Parameter rc1. 2 tEmP 5 °C Display RC 1.2 Temperature Input Temperature CH1 Device designation Target temp. Cooling block 3 . . . 20 °C 3 °C oper Settings menu A hi Input Display...

  • Page 21: Description Of Menu Functions

    Series RC 1.2 Rack 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 22: Submenu 1

    Series RC 1.2 Rack 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 Setpoint temperature Display →...

  • Page 23: Submenu 1 (Global Settings)

    Series RC 1.2 Rack 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) Note: This menu will be hidden if the menu is locked.
  • Page 24 Series RC 1.2 Rack 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 25: Factory Settings

    Series RC 1.2 Rack 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 26: Exit Submenu

    Series RC 1.2 Rack Exit submenu 1 Display → Submenu → Selecting this will return you to the main menu. 5.3.4.1 Submenu 2 (Analog Output 1) The cooling block temperature of the cooler is output at the analogue output. For devices with the “Digital Output Modbus RTU” option, the menu items for the analogue output are not available.

  • Page 27: Set Favourite Menu

    Series RC 1.2 Rack 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 28: Modbus Register

    5.7 Modbus Register Description Address Access Data type Default Selection Resolution Unit Cooling block temperature measure- 2000 Float °C ment Cooling 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 29 Description Address Access Data type Default Selection Resolution Unit 4 := 38400 5 := 57600 6 := 115200 Modbus Parity selection 3, 16 9010 Uint16 0 := None 1 := Odd 2 := Even Modbus Device address selection 3, 16 9011 Uint16 Lock menu...
  • Page 30 Description Address Access Data type Default Selection Resolution Unit Bit 5 := Bit 6 := Gas pump controller deactivated Bit 7 := 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...
  • Page 31 Description Address Access Data type Default Selection Resolution Unit Error register 9 10013 Uint16 Error register 10 10014 Uint16 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...

  • Page 32: Service

    Series RC 1.2 Rack 6 Service For all work on the device, the general instructions in the chapter Safety instructions [> page 6] must be observed! DANGER Electrical voltage Electrocution hazard. a) Disconnect the device from power supply. b) Make sure that the equipment cannot be reconnected to mains unintentionally. c) The device must be opened by trained staff only.
  • Page 33 Series RC 1.2 Rack Depending on the ambient conditions and installation location, ensure that the air inlet and outlet are free from foreign ob- jects. A visual inspection is required at least every 6 months. However, depending on the cooler model, various options may be included. In this case the following routine maintenance is re- quired: –...

  • Page 34: Service And Repair

    Series RC 1.2 Rack 7 Service and repair If an error occurs during operation, you will find troubleshooting and corrective information in this chapter. Repairs to the equipment may only be performed by Bühler authorised personnel. If you have any questions, please contact our service department: Tel.: +49-(0)2102-498955 or your local representative.

  • Page 35: Opening The Housing

    Series RC 1.2 Rack CAUTION Hot surface Risk of burns The housing can be up to 60 °C during operation. Allow the unit to cool down before working on it. 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.

  • Page 36: Replacing The Controller Board

    Series RC 1.2 Rack 7.1.3 Replacing the controller board – Open the device as described in the chapter Opening the housing [> page 33]. – The controller board can be removed either directly or together with the drawer. To remove the drawer, loosen the side screw from the outside and the two nuts at the bottom (inside).

  • Page 37: Replacing The Mcp2 Microcontroller Board

    Series RC 1.2 Rack 7.1.4 Replacing the MCP2 microcontroller board – Open the device as described in the chapter Opening the housing [> page 33]. – Remove the MCP2 board from the control board. – Attach the new board. – Reassemble the device in the reverse order. 7.1.5 Replacing the MCD400 display module –...

  • Page 38: Replacing The Filter Element (Option)

    Series RC 1.2 Rack 7.1.9 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. – Twist off the swivel nut counter-clockwise and remove the filter cover. –...

  • Page 39: Troubleshooting

    Series RC 1.2 Rack 7.2 Troubleshooting Problem/malfunction Possible cause Action Condensate inside the gas – Condensate trap full – Empty condensate trap output – Valve inside the automatic condensate – Flush in both directions drain may be stuck – Cooler overload –...

  • Page 40: Error Messages In The Display

    Series RC 1.2 Rack 7.2.1 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 41: Spare Parts

    Series RC 1.2 Rack 7.3 Spare parts 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 9100100007 MCD400 display module 9100030265 Modbus RTU interface module 9144050079 Connecting cable controller board display module 9144051038...

  • Page 42: Disposal

    Series RC 1.2 Rack 8 Disposal CAUTION! The cooling circuit of the cooler is filled with refrigerant R600a. The heat exchanger contains a 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 43: Appendices

    Series RC 1.2 Rack 9 Appendices 9.1 Gas Cooler Technical Data RC 1.2 Rack Gas Cooler Technical Data Rated cooling capacity (at 25 °C): 320 kJ/h Ambient temperature: 5 °C to 50 °C Ready for operation: after max. 15 minutes Gas outlet dew point preset: 5 °C...
  • Page 44 Series RC 1.2 Rack RC 1.2+ Rack Gas Cooler Technical Data Rated cooling capacity (at 25 °C): 320 kJ/h Ambient temperature: 5 °C to 50 °C Ready for operation: after max. 15 minutes Gas outlet dew point preset: 5 °C adjustable: 3 °C to 20 °C Dew point fluctuations static:...

  • Page 45: Technical Data - Options

    Series RC 1.2 Rack 9.2 Technical Data - Options Analogue Output Technical Data Signal: 4-20 mA or 2-10 V corresponds to -20 °C to +60 °C cooling block temperature Connection: M12x1 connector, DIN EN 61076-2-101 Technical Data, digital output Signal: Modbus RTU (RS-485) Connection: M12x1 connector, DIN EN 61076-2-101 Technical Data Cpsingle Condensate Pumps Ambient temperature:...

  • Page 46: Performance Curves

    Series RC 1.2 Rack 9.3 Performance curves RC 1.2 Rack Ambient temperature (°C) RC 1.2 Rack Note: The limit curves for the heat exchangers exchanger apply to a dew point of 40 °C. RC 1.2+ Rack Ambient temperature (°C) EGK 2-19+ RC 1.2+ Rack 2 PTG-2/ PTV-2 in series (dew point = 70 °C) 2 PTG-2/ PTV-2 in series (dew point = 50 °C)

  • Page 47: Typical Installation Arrangement (1 Gas Path)

    Series RC 1.2 Rack 9.4 Typical installation arrangement (1 gas path) 1 Cooler/cooling nest 1 3 Filter (optional) 2 Moisture detector (optional) 4 Condensate Pump 9.5 Typical installation arrangement (2 gas paths) 1 Cooler/cooling nest 1 4 Filter (optional) 2 Cooler/cooling nest 2 5 Condensate Pump 3 Moisture detector (optional) 9.6 Heat exchanger...

  • Page 48: Heat Exchanger Overview

    Series RC 1.2 Rack 9.6.2 Heat exchanger overview RC 1.2 Rack Heat exchanger PTS-I PTV-I Materials in contact with media Stainless steel DURAN Glas PVDF PTFE Weight 0.5 kg 0.2 kg 0.125 kg Flow rate v 500 Nl/h 280 Nl/h 280 Nl/h Inlet dew point τ...

  • Page 49: Dimensions

    Series RC 1.2 Rack 9.7 Dimensions RC 1.2 Rack S1 = Electric supply S2 = Status output, Analogue/digital output (optional) BE450040 ◦ 07/2025 Bühler Technologies GmbH...
  • Page 50 Series RC 1.2 Rack RC 1.2+ Rack S1 = Electric supply S2 = Status output, Analogue/digital output (optional) 48 Bühler Technologies GmbH BE450040 ◦ 07/2025...

  • Page 51: Attached Documents

    Series RC 1.2 Rack 10 Attached documents – Declaration of Conformity KX450021 – RMA – Decontamination Declaration BE450040 ◦ 07/2025 Bühler Technologies GmbH...
  • Page 53 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 54 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...

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