Operating manual

Recirculating Coolers

FL20006

FLW20006

English

1.951.4837-V3 10/15

19514837-V3.doc

JULABO GmbH

77960 Seelbach / Germany

Tel. +49 (0) 7823 / 51-0

Fax +49 (0) 7823 / 24 91 [email protected]

www.julabo.com

Print date: 29.09.2015

Congratulations!

You have made an excellent choice.

JULABO thanks you for the trust you have placed in us.

This operating manual has been designed to help you gain an understanding of the operation and possible applications of our circulators. For optimal utilization of all functions, we recommend that you thoroughly study this manual prior to beginning operation.

The JULABO Quality Management System

Temperature control devices for research and industry are developed, produced, and distributed according to the requirements of ISO 9001 and

ISO 14001. Certificate Registration No. 01 100044846

Unpacking and inspecting

Unpack the recirculating cooler and accessories and check for damages incurred during transit. These should be reported to the responsible carrier, railway, or postal authority, and a request for a damage report should be made. These instructions must be followed fully for us to guarantee our full support of your claim for protecting against loss from concealed damage. The form required for filing such a claim will be provided by the carrier.

Printed in Germany Changes without prior notification reserved

Important: keep operating manual for future use

2

TABLE OF CONTENTS

1. Intended use ............................................................................................................................... 4

1.1. Description ...................................................................................................................... 4

2. Operator responsibility – Safety instructions ............................................................................... 4

2.1. Installation Log for FL20006 ............................................................................................ 6

2.2. Disposal .......................................................................................................................... 6

2.3. EC Conformity ................................................................................................................. 7

2.4. Technical specifications .................................................................................................. 8

2.5. Cooling water connection .............................................................................................. 10

3. Safety notes for the user ........................................................................................................... 11

3.1. Explanation of safety notes ........................................................................................... 11

3.2. Explanation of other notes ............................................................................................. 11

3.3. Safety instructions ......................................................................................................... 11

4. Installation ................................................................................................................................ 12

4.1. Tubing ........................................................................................................................... 14

5. Operating controls and functional elements .............................................................................. 15

6. Operating procedures ............................................................................................................... 17

6.1. Bath fluids ..................................................................................................................... 17

6.2. Power connection .......................................................................................................... 17

6.3. Filling ............................................................................................................................ 18

6.4. Switching on / Start - Stop ............................................................................................. 18

6.5. Setting the feed pressure .............................................................................................. 19

6.6. Setting the temperatures ............................................................................................... 19

6.7. AUTOSTART ON / OFF ................................................................................................ 20

6.8. Remote control: activate – deactivate ............................................................................ 20

7. Safety installations .................................................................................................................... 21

7.1. Excess temperature protection ...................................................................................... 21

7.2. Low level protection ...................................................................................................... 21

8. Troubleshooting guide / Error messages .................................................................................. 21

9. Electrical connections ............................................................................................................... 23

10. Remote control ................................................................................................................ 24

10.1. Setup for remote control ................................................................................................ 24

10.2. Communication with a PC or a superordinated data system.......................................... 24

10.3. List of commands .......................................................................................................... 25

10.4. Status messages ........................................................................................................... 25

11.

10.5. Error messages ............................................................................................................. 26

Cleaning / repairing the unit ............................................................................................. 27

11.1. JULABO Service – Online remote diagnosis ................................................................. 29

11.2. Draining ........................................................................................................................ 30

12.

13.

Warranty conditions ......................................................................................................... 31

Example Installation Log ................................................................................................. 32

3

1. Intended use

JULABO recirculating coolers have been designed for temperature application to specific fluids. The pump connections can be used for cooling applications in an external circuit at a constant temperature.

JULABO water baths are not suitable for direct temperature control of foods, semiluxury foods and tobacco, or pharmaceutical and medical products. Direct temperature control means unprotected contact of the object with the bath medium (bath fluid).

1.1. Description

 The recirculating coolers are operated via the splash-proof keypad. The implemented microprocessor technology allows to set and to store the setpoint that can be indicated on the LED temperature display.

 The PID temperature regulation is used to withdraw heat from the bath fluid by means of the cooling machine and to automatically regulate the required need.

PID1

 Electrical connections:

1. The serial interface RS232 allows modern process technology without

additional interface.

2. Alarm output for external alarm message.

RS232

 Manually adjustable by-pass (handwheel) to reduce the pump capacity

(e. g. for glass equipment).

2. Operator responsibility – Safety instructions

The products of JULABO ensure safe operation when installed, operated, and maintained according to common safety regulations. This section explains the potential dangers that may arise when operating the circulator and also specifies the most important safety precautions to preclude these dangers as far as possible.

The operator is responsible for the qualification of the personnel operating the units.

 The personnel operating the units should be regularly instructed about the dangers involved with their job activities as well as measures to avert these dangers.

 Make sure all persons tasked with operating, installing, and maintaining the unit have read and understand the safety information and operating instructions.

 When using hazardous materials or materials that could become hazardous, the unit may be operated only by persons who are absolutely familiar with these materials and the unit. These persons must be fully aware of possible risks.

If you have any questions concerning the operation of your unit or the information in this manual, please contact us!

Contact JULABO GmbH

Eisenbahnstraße 45

77960 Seelbach / Germany

Tel. +49 7823 51-0

Fax +49 7823 2491 [email protected]

www.julabo.com

4

2 or

2

Safety recommendations for the operator

 You received a product developed for industrial use. Nevertheless, avoid strikes to the housing, vibrations, damages to the keypad foil (keys, display) or contamination.

 Make sure the product is regularly checked for proper condition. Regularly check (at least every

2 years) the proper condition of the mandatory, warning, prohibition and safety labels.

 Take care that the mains supply features a low impedance to avoid any negative affects on the instrument being operated in the same mains.

 This unit is designed for operation in a controlled electromagnetic environment. This means that transmitting devices (e.g. cellular phones) should not be used in the immediate vicinity. Magnetic radiation may influence other units with components susceptible to magnetic fields (e.g. a monitor). We recommend to keep a minimum distance of 1 m.

 Permissible ambient temperature: max. 40 °C, min. 5 °C.

 Permissible relative air humidity: 50 % (40 °C).

 Do not store in an aggressive atmosphere. Protect from contaminations.

 Do not expose to sunlight.

Appropriate Operation

Only qualified personnel is authorized to perform configuration, installation, maintenance and repairs of the water bath.

Routine operation can also be carried out by untrained personnel who should however be instructed by trained personnel.

Use

For the use according to the intended purpose, special material requirements have to be respected

(bath fluids). Only use non-acid and non corroding materials.

Observe all warnings for the used materials (bath fluids) and the respective instructions (safety data sheets).

Only use the unit in well ventilated areas. (see page 12).

The recirculating coolers are not for use in explosive atmosphere

When using hazardous materials or materials that could become hazardous, the operator must affix the enclosed safety labels (1 + 2) to the front of the unit so they are highly visible:

1 Danger area. Attention! Observe instructions.

(operating manual, safety data sheet)

Carefully read the user information prior to beginning operation.

Scope: EU

Carefully read the user information prior to beginning operation.

Scope: USA, NAFTA

Observe the instructions in the manuals for instruments of a different make that you connect to the circulator, particularly the corresponding safety instructions. Also observe the pin assignment of plugs and technical specifications of the products.

5

2.1. Installation Log for FL20006

EN 378-4:2008-06

Documentation

2.2. Disposal

The operator is obliged to keep an installation log for the refrigeration unit if the filling volume of the refrigerant exceeds 3 kg!

The installation log must be kept with the unit.

If the information and data is recorded on a computer, the current status must be printed out (hard copy) and kept with the unit.

It must be assured that the log is available to an expert in case of repairs and repeated inspections.

The installation log must include the following information:

See example on page 32

This unit contains the refrigerant R404A, which at this time is not considered harmful to the ozone layer. However, over the long operating period of the unit, disposal rules may change. Therefore, only qualified personnel should handle the disposal.

Valid in EU countries

See the current official journal of the European Union – WEEE directive.

Directive of the European Parliament and of the Council on waste electrical and electronic equipment (WEEE).

This directive requires electrical and electronic equipment marked with a crossedout trash can to be disposed of separately in an environmentally friendly manner.

Contact an authorized waste management company in your country.

Disposal with household waste (unsorted waste) or similar collections of municipal waste is not permitted!

6

2.3. EC Conformity

7

2.4. Technical specifications

Recirculating Cooler

Cooling

Working temperature range

Temperature stability

Temperature selection: via key pad remote control via personal computer

Temperature indication:

Resolution

Temperature control

Temperature sensor

Excess temperature protection

Low liquid level protection

Cooling capacity

Medium: Mixture water-glycol

Cooling compressor

°C

°C

°C

°C kW

FL20006 air cooled

-25 ... +40

±0.5

FLW20006 water coolrd

-25 … +40 digital indication on LED-DISPLAY indication on monitor

LED-DISPLAY

0.1

PID 1

Pt 100

85 °C - fixed value float switch

+20 0 -10 -20 +20 0 -10 -20

20.0 10.0 6.0 2.5

1--stage

20.0 12.0 7.0 3.0

Refrigerant

Electrical connections:

Computer interface

Alarm output

Circulating pump: discharge, max.

R404A

RS232 at 0 bar l/min 80 at 0 Liter bar bar for external alarm signal

0.8 ... 6.0

Manometer

80

0.8 ... 6.0 pressure, adjustable

Feed pressure indication

Filling level indicator

Filling volume

Dimensions (WxLxH)

Weight

Ambient temperature range

Return flow temperature

Cooling water

Flow rate at 15 °C inlet temperature

Noise level, 1 m distance

IP class according to IEC 60 529 sight glass

from ... to liters 15 ... 37 cm kg

95x115x161

360

°C

°C

5 ... 40

80 max. l/min ----- dBA 73

IP 21

330

24

Mains power connection 400 V/3PNPE/50 Hz V/ Hz 360-440/3PNPE /50

Current input at 400 V A 18

Mains power connection 230 V/3PNPE/60 Hz V/ Hz 207-253/3PPE /60

Current input at 230 V A 36

All measurements have been carried out at: rated voltage and frequency, ambient temperature: 20 °C

360-440/3PNPE /50

18

207-253/3PPE /60

36

8

Warning functions and safety installations

Excess temperature protection

Low liquid level protection

Alarm message

Excess temperature - Warning function

Overload protection

85 °C - fixed value float switch optical + audible (permanent)

75 °C for compressor and pump motor

Classification according to DIN 12876-1 class I

Environmental conditions according to IEC 61 010-1:

Use only indoor.

Altitude up to 2000 m - normal zero.

Ambient temperature: +5 ... +40 °C

Air humidity:

Max. rel. humidity 80 % for temperatures up to +31 °C, linear decrease down to 50 % relative humidity at a temperature of +40 °C

Max. mains fluctuations of ±10 % are permissible.

The unit corresponds to Class I

Overvoltage category II

Pollution degree 2

Caution:

The unit is not for use in explosive environment.

Standards for interference resistance according to EN 61326-1

This unit is an ISM device classified in Group 1 (using high frequency for internal purposes) Class A

(industrial and commercial range).

9

2.5. Cooling water connection

Only for water cooled models - FLW:

Cooling water pressure (IN / OUT )

Difference pressure (IN - OUT )

Flow rate on FLW 20006 max. 6 bar

2 bar to 6 bar typical 24.0 l/min

Cooling water temperature 15 °C

Notice: Cooling water circuit

Risk of oil leaking from the refrigeration system (compressor) of the recirculating cooler into the cooling water in case of a fault in the cooling water circuit!

Observe the laws and regulations of the water distribution company valid in the location where the unit is operated.

Recommended quality of cooling water:

pH – value

Sulfate [SO4 2- ]

Hydrocarbonate [HCO3- ] / Sulphate [SO4 2-]

Hardness [Ca2+, Mg2+] / [HCO3-]

Alkalinity

Conductivity

Chloride (CL-)

Phosphate (PO43-)

Ammonia (NH3)

Free Chlorine

Ferri Ions (Fe3+ )

Mangano Ions (Mn2+)

Carbon dioxide (CO2)

Hydrosulfide (H2S)

Content of oxygen

Algae growth

Suspended solids

7,5 to 9,0

< 100 ppm

> 1 ppm

> 0,5 dH

60 ppm < [HCO3-] < 300 ppm

< 500 μs / cm

< 50 ppm

< 2 ppm

< 0,5 ppm

< 0,5 ppm

< 0,5 ppm

< 0,05 ppm

< 10 ppm

< 50 ppm

< 0,1 ppm impermissible impermissible

Notice:

Danger of corrosion of heat exchanger due to unsuitable quality of cooling water.

• Due to its high content of lime hart water is not suitable for cooling and causes calcination of the heat exchanger.

• Ferrous water or water containing ferrous particles will cause formation of rust even in heat exchangers made of stainless steel.

• Chlorous water will cause pitting corrosion in heat exchangers made of stainless steel.

• Due to its corrosive characteristics distilled and deionized water is unsuitable and will cause corrosion of the bath. .

• Due to its corrosive characteristics sea water is not suitable.

• Due to its microbiological (bacteria) components which settle in the heat exchanger untreated and unpurified river water and water from cooling towers is unsuitable.

• Avoid particulate matter in cooling water.

• Avoid putrid water.

10

3. Safety notes for the user

3.1. Explanation of safety notes

In addition to the safety warnings listed above, warnings are posted throughout the manual. These warnings are designated by an exclamation mark inside an equilateral triangle. “Warning of a dangerous situation (Attention! Please follow the documentation).”

The danger is classified using a signal word.

Read and follow these important instructions.

Warning:

Describes a possibly highly dangerous situation. If these instructions are not followed, serious injury and danger to life could result.

Caution:

Describes a possibly dangerous situation. If this is not avoided, slight or minor injuries could result. A warning of possible property damage may also be contained in the text.

Notice:

Describes a possibly harmful situation. If this is not avoided, the product or anything in its surroundings can be damaged.

3.2. Explanation of other notes

Note!

Draws attention to something special.

Important!

Indicates usage tips and other useful information.

3.3. Safety instructions

Follow the safety recommendations to prevent damage to persons or property. Further, the valid safety instructions for working places must be followed.

• Only connect the unit to a power socket with earthing contact (PE – protective earth)!

• The power supply plug serves as a safe disconnecting device from the line and must always be easily accessible.

• Place the instrument on an even surface on a pad made of non-inflammable material.

• Do not stay in the area below the unit.

• Make sure you read and understand all instructions and safety precautions listed in this manual before installing or operating your unit.

• Never operate the unit without bath fluid in the bath.

• Do not drain the bath fluid while it is hot or cold!

Check the temperature of the bath fluid prior to draining (by switching the unit on for a short moment for example).

• Use suitable connecting tubing.

• Avoid sharp bends in the tubing, and maintain a sufficient distance from surrounding walls.

11

4. Installation

• Make sure that the tubing is securely attached.

• Regularly check the tubing for material defects (e.g., for cracks).

• Never operate damaged or leaking equipment.

• Always turn off the unit and disconnect the mains cable from the power source before performing any service or maintenance procedures, or before moving the unit.

• Always turn off the unit and disconnect the mains cable from the power source before cleaning the unit.

• Always empty the bath before moving the unit.

• Transport the unit with care.

• Sudden jolts or drops may cause damage in the interior of the unit.

• Observe all warning labels.

• Never remove warning labels.

• Never operate equipment with damaged mains power cables.

• Repairs are to be carried out only by qualified service personnel.

• Some parts of the bath tank and the pump connections may become extremely hot during continuous operation. Therefore, exercise particular caution when touching these parts.

• Some parts of the bath tank and the pump connections may become extremely cold during continuous operation. Therefore, exercise particular caution when touching these parts.

• Place the unit on an even surface on a base made of nonflammable material. Using the castors (10a, 10b) move the unit to the intended location.

For better stability, apply the holding breaks on the front casters

(10a).

• Cooling machine, pump motor and electronics produce intrinsic heat that is dissipated via the venting openings! Never cover these openings!

• Do not set up the unit in the immediate vicinity of heat sources and do not expose to sun light.

• Keep at least 20 cm of open space on the front and rear venting grid.

• The place of installation should be large enough and provide sufficient air ventilation to ensure the room does not warm up excessively because of the heat the instrument rejects to the environment.

For a fault (leakage) in the refrigeration system, the standard EN

378 prescribes a certain room space to be available for each kg of refrigerant.

> For 0.52 kg of refrigerant R-404A, 1 m3 of space is required.

12

Caution: Pump pressure

• Determine and check the max. admissible pressure for the external circuit before putting the unit into operation. The max. pressure is determined by the weakest element in the circuit (e. g. glass equipment).

• Securely attach all tubing to prevent slipping.

• Do not seal the overflow!

• Connect the tubings for cooling the external system to the pump connectors for feed and return (14) on the rear of the recirculating cooler.

– Return - Feed

• Connect a piece of tubing to the overflow connector

(15) and drain into a suitable vessel, which always has to be placed lower thant the exit „Overflow“.

Do not seal the overflow connector!

• Turn the adjusting valve (13) counter-clockwise to set the lowest manometric pressure.

• Before operating the unit after transport, wait about

one hour after setting it up. This will allow any oil that has accumulated laterally during transport to flow back down thus ensuring maximum cooling performance of the compressor.

¾”

• Only water cooled models - FLW:

Ensure circulation of cooling water by connecting the tubing to cooling water inlet (IN)and outlet (OUT) on the rear (18) of the recirculating cooler.

Cooling water see page 9.

Cooling water connectors G3/4" external thread

Tubing

IN

3/4" inner dia. Tubing, compression-proof

Cooling water inlet

OUT Cooling water outlet

Even high quality heat exchangers as they are installed in our equipment can be damaged by unsuitable cooling water.

The quality of the cooling water depends on the local conditions.

The heat exchanger may become leaky due to corrosion or it may become clogged due to particulate matter

Notice: Flood hazard!

In case the system to be cooled is located at a higher level than the recirculating cooler, avoid possible flowback of bath liquid back when the unit is switched off.

13

Return flow safety device

If the filling volume of the bath tank is not sufficient, prevent the liquid from flowing back by using shut-off valves..

Order No. Description

8 970 458 Shut-off valve G 1¼“

Suitable for

FL(W) 7006/11006/20006

The following questions shall help to recognize possible dangers and to reduce the risks to a minimum.

• Are all tubes and electrical cables connected and installed?

Note: sharp edges, hot surfaces in operation, moving machine parts, etc.

What to do when a dangerous substance was spilled on or in the unit?

Before starting to work, obtain information concerning the substance and determine the method of decontamination.

4.1. Tubing

Caution:

• Employ suitable connecting tubing.

• Make sure that the tubing is securely attached.

• Avoid sharp bends in the tubing, and maintain a sufficient distance from surrounding walls.

• Regularly check the tubing for material defects (e.g. for cracks).

• Preventive maintenance: Replace the tubing from time to time.

Recommended tubing:

Order No. Description

8930325 1 m Reinforced tubing 1“ inner dia. (-40 ... +120°C)

Suitable for

FL(W) 7006/11006/20006

Tubing insulation

8930425 1 m Insulation, 35 mm inner dia.

Tube clamps

8970484 2 Tube clamps, size 5

Reinforced tubing 1“ inner dia.

Reinforced tubing 1“ inner dia.

14

5. Operating controls and functional elements

Front view Rear view

Top view

15

1

2.0

2.1

2.2

3.0

3.1

4

5

3.2

3.3

6

7

13

14

8

9

10a

10b

11

15

16

17

18

19

ON

RS232

Mains power switch

°C

Keypad, spash-water protected

Edit keys (set point increase or decrease)

Enter key Store set point value / parameter

Indication

LED temperature display

Control indicator – Cooling

Control indicator – Alarm

Fill in opening, screwed plug

Feed pressure indication: Manometer

Interface RS232: remote control via personal computer

Alarm output (for external alarm signal)

Filling level indication

Drain tap with drain port

Castor with brake (at the front)

Castor without brake (at the back)

Venting grid, removable

Feed pressure adjusting valve

Pump connector OUT – pressure pump

Pump connector IN– Return

FL/FLW20006 G 1¼“

Overflow connector

1 Motor protection switch for compressor motor

2 + 3 Mains circuit breakers (resettable) F1, F2 - 4 A (for Electronics)

4 + 5 Mains circuit breakers (resettable) F3, F4 - 10 A (for Pump motor)

Mains power cable with plug

Only water cooled models

IN Cooling water inlet

OUT Cooling water outlet

G3/4" external thread

3/4" inner dia. Tubing, compression-proof

Cooling water drain for residual water in case of service

16

6. Operating procedures

6.1. Bath fluids

Caution:

No liability for use of other bath liquids!

Please contact JULABO before using other than recommended bath fluids. JULABO takes no responsibility for damages caused by the selection of an unsuitable bath fluid

Do not use alcohols.

Water:

The quality of water depends on local conditions.

• Due to the high concentration of lime, hard water is not suitable for temperature control because it leads to calcification in the bath.

• Ferrous water can cause corrosion - even on stainless steel.

• Chloric water can cause pitting corrosion.

• Distilled and deionized water is unsuitable. Their special properties cause corrosion in the bath, even in stainless steel.

No liablity for use with water.

Danger of freezing at working temperatures <5 °C.

Recommended bath fluids:

Bath fluids soft/decalcified water

Temperature range

5 °C to 80 °C

See website for list of recommended bath fluids.

Contact: www.julabo.com

6.2. Power connection

Caution:

• Only connect the unit to a power socket with earthing contact (PE – protective earth)!

• The power supply plug serves as safe disconnecting device from the line and must be always easily accessible.

• Never operate equipment with damaged mains power cables.

• Regularly check the mains power cables for material defects (e.g. for cracks).

We disclaim all liability for damage caused by incorrect line voltages!

Make sure that the line voltage and frequency match the supply voltage specified on the type plate.

17

6.3. Filling

Top view

Take care that no liquid enters the interior of the circulating cooler.

 Connect the tubing from the external system to the pump connectors and check for leaks

Respect instructions from page 12 to page 14!

 Check to make sure that the drain taps (9a, 9b) are closed.

• Unscrew the plug from the filling port (4).

• Fill in bath fluid up to marking „H“ of the filling level indicator.

H

• Turn the mains switch (1) on (Switching on - see below)

L

• Switch on unit. To do so press button for approx. 4 seconds.

• Bath fluid is pumped into the externally connected system.

Refill fluid up to marking „H“.

• The recirculating cooler is ready for operation.

• Close the the fill in opening (4) with the screw plug!

6.4. Switching on / Start - Stop

ON

Switching on:

The recirculating cooler is turned on and off with the mains switch.

The unit performs a self-test. All segments of the 4-digit LED temperature DISPLAY and all indicator lights will illuminate.

Then the software version and the type of unit are indicated.

The display " OFF" indicates the unit is ready to operate (standby mode).

45

60

4 s

30

15

Start: Press enter for about 4 seconds.

The LED temperature DISPLAY indicates the actual bath temperature.

Stop: 1. Press enter for about 4 seconds.

2. Wait until the LED display stops blinking!

3. Turn the unit off with the mains power switch.

18

6.5. Setting the feed pressure

max.

Set the max. permissible feed pressure (example: 2 bar) by slowly closing the adjusting valve (13) on the rear and looking at the manometer (5).

 The max. pressure is determined by the weakest element in the circuit (e. g. glass equipment).

Fixing a leak on the adjustment valve

The stuffing box gland on the adjustment valve must be tightened if it develops a leak.

1 2 3 4

Undo the nut (a.f. 8) and remove the hand wheel on the adjustment valve,

Unscrew the stuffing box gland cover,

Remove the insulation,

5

1.

2.

3.

4. + 5. Tighten the nut on the seal (a.f. 27),

6. Place the seal back over the screw connection,

7. Secure the stuffing box gland cover,

8. Attach the hand wheel to the adjustment valve and secure the nut.

The adjustment valve must turn easily after the nut has been tightened.

6.6. Setting the temperatures

Factory setting: 25 °C  Setting can be carried out in the start/stop condition.

1.

Press one of the keys for a short moment.

The setpoint value instead of the actual value is indicated on the display for about 8 seconds.

The value can now be changed.

2.

Change value:

Press to set a higher value.

Press to set a lower value.

Keep the keys depressed for the value to change fast.

3.

Press enter to store the value.

19

6.7. AUTOSTART ON / OFF

The recirculating cooler has been configured and supplied by JULABO according to N.A.M.U.R. recommendations. This means for the start mode, that the unit must enter a safe operating state after a power failure (non-automatic start mode). This safe operating state is indicated by „OFF“ on the LED temperature display. A complete shutdown of the main functional elements such as compressor and circulating pump is effected simultaneously.

If such a safety standard is not required, the AUTOSTART function

(automatic start mode) may be activated, thus allowing the start of the circulator directly by pressing the mains power switch

Keep depressed enter and turn on the unit with the mains power switch.

For a short while the LED DISPLAY indicates the effective start mode:



AUTOSTART on.



AUTOSTART off.

Warning:

For supervised or unsupervised operation with the AUTOSTART function, avoid any hazardous situation to persons or property.

The recirculating cooler does no longer conform to N.A.M.U.R. recommendations.

6.8. Remote control: activate – deactivate

(Interface OFF)

(Interface On)

The recirculating cooler is to be prepared for remote control by a personal computer via the serial interface RS232.

Set the interface item from >IOFF< to >ION<.

Remote control: activate – deactivate:

• Switch off recirculating cooler by pressing the mains switch and wait approx. 5 seconds.

• Keep depressed the keys and enter simultaneously and turn on the unit with the mains power switch.

>I OFF< No remote control via RS232 (Factory setting)

>I On< Remote control via RS232

 The software version and the type of unit is indicated

(see example on the left).

The display " rOFF" indicates the unit is ready to be operated via remote control.

20

7. Safety installations

7.1. Excess temperature protection

+

 This safety installation is independent of the control circuit.

When the temperature of the bath fluid has reached the safety temperature (85

°C), a complete shutdown of the compressor and pump is effected.

The alarm is indicated by optical and audible signals (continuous tone) and on the LED-DISPLAY appears the error message " Error 14".

7.2. Low level protection

+



This safety installation is independent of the control circuit.

If the low liquid level protection device is triggered, a complete shutdown of the compressor and circulating pump is effected.

The alarm is indicated by optical and audible signals (continuous tone) and on the LED-DISPLAY appears the error message

" Error 01".

 Turn off the unit with the mains switch, refill bath fluid and turn the unit on again!

Caution:

For refill always use the same bath fluid type that is already in the bath.

Notice:

Check the low liquid level protection device at least twice a year!

To execute a functional test, drain the liquid until the alarm for low liquid level is triggered. Refill liquid afterwards.

8. Troubleshooting guide / Error messages

+



Whenever the microprocessor electronics registers a failure, a complete shutdown of the compressor and circulating pump is performed. The alarm light

" " illuminates and a continuous signal tone sounds.

The LED temperature display indicates the cause for the alarm in form of a code.

Press enter to quit the audible signal.

• The recirculating cooler is operated without bath fluid, or the liquid level is insufficient.

Replenish the bath tank with the bath fluid.

• Tube breakage has occured (insufficient filling level due to excessive bath fluid pumped out). Replace the tubing and replenish the bath tank with the bath fluid.

Cable of the working temperature sensor interrupted or short-circuited.

Error in A/D converter.

21

The return temperature is above the switch-off value of the high temperature protection (85°C). Check dimensioning of application.

Use a stronger recirculating cooler if necessary.

• The motor protection switch for the compressor motor is off. Set motor protection switch to >1< . Check the fuses.

• The pressure sensor of low pressure side (evaporation pressure) is faulty, short-circuited or has a line interruption.

Have the repair done by a specialist.

• The motor protection switch for the compressor motor is off. Set motor protection switch to >1< . Check the fuses.

• The pressure sensor of high pressure side is faulty, short-circuited or has a line interruption.

Have the repair done by a specialist.

The suction gas temperature sensor is faulty, short-circuited or has a line interruption.

Have the repair done by a specialist.

After eliminating the malfunction, press the mains power switch off and on again to cancel the alarm state.

If the unit cannot be returned to operation, contact an authorized service station.

Warning without a complete shutdown of the unit

Excess temperature warning starting at 75 °C

The return temperature soon reaches the swith-off value of the high temperature protection (85 °C).

Cooling of the condenser is affected. (see page 27)

• Clean air-cooled condenser.

• Check the flow rate and cooling water temperature on water-cooled condenser.

If the unit cannot be returned to operation, contact an authorized JULABO service station.

Disturbances that are not indicated.

Overload protection:: a) for cooling machine b) for pump motor

After a short cooling interval, the unit will automatically start running.

1 Motor protection switch for compressor motor

2 + 3 Mains circuit breakers (resettable) F1, F2 - 4 A (for Electronics)

4 + 5 Mains circuit breakers (resettable) F3, F4 - 10 A (for Pump motor)

22

9. Electrical connections

Notice: Use shielded cables only.

The shield of the connecting cable is electrically connected to the plug housing.

The unit ensures safe operation if connecting cables with a maximum length of 3 m are used. The use of longer cables does not affect proper performance of the unit, however external interferences may have a negative impact on safe operation.

5 1

6

RS232 serial interface

This port can be used to connect a computer with an RS232 cable for remote control of the recirculating cooler.

Pin assignments RS232:

Pin 2

Pin 3

Pin 5

Pin 7

Pin 8

RxD

TxD

0 V

RTS

CTS

Receive Data

Transmit Data

Signal GND

Request to send

Clear to send

Pin 1; 4; 6, 9 Reserved - do not use!

Accessories:

Order No.

8 980 073

8 900 110

Description

RS232 interface cable 9-pol./9-pol. , 2,5 m

USB interface adapter cable

Alarm output

Potential-free change-over contact for external alarm signal.

Pin 2 and 3 are connected in case of an alarm.

Pin 2 and 1 are connected in normal condition or mains switch "Off".

or

Switching capacity max. 30 W / 30 VA

Switching voltage max. 30 V∼/−

Switching current max. 1 A

23

10. Remote control

10.1. Setup for remote control

5

9

RS232

1

6

Check the interface parameters for both interfaces (on recirculating cooler and

PC) and make sure they match.

Interface parameters are pre-determined.

Type

Baudrate

Parity

Handshake

RS232

4800 bauds even hardware handshake

10.2. Communication with a PC or a superordinated data system





If the recirculating cooler is put into remote control mode the MULTI-DISPLAY

(LED) will read „R -OFF-„ = REMOTE STOP. The recirculating cooler is now operated via the computer.

In general, the computer (master) sends commands to the recirculating cooler

(slave). The recirculating cooler sends data (including error messages) only when the computer sends a query.

In remote control mode:

After a power interruption the order to start and all values which have to be adjusted must be resent from the personal computer via the interface.

AUTOSTART is not possible.

A transfer sequence consists of:

• command

• space out/in command

(⇔; Hex: 20) out/in command

• parameter period)

• end of file

(the character separating decimals in a group is the out command

(↵; Hex: 0D) out/in command

• The response (data string) after an in command is always followed by a line feed (LF, Hex: 0A).

Important times for a command transmission:

To ensure a safe data transfer, the time gap between two commands should be at least 250 ms.

The recirculating cooler automatically responds to an in command with a data string followed by a LF (Line Feed). The next command should only be sent after 10 ms.

The commands are divided into in or out commands.

in commands:

out commands: asking for parameters to be displayed setting parameters

24

 The out commands are valid only in remote control mode.

Examples:

Command to set the working temperature to15,5 °C:

Command to ask for the working temperature

Response from the recirculating cooler:

out_sp_00 ⇔ 15.5↵

in_sp_00↵

15.5↵ LF

10.3. List of commands

out commands: Setting parameters or temperature values.

Command Parameter Response of recirculating cooler

out_mode_05 out_mode_05 out_sp_00

0

1 xxx.xx

Stop the unit = R –OFF-.

Start the unit.

Set working temperature

in commands: Asking for parameters or temperature values to be displayed.

Command Parameter Response of recirculating cooler

version status in_pv_00 in_sp_00 in_mode_05 none none none none none

Number of software version (V X.xx)

Status message, error message (see page 25 )

Actual bath temperature.

Working temperature

Recirculating cooler in Stop/Start condition:

0 = Stop

1 = Start

10.4. Status messages

Status messages

00 MANUAL STOP

01 MANUAL START

02 REMOTE STOP

03 REMOTE START

Description

Recirculating cooler in „OFF“ state.

Recirculating cooler in keypad control mode.

Recirculating cooler in „r OFF“ state.

Recirculating cooler in remote control mode.

25

10.5. Error messages

Error messages Description

-01 LOW LEVEL ALARM

-05 WORKING SENSOR ALARM

-10 VALUE TOO SMALL

Low liquid level alarm.

Working temperature sensor short-circuited or interrupted.

-03 EXCESS TEMPERATURE WARNING High temperature warning. Starting at 75 °C

(no deactivation)

The return temperature soon reaches the switch-off value of the high temperature warning function (85 °C)

-07 I 2 C-BUS ERROR Internal error when reading or writing the I 2 C bus.

-08 INVALID COMMAND Invalid command.

-09 COMMAND NOT ALLOWED IN

CURRENT OPERATING MODE

Invalid command in current operating mode.

Entered value too small.

-11 VALUE TOO LARGE Entered value too large.

-12 TEMPERATURE MEASUREMENT

ALARM

-14 EXCESS TEMPERATURE

PROTECTOR ALARM

-20 WARNING: CLEAN CONDENSOR OR

CHECK COOLING WATER CIRCUIT

OF REFRIGERATOR

-51 PRESSURE SENSOR ALARM LOW

PRESSURE SIDE

-52 PRESSURE SENSOR ALARM HIGH

PRESSURE SIDE

-53 SUCTION GAS TEMPERATURE

SENSOR ALARM

Error in A/D converter.

The return temperature is above the switch-off value of the high temperature warning function of 85 °C.

Check dimensioning of application.

Use a stronger recirculating cooler if necessary.

Cooling of the condenser is affected. Clean air-cooled condenser.

Check the flow rate and cooling water temperature on water-cooled condenser.

• The motor protection switch for the compressor motor is off. Set motor protection switch to >1< .

Check the fuses.

• The pressure sensor of low pressure side

(evaporation pressure) is faulty, short-circuited or has a line interruption.

Have the repair done by a specialist.

• The motor protection switch for the compressor motor is off. Set motor protection switch to >1< .

Check the fuses.

• The pressure sensor of high pressure side is faulty, short-circuited or has a line interruption.

Have the repair done by a specialist.

The suction gas temperature sensor is faulty, shortcircuited or has a line interruption.

Have the repair done by a specialist.

26

11. Cleaning / repairing the unit

Caution:

Always turn off the unit and disconnect the mains cable from the power source before cleaning the unit.

Prevent humidity from entering into the circulator.

Electrical connections and any other work must be performed by qualified personnel only.

Notice:

Risk of hand injuries when mounting the venting grid.

Maintaining the cooling performance

Air cooled models = FL

To maintain the full cooling performance, clean the condenser from time to time.

• Switch off the unit, disconnect mains power cable.

• Hold the venting grid, pull out and remove.

• Clean the ribbed condenser with a vacuum cleaner.

• Replace the venting grid.

• Switch on the unit.

The following service procedures are to be carried out only by qualified service personnel.

In order to maintain a good condition of the cooling compressor, the dirt pan in the cooling water inlet should be cleaned in regular intervals.

• Switch the unit off, disconnect the power plug.

• Interrupt the cooling water inlet.

• Loosen the screws at the back and remove right side panel.

• Dirt collects behind the lock screw of the dirt trap. Remove lock screw.

• Remove the dirt by opening the water input for a short moment (rinse).

• Return and fasten lock screw to dirt trap.

• Open cooling water inlet and check screw coupling for leak tightness.

• Replace right side panel.

• The unit is ready to operate again.

27

Cleaning:

Clean the outside of the unit using a wet cloth and low surface tension water.

The recirculating cooler is designed for continuous operation under normal conditions. Periodic maintenance is not required.

The tank should be filled only with a bath fluid recommended by

JULABO. To avoid contamination, it is essential to change the bath fluid from time to time.

Repairs:

Before asking for a service technician or returning a JULABO instrument for repair, please contact an authorized JULABO service station.

When returning the unit:

• Clean the unit in order to avoid any harm to the service personnel

• FLW20006: drain residual water of cooling water circuit.

(19 – Cooling water drain for residual water)

• Attach a short fault description.

• When returning a unit, take care of careful and adequate packing.

• During transport the unit has to stand upright. Mark the packing correspondingly.

• JULABO is not responsible for damages that might occur from insufficient packing.

JULABO reserves the right to carry out technical modifications with repairs for providing improved performance of a unit.

28

11.1. JULABO Service – Online remote diagnosis

JULABO circulators of the HighTech series are equipped with a black box. This box is implemented in the controller and records all significant data for the last 30 minutes.

In case of a failure, this data can be read out from the unit by using special software. This software is available as a free download from www.julabo.com

\EasyBlackBox.

• Installation is easy and is performed step by step.

Please observe the instructions.

• Data read-out is possible in the conditions

“OFF”, “R OFF” or “ALARM”.

• Connect the circulator to the computer using an interface cable.

• Start the EasyBlackBox program.

The program asks for the port used (COM1, ......) and the baud rate of the unit.

You do not have this information on hand? Simply try it out!

The program continues to send the request until the correct settings are made.

• Data is read out and shown on the monitor divided in the sections

>Einstellungen/Settings<,

>Alarmspeicher/Alarms stored<,

>Blackbox<

 see example

• After pressing >Speichern/Save< a text file is compiled. The program proposes a filename -

>C:\model description and barcode no.<.

Modifications are possible.

• E-mail this file to [email protected],

JULABO's service department. JULABO is thus able to provide rapid support.

29

11.2. Draining

Notice:

Store and dispose the used bath fluid according to the laws for environmental protection.

Risk of injury for hands when mounting the venting grid.

The unit has two drain taps. Both have to be used.

First drain the large tank via drain tap A, the drain the remaining liquid via drain tap B.

• Turn off the unit and disconnect the mains cable from the power source.

• Hold the venting grid, pull out and remove.

• Place a suitable vessel for accepting the used bath liquid underneath the drain.

• Assemble the barbed fitting to the drain tap.

Slide a short piece of tube onto the barbed fitting and hold it into a pail.

• Open the drain tap and empty the unit completely.

• Tighten the drain tap after draining the unit and replace the venting grid.

30

12. Warranty conditions

JULABO GmbH warrants its products against defects in material or in workmanship, when used under appropriate conditions and in accordance with appropriate operating instructions for a period of ONE YEAR.

Extension of the warranty period – free of charge

With the ‘1PLUS warranty’ the user receives a free of charge extension to the warranty of up to 24 months, limited to a maximum of 10 000 working hours.

To apply for this extended warranty the user must register the unit on the JULABO web site www.julabo.com

, indicating the serial no. The extended warranty will apply from the date of JULABO

GmbH’s original invoice.

JULABO GmbH reserves the right to decide the validity of any warranty claim. In case of faults arising either due to faulty materials or workmanship, parts will be repaired or replaced free of charge, or a new replacement unit will be supplied.

Any other compensation claims are excluded from this guarantee.

31

13. Example Installation Log

Type of Unit:

Refrigerant:

FL Year of manufacture:

Permissible operating overpressure

Filling volume refrigerant:

1

2

3

4

5

6

7

Details of all maintenance and repairs

Quantity and type (new, reused or recyceled) of the refrigerant used for filling

Quantity of refrigerant drained from the unit

If an analysis of the reused refrigerant is available, please list the results

Origin of the refrigerant

Modification and exchange of unit components

Results of every regular routine test

Extended down times

32