Huber Unichiller 600T, Unichiller 600Tw Operation Manual

Unichiller®
OPERATION MANUAL
Unichiller®
OPERATION MANUAL
Unichiller®
Pilot ONE®
This operation manual is a translation of the original operation manual.
Also for models with heater and with/without an emergency stop switch (optional).
VALID FOR:
CLASSIC
Unichiller® 0xx
Unichiller® 1x0
TOWER
Unichiller® 0xxT
Unichiller® 1x0T
Unichiller® 2x0T
Unichiller® 3x0T
Unichiller® 4x0T
Unichiller® 500T
Unichiller® 600T
Unichiller® 700T
Abbreviations used in model names:
Without = with air cooling, P = stronger pump, w = with water cooling, -H = with heater,
-WO = winter option
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OPERATION MANUAL
„Pilot ONE“
Layout of the “Home”
screen
6
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OPERATION MANUAL
Table of contents
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1
Introduction
1.1
1.2
1.2.1
1.2.2
1.2.3
1.2.4
1.3
1.3.1
1.3.1.1
1.3.1.2
1.3.1.3
1.3.2
1.3.3
1.4
1.4.1
1.4.2
1.4.2.1
1.4.3
1.4.3.1
1.4.3.2
1.4.3.3
1.4.3.4
1.5
1.5.1
Details on the declaration of conformity....................................................... 12
Safety .......................................................................................................... 12
Symbols used for Safety Instructions .............................................................. 12
Representation of safety identifiers ............................................................... 13
Proper operation............................................................................................. 13
Reasonably foreseeable misuse ...................................................................... 14
Responsible bodies and operators – Obligations and requirements............... 14
Obligations of the responsible body ............................................................... 14
Proper disposal of resources and consumables ......................................... 15
Temperature control unit with natural refrigerants (NR) .......................... 15
Temperature control units with fluorinated greenhouse gases/refrigerants17
Requirements for operators ........................................................................... 17
Obligations of the operators ........................................................................... 18
General information ..................................................................................... 18
Description of workstation ............................................................................. 18
Safety devices to DIN 12876 ........................................................................... 18
Temperature control units (with heater) with electronic low level sensor 18
Further protective devices .............................................................................. 19
Power interruption ..................................................................................... 19
Alarm functions .......................................................................................... 19
Warning messages...................................................................................... 19
Emergency stop switch (optional) .............................................................. 19
Exemplary illustrations of the cooling variants .............................................. 20
Consequence of inadequate energy dissipation ............................................. 20
2
Commissioning
2.1
2.1.1
2.1.1.1
2.1.1.2
2.1.2
2.1.2.1
2.1.2.2
2.2
2.2.1
2.2.1.1
2.2.1.2
2.2.2
2.2.2.1
2.2.2.2
2.3
2.4
2.4.1
2.5
2.6
2.7
In-plant transport......................................................................................... 22
Lifting and transporting the temperature control unit ................................... 22
Temperature control unit with lifting eyes ................................................ 22
Temperature control unit without lifting eyes ........................................... 23
Positioning the temperature control unit ....................................................... 23
Temperature control unit with casters ...................................................... 23
Temperature control unit without casters ................................................. 23
Transportation lock ...................................................................................... 23
Transportation lock Type A ............................................................................. 24
Releasing the transportation lock (operating position).............................. 24
Tightening the transportation lock (transport position) ............................ 24
Transportation lock Type B ............................................................................. 24
Releasing the transportation lock (operating position).............................. 25
Tightening the transportation lock (transport position) ............................ 25
Unpacking .................................................................................................... 25
Ambient conditions ...................................................................................... 25
EMC-specific notes .......................................................................................... 26
Installation conditions .................................................................................. 27
Recommended temperature control and cooling water hoses ...................... 27
Wrench sizes and torques............................................................................. 28
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2.8
2.9
2.10
2.10.1
2.10.2
2.10.3
2.11
2.11.1
2.12
2.12.1
2.12.2
2.12.3
Temperature control units with water cooling .............................................. 28
Temperature control unit for outdoor installation incl. winter operation ...... 29
Preparations for operation ........................................................................... 30
Unscrewing/activating the leveling feet (if any) ............................................. 30
Opening/closing valves ................................................................................... 31
Emergency stop switch (optional): Check switching status ............................ 31
Connecting externally closed application ...................................................... 31
Connecting an externally closed application .................................................. 31
Connecting to the power supply ................................................................... 32
Connection using socket with protective earth (PE) ....................................... 32
Connection via hard wiring ............................................................................. 32
Connecting the functional earth ..................................................................... 33
3
Function description
3.1
3.1.1
3.1.2
3.2
3.3
3.4
3.4.1
3.5
3.5.1
3.5.2
3.5.2.1
3.5.2.2
3.6
3.7
3.7.1
3.8
3.8.1
3.8.2
3.8.3
3.8.4
3.9
3.9.1
3.9.2
3.9.3
3.9.3.1
3.9.3.2
3.9.4
3.9.4.1
3.9.4.2
Function description of the temperature control unit ................................... 34
General functions............................................................................................ 34
Other functions ............................................................................................... 34
Information on the thermal fluids ................................................................ 35
To be noted when planning the test ............................................................. 36
“Pilot ONE®” controller ................................................................................ 37
Functional overview of “Pilot ONE®” .............................................................. 37
Clock/event function .................................................................................... 39
Rechargeable accumulator ............................................................................. 39
Programmable event function ........................................................................ 39
Event function “Alarm clock event” ........................................................... 39
Event function “Program event” ................................................................ 39
Operation via the touch screen..................................................................... 40
Display instruments ..................................................................................... 40
The touchscreen [88] ...................................................................................... 40
Control instruments ..................................................................................... 40
The touchbuttons............................................................................................ 41
The categories ................................................................................................. 41
The sub-categories .......................................................................................... 41
The dialogs ...................................................................................................... 41
Function examples ....................................................................................... 41
Display of software version............................................................................. 41
Start & Stop ..................................................................................................... 42
Copying the settings to a data carrier ............................................................. 42
Saving to a USB flash drive ......................................................................... 42
Loading from a USB flash drive................................................................... 43
Restore factory settings .................................................................................. 43
Restore to factory settings without overtemperature protection .............44
Restore to factory settings including overtemperature protection ...........44
4
Setup mode
4.1
4.1.1
4.1.1.1
4.1.1.2
4.1.2
4.1.3
4.1.4
4.1.4.1
Setup mode ................................................................................................. 46
Emergency stop switch (optional): Activate / Deactivate ............................... 46
Emergency stop switch (optional): Activate ............................................... 46
Emergency stop switch (optional): Deactivate ........................................... 46
Turning on the temperature control unit ....................................................... 46
Turning off the temperature control unit ....................................................... 47
Setting the overtemperature protection ........................................................ 48
General information on the overtemperature protection ......................... 48
34
46
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OPERATION MANUAL
4.1.4.2
4.1.4.3
4.1.4.4
4.1.5
4.1.6
4.1.6.1
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.2.8
4.2.8.1
4.2.8.2
4.2.8.3
4.2.8.4
4.2.9
4.2.9.1
4.2.9.2
4.2.9.3
4.2.10
4.2.11
4.2.12
4.2.13
4.2.14
4.3
4.3.1
4.3.1.1
4.3.1.2
Setting “OT limit: heating” ......................................................................... 48
Setting “Process Safety” ............................................................................. 49
Monitoring via “Display OT values” ............................................................ 49
Testing overtemperature protection for functionality ................................... 49
Adjusting the Delta T limiter ........................................................................... 50
Changing the Delta T limiter ....................................................................... 50
The temperature control circuit .................................................................... 50
Select temperature control: Internal or process ............................................ 51
Temperature control to internal temperature ............................................... 51
Temperature control to process temperature................................................ 51
Delta T limiter ................................................................................................. 52
Monitoring the Pt100 temperature sensors ................................................... 52
Optimum control parameters for optimum temperature control .................. 52
Sub-category: “Select auto/expert mode”...................................................... 52
Sub-category: “Configuration auto” ............................................................... 53
Sub-category: “Find parameters” ............................................................... 53
Sub-category: “Control Dynamics” ............................................................. 55
Sub-category: “Fluid Properties” ................................................................ 56
Sub-category: “Display parameters” .......................................................... 57
Sub-category: “Configuration manual” ........................................................... 57
Sub-category: “Change parameters” .......................................................... 57
Sub-category: “Display parameters” .......................................................... 58
Sub-category: “Control structure”.............................................................. 58
Sub-category: “Reset parameters” ................................................................. 59
Sub-category: “Display parameters”............................................................... 59
Freeze protection for temperature control unit (optional) ............................ 59
Setting the setpoint thresholds ...................................................................... 60
Setting the setpoint ........................................................................................ 60
Filling, venting and draining ......................................................................... 61
Externally closed application .......................................................................... 61
Filling and venting externally closed application........................................ 61
Draining externally closed applications ...................................................... 63
5
Normal operation
5.1
5.1.1
5.1.1.1
5.1.1.2
5.1.2
5.1.2.1
5.1.2.2
Automatic operation .................................................................................... 64
Temperature control....................................................................................... 64
Starting the temperature control process .................................................. 64
Ending the temperature control process ................................................... 64
Temperature control via a created temperature control program ................65
Starting the temperature control program ................................................ 65
Ending/cancelling the temperature control program ................................ 65
6
Interfaces and software update
6.1
6.1.1
6.1.2
6.1.2.1
6.1.2.2
6.2
6.2.1
6.2.2
6.2.3
6.3
Interfaces at the “Pilot ONE®” controller ...................................................... 66
10/100 Mbps Ethernet for RJ45 network sockets .......................................... 66
USB-2.0 interface ............................................................................................ 66
USB-2.0 interface, host ............................................................................... 67
USB-2.0 interface, device ........................................................................... 67
Interfaces at the top side of the Unichiller. ................................................... 67
Female RS232 Serial (with adapter cable) ...................................................... 67
Connection jack for Pt100 process controller sensor ..................................... 67
Service interface ............................................................................................. 68
Interfaces at the Com.G@te® (optional) ....................................................... 68
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6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
6.4
Jack LEVEL (Com.G@te® external only) .......................................................... 69
Connector POKO (floating contact) alarm ...................................................... 69
Jack AIF Reg-E-Prog ......................................................................................... 70
Jack ECS (External Control Signal) standby ..................................................... 71
Jack RS232/RS485 serial.................................................................................. 72
Firmware update.......................................................................................... 72
7
Service/maintenance
7.1
7.2
7.3
7.3.1
7.3.2
7.3.2.1
7.3.2.2
7.3.3
7.3.4
7.3.5
7.4
7.4.1
7.4.2
7.4.2.1
7.4.3
7.5
7.6
7.7
7.8
Messages from the temperature control unit ............................................... 73
Replacing the “Pilot ONE®”........................................................................... 73
Maintenance ................................................................................................ 73
Function check and visual inspection ............................................................. 74
Replacing temperature control or coolant hoses ........................................... 75
Replacing temperature control hoses ........................................................ 75
Replacing coolant hoses ............................................................................. 75
Clean liquefier fins (air-cooled temperature control unit) ............................. 75
Clean hat-type strainer (dirt trap) (water-cooled temperature control unit) .76
Emergency stop switch (optional): Function test ........................................... 76
Thermal fluid inspection, replacement and circuit cleaning ........................... 77
Thermal fluid inspection ................................................................................. 77
Thermal fluid replacement ............................................................................. 77
Externally closed application ...................................................................... 78
Rinsing the thermal fluid circuit ...................................................................... 78
Cleaning the surfaces ................................................................................... 79
Inspect the mechanical seal .......................................................................... 80
Plug contacts................................................................................................ 80
Decontamination/repairs ............................................................................. 80
8
Shutting down
8.1
8.2
8.3
8.3.1
8.4
8.5
8.6
8.7
8.8
8.8.1
8.8.2
8.8.3
8.9
Safety instructions and basic principles ........................................................ 81
Switch-off .................................................................................................... 81
Draining the cooling water ........................................................................... 82
Draining process ............................................................................................. 82
Transportation lock ...................................................................................... 82
Packing ........................................................................................................ 82
Shipping ....................................................................................................... 82
Disposal ....................................................................................................... 83
Contact data ................................................................................................ 84
Telephone number: Customer Support .......................................................... 84
Telephone number: Sales ............................................................................... 84
Email address: Customer Support................................................................... 84
Certificate of Compliance ............................................................................. 84
9
Annex
73
81
85
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OPERATION MANUAL
Foreword
Dear Customer,
Thank you for choosing a temperature control unit from Peter Huber Kältemaschinenbau AG. You
have made a good choice. Thank you for your trust.
Please read the operation manual carefully before putting the unit into operation. Strictly follow all
notes and safety instructions.
Follow the operation manual with regard to transport, start-up, operation, maintenance, repair,
storage and disposal of the temperature control unit.
We fully warrant the temperature control unit for the specified normal operation.
The models listed on page 5 are referred to in this operation manual as temperature control units
and Peter Huber Kältemaschinenbau AG as Huber company or Huber.
Liability for errors and misprints excluded.
The following trademarks and the Huber logo are registered trademarks of Peter Huber Kältemaschinenbau AG
in Germany and/or other countries worldwide: BFT®, CC®, CC-Pilot®, Com.G@te®, Compatible Control®,
CoolNet®, DC®, E-grade®, Grande Fleur®, KISS®, Minichiller®, Ministat®, MP®, MPC®, Peter Huber Minichiller®,
Petite Fleur®, Pilot ONE®, RotaCool®, Rotostat®, SpyControl®, SpyLight®, Tango®, TC®, UC®, Unical®, Unichiller®,
Unipump®, Unistat®, Unistat-Pilot®, Unistat Tango®, Variostat®, Web.G@te®. The following trademarks are
registered in Germany to DWS Synthesetechnik: DW-Therm®, DW-Therm HT®
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11
Introduction
OPERATION MANUAL
Chapter 1
1
Introduction
1.1
Details on the declaration of conformity
The equipment complies with the basic health and safety requirements of the European Directives
listed below:
▪ Machinery Directive
▪ Low Voltage Directive
▪ EMC Directive
1.2
Safety
1.2.1
Symbols used for Safety Instructions
Safety instructions are marked by the below combinations of pictograms and signal words. The
signal word describes the classification of the residual risk when disregarding the operation manual.
Denotes an immediate hazardous situation that will result in death or serious injuries.
Denotes a general hazardous situation that may result in death or serious injuries.
Denotes a hazardous situation that can result in injury.
Denotes a situation that can result in property material damage.
Denotes important notes and usable hints.
Notes in conjunction with Ex px cabinets.
Safety information and
procedure
The safety information in this operation manual is designed to protect the responsible body, the
operator and the equipment from damage. Safety instructions appear at the beginning of each
chapter and before instructions. First inform yourself about any residual risks due to misuse before
you start an operation.
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Introduction
Chapter 1
1.2.2
OPERATION MANUAL
Representation of safety identifiers
The following pictograms are used as safety identifiers. The table gives an overview of the safety
identifier used here.
Overview
Identifier
Description
Mandatory sign
- Observe the instructions
Warning sign
- General warning sign
- observe the instructions
- Warning of electrical voltage
- Warning of hot surface
- Warning of flammable substances
1.2.3
Proper operation
Operating the temperature control unit in a potentially explosive area
DEATH THROUGH EXPLOSION
 Do NOT install or start up the temperature control unit within an ATEX zone.
Improper use
SERIOUS INJURY AND PROPERTY DAMAGE
 Store the operation manual where it is easy to access in close proximity to the temperature
control unit.
 Only adequately qualified operators may work with the temperature control unit.
 Operators must be trained before handling the temperature control unit.
 Check that the operators have read and understood the operation manual.
 Define precise responsibilities of the operators.
 Personal protective equipment must be provided to the operators.
 Be sure to follow the responsible body’s safety rules to protect life and limb and to limit damages!
Modifications to the temperature control unit by third-parties
DAMAGE TO THE TEMPERATURE CONTROL UNIT
 Do not allow third parties to make technical modifications to the temperature control unit.
 The EU declaration of conformity becomes invalid if any modifications are made to the temperature control unit without the approval of Huber.
 Only specialists trained by Huber may carry out modifications, repairs or maintenance work.
 The following must be observed without fail:
 Only use the temperature control unit in a fault-free condition!
 Have the start-up and repairs carried out by specialists only!
 Do not ignore, bypass, dismantle or disconnect any safety devices!
The temperature control unit must not be used for any purposes other than temperature control in
accordance with the operation manual.
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Introduction
OPERATION MANUAL
Chapter 1
The temperature control unit is manufactured for industrial use. The temperature control unit maintains the temperature of certain applications, including glass or metal reactors or other expedient
items in laboratories and industry. Flow-through coolers and calibration baths must be used only in
combination with Huber temperature control units. Thermal fluids suitable for the overall system
are used. The chilling and heating capacity is provisioned at the pump connections or - where present - in the tempering bath. The technical specification of the temperature control unit is given in
the data sheet (from page 85 in section »Annex«). The temperature control unit must be installed,
configured and operated according to the handling instructions in this operating manual. Failure to
comply with the operation manual is deemed improper use. The temperature control unit conforms
to state-of-the-art technology and the recognized safety regulations. Safety devices are built into
your temperature control unit.
1.2.4
Reasonably foreseeable misuse
Without an Ex px cabinet, the temperature control unit is NOT protected against explosion and
must NOT be installed or put into operation within an ATEX Zone. When operating the temperature control unit in conjunction with an Ex px cabinet, the information in the annex (Section ATEX
operation) must be observed and followed. This annex is only provided for temperature control
units delivered with an Ex px cabinet. If this annex is missing, please immediately contact the Customer Support of Huber (the telephone number is provided on page 84 in Section »Contact data«).
Use with medical devices (e.g. in Vitro diagnostic procedure) or for direct foodstuff temperature
control is NOT permissible.
The temperature control unit must NOT be used for any purposes other than temperature control in
accordance with the operation manual.
The manufacturer accepts NO liability for damage caused by technical modifications to the temperature control unit, improper handling or use of the temperature control unit if the operation manual is not observed.
1.3
Responsible bodies and operators – Obligations and
requirements
1.3.1
Obligations of the responsible body
The operation manual is to be stored where it is easy to access in close proximity to the temperature
control unit. Only adequately qualified operators (e.g. chemists, CTA, physicists etc.) are permitted
to work with the temperature control unit. Operators must be trained before handling the temperature control unit. Check that the operators have read and understood the operation manual. Define
precise responsibilities of the operators. Personal protective equipment must be provided to the
operators.
▪ The responsible body must install a condensation water / thermal fluid drip tray below the temperature control unit.
▪ The responsible body must check whether national regulations require the mandatory installation
of a drain tray for the installation area of the temperature control unit/the entire system.
▪ Our temperature control unit complies with all applicable safety standards.
▪ Your system, which uses our temperature control unit, must be as safe.
▪ The responsible body must design the system to ensure it is safe.
▪ Huber is not responsible for the safety of your system. The responsible body is responsible for the
safety of the system.
▪ Although the temperature control unit provided by Huber meets all the applicable safety standards, integration into a system may give rise to hazards that are characteristic of the other system’s design and beyond the control of Huber.
▪ It is the responsibility of the system integrator to ensure that the overall system, into which this
temperature control unit is integrated, is safe.
▪ The >Mains isolator< [36] (if present) may be provided with a facility to lock the main isolator in
the off position to facilitate safe system installation and maintenance of the temperature control
unit. It is the responsibility of the responsible body to develop any lock-out/tag-out procedure in
accordance with local regulations (e.g. CFR 1910.147 for the US).
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Chapter 1
OPERATION MANUAL
1.3.1.1
Proper disposal of resources and consumables
Do comply with all national disposal regulations applicable for you. Contact your local waste management company for any questions concerning disposal.
Overview
Material / Aids
Disposal / Cleaning
Packing material
Keep the packaging material for future use (e.g. transport).
Thermal fluid
Please refer to the safety data sheet of the thermal fluid used for information on its
proper disposal.
Use the original thermal fluid container when disposing it.
Filling accessories, e.g.
beaker
Clean the filling accessories for reuse. Make sure that the materials and cleaning
agents used are properly disposed of.
Aids such as towels,
cleaning cloths
Tools used to take up spilled thermal fluid must be disposed of in the same fashion
as the thermal fluid itself.
Tools used for cleaning must be disposed of depending on the cleaning agent used.
Cleaning agents such as
stainless steel cleaning
agents, sensitive-fabrics
detergents
Please refer to the safety data sheet of the cleaning agent used for information on its
proper disposal.
Use the original containers when disposing of large quantities of cleaning agents.
Consumables such as air
filter mats, temperature
control hoses
Please refer to the safety data sheet of the consumables used for information on
their proper disposal.
1.3.1.2
Temperature control unit with natural refrigerants (NR)
Over 8 g refrigerant per m³ room air
DEATH OR SERIOUS INJURY DUE TO EXPLOSION
 Observe the rating plate (amount of natural refrigerant contained) and the room size (maximum room
concentration of natural refrigerant in case of leakage) when installing the temperature control unit.
 Over 8 g refrigerant per m³ room air: A gas warning sensor must be fitted and functioning.
 The gas warning sensor must be calibrated and maintained at regular intervals (between 6 and
12 months).
 The temperature control unit is not approved for operation in an ATEX zone.
Huber products with natural refrigerants work with numerous proven, safe and highly-sustainable
technologies. The relevant standards and regulations for temperature control units with natural
refrigerants contain a number of stipulations, the importance of complying with which is set out
below. Also observe on page 13 the section »Proper operation«.
Huber temperature control units are constructed to be permanently sealed and are carefully
checked for leak tightness. Temperature control units with more than 150 g natural refrigerant are
equipped with an additional gas warning sensor. To find out whether your temperature control unit
is equipped with a gas warning sensor, refer to the data sheet from page 85 in section »Annex«.
The fill quantity of your temperature control unit is stated on the data sheet (from page 85 in section »Annex«) or on the rating plate on the rear of the temperature control unit. Observe page 25,
section »Ambient conditions« and page 27, section »Installation conditions«.
Class of
application
field
A
Application field
Example of the installation
location
General
Publicly accessible area in a
public building
B
Monitored
Laboratories
C
Access only for
authorized persons
Production equipment
Max.
quantity of
refrigerant
3
8 g/m
ambient air
Max. permissible
quantity above
ground level (GL)
AND
Classifying the application field
1.5 kg
2.5 kg
10.0 kg
Temperature control units with more than 1 kg refrigerant must not be installed below ground level (GL).
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Introduction
OPERATION MANUAL
Chapter 1
Temperature control units with up to 150 g natural refrigerant
▪ The temperature control unit has been constructed to the requirements of EU and EFTA countries.
▪ Use the table as guidance for classifying the application field. Respect the max. refrigerant quantity stated therein.
Temperature control units WITH pre-installed gas warning sensor and > 150 g natural refrigerant
▪ The temperature control unit has been constructed to the requirements of EU and EFTA countries.
▪ Use the table as guidance for classifying the application field. Respect the max. refrigerant quantity or the permissible highest quantity above ground level (GL) stated therein.
▪ Ventilation with optional supply and exhaust air connection: Use the temperature control unit’s
supply and exhaust air connection to connect it to the building’s exhaust system (see wiring diagram from page 85 in Section »Annex«). First, remove the cover to the air inlet connection; an air
filter mat is installed behind it. This air filter mat must be checked / replaced at regular intervals
so that the air flowing into the temperature control unit is not reduced (see page 74, Section
»Function check and visual inspection«). Connect the building’s exhaust system with the temperature control unit’s exhaust air port. The cover of the supply air port mustnot be removed if the
exhaust system provided in a building is not used.
▪ The mounting plate for mounting a gas warning sensor is located inside the temperature control
unit in the vicinity of the >Cable entry gas warning sensor< [100].
▪ For the position of the >Cable entry gas warning sensor< [100], please refer to the wiring diagram
from page 85 in Section »Annex«.
▪ Additional information on the pre-installed gas detection sensor:
-
-
-
The built-in gas detection sensor enables a safety shutdown at 20% of the lower explosive
limit via a power disconnect relay that is to be installed by the responsible body. The
temperature control unit is thus switched off early and safely in case of fault.
A 24 V DC external power supply must be available for the pre-installed gas warning sensor. The alarm output of the gas warning sensor uses a 4 - 20 mA signal. Please refer to the
data sheet of the gas warning sensor for further technical information. A separate processing unit is available as an accessory for the control of the power disconnect relay. The
processing unit provides a potential-free switching contact and simultaneously supplies
power to and analyzes the gas warning sensor. Both variants require the responsible body
to provide the necessary dimensioning and installation. Please refer to the data sheet of
the gas warning sensor for the technical installation information. The alarm of the gas detection system can be connected to the responsible body’s alarm control unit. The responsible body is responsible for this and other measures.
The responsible body is responsible for the calibration of the gas detection sensor prior to
initial operation and the observance of calibration and maintenance intervals specified in
the operating manual. We recommend to set calibration and maintenance intervals between 6 and 12 months if no information is provided. For increased safety requirements,
shorter intervals can be specified. On request, we will recommend a specialist company to
carry out calibration and maintenance.
Temperature control units WITHOUT pre-installed gas warning sensor and > 150 g natural refrigerant
Over 8 g refrigerant per m³ room air
DEATH OR SERIOUS INJURY DUE TO EXPLOSION
 Observe the rating plate (amount of natural refrigerant contained) and the room size (maximum room concentration of natural refrigerant in case of leakage) when installing the temperature control unit.
 Over 8 g refrigerant per m³ room air: A gas warning sensor must be fitted and functioning.
 The gas warning sensor must be calibrated and maintained at regular intervals (between 6 and
12 months).
 The temperature control unit is not approved for operation in an ATEX zone.
▪ The temperature control unit has been constructed to the requirements of EU and EFTA countries.
▪ Use the table as guidance for classifying the application field. Respect the max. refrigerant quanti-
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Chapter 1
OPERATION MANUAL
ty or the permissible highest quantity above ground level (GL) stated therein.
▪ Ventilation with optional supply and exhaust air connection: Use the temperature control unit’s
supply and exhaust air connection to connect it to the building’s exhaust system (see wiring diagram from page 85 in Section »Annex«). First, remove the cover to the air inlet connection; an air
filter mat is installed behind it. This air filter mat must be checked / replaced at regular intervals
so that the air flowing into the temperature control unit is not reduced (see page 74, Section
»Function check and visual inspection«). Connect the building’s exhaust system with the temperature control unit’s exhaust air port. The cover of the supply air port mustnot be removed if the
exhaust system provided in a building is not used.
▪ NO gas warning sensor is installed in this temperature control unit! Make sure that the installation site of the temperature control unit is sufficiently protected in the event of malfunction.
These include:
1.3.1.3
Installation of a gas warning sensor for the building (room monitoring).
Permanent ventilation of the temperature control unit and/or the installation site.
All-pole disconnection in the event of malfunction of the temperature control unit.
Temperature control units with fluorinated greenhouse gases/refrigerants
F gases regulation (EC) No. 517/2014 of April 16, 2014, on fluorinated greenhouse gases, and repealing Regulation (EC) No. 842/2006.
These regulations deal with all systems that contain fluorinated refrigerants. The substances dealt
with in Directive (EC) No. 1005/2009 of the European Parliament and of the Council of 16 September
2009 that deplete the ozone layer are excluded (CFC/HCFC).
The directive regulates the reduction of the emission, utilization, recovery, and destruction of certain fluorinated greenhouse gases. It also regulates the identification and disposal of products and
devices that contain these gases. Since July 4, 2007, responsible bodies must check their stationary
refrigeration systems for leaks at regular intervals, and have any leaks eliminated immediately.
Directive (EC) No. 303/2008 contains stipulations on the training and certification of companies and
personnel that are permitted to execute the specified activities.
Obligations of the responsible bodies:
▪ Directive (EC) No. 842/2006 already imposed a number of obligations upon responsible bodies
regarding certain fluorinated greenhouse gases. The new Ordinance on Fluorinated Greenhouse
Gases upholds these to a large extent. Some duties are added while others are designed differently by this new ordinance. Please refer to the text of this ordinance for a complete overview of the
individual responsibilities of responsible bodies.
▪ General obligation to reduce emissions.
▪ Only certified companies may maintain, repair or decommission refrigeration systems. The responsible bodies must verify that these companies are certified.
▪ Regular leak tests of stationary refrigeration systems by certified personnel (such as Huber service
engineers). The required test interval is based on the refrigerant filling capacity and the type of
refrigerant, converted to CO22 equivalent.
▪ Responsibility of responsible bodies operating a plant to recover F-gases by certified personnel.
▪ Obligatory documentation requirement in the refrigeration system’s operation manual, specifying
type and volume of refrigerant used or recovered. The responsible body must keep the records
for at least 5 years after their creation and present it to the responsible authority upon request.
▪ Temperature control units with natural refrigerants (NR) are exempt from this Directive.
▪ Please refer to the data sheet or name plate of your temperature control unit for the quantity and
type of refrigerant.
▪ Additional information about the definition of the inspection interval can be found on our website.
1.3.2
Requirements for operators
Work on the temperature control unit is reserved for appropriately qualified specialists, who have
been assigned and trained by the responsible body to do so. Operators must be at least 18 years old.
Under 18-year olds may operate the temperature control unit only under the supervision of a qualified specialist. The operator is responsible vis-a-vis third-parties in the work area.
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Introduction
OPERATION MANUAL
1.3.3
Chapter 1
Obligations of the operators
Carefully read the operation manual before operating the temperature control unit. Please observe
the safety instructions. When operating the temperature control unit, wear appropriate personal
protective equipment (e.g. safety goggles, protective gloves, non-slip shoes).
1.4
General information
1.4.1
Description of workstation
The workstation is located at the control panel in front of the temperature control unit. The workstation is determined by the customer's connected peripheries. Accordingly, it must be designed
safe by the responsible body. The workstation design also depends on the applicable requirements
of the German occupational health and safety regulations [BetrSichV] and the risk analysis for the
workstation.
1.4.2
Safety devices to DIN 12876
The rating of your temperature control unit is stated on the data sheet in the appendix.
Rating of laboratory
thermostats and
laboratory baths
Classification
Temperature
control medium
I
Non-combustible
II
Combustible
b)
III
Combustible
b)
Technical requirements
a)
Overheat protection
Identification
c)
d)
NFL
Adjustable overheat protection
FL
Adjustable overtemperature protection
and additional low-level protection
FL
a)
Usually water; other fluids only if non-combustible even within the temperature range of an individual fault.
b)
The temperature control media must have a combustion point of ≥ 65 °C.
c)
The overheat protection can, for instance, can be realized using a suitable fill level sensor or a suitable temperature limiter.
d)
Optional at the choice of the manufacturer.
Overview of the temperature thresholds
1.4.2.1
Temperature control units (with heater) with electronic low level sensor
The low level protection operates via a pressure sensor in the fluid circuit. The pump and the thermal fluid provide the required pressure at the pressure sensor. Air in the system (fill level too low,
inadequately vented) prevents the pressure from reaching value specified at the pressure sensor.
Temperature control and circulation are interrupted.
Overtemperature protection (for temperature control units with heater)
There is no longer a need for mechanical tools to set the trigger values of the overtemperature
protection. It is replaced by a software engineering tool. The threshold value for the overtemperature protection can be set only if a code, randomly generated by “Pilot ONE”, is entered correctly. As
with the mechanical tool, accidental settings are thus prevented.
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1.4.3
OPERATION MANUAL
Further protective devices
Emergency strategy – isolate the power supply!
To determine the type of switch or switch combination your temperature control unit is equipped
with, please refer to the connection sketch starting on page 85 in the section »Annex«.
Temperature control units with >Mains isolator< [36] (red/yellow or gray): Turn the >Mains
isolator< [36] to the “0” position!
Temperature control units with >Mains isolator [36] (red/yellow) and additional >Appliance
switch< [37] (gray): Turn the >Mains isolator< [36] to the “0” position! Then turn the >Appliance
switch< [37] to the “0” position!
Temperature control units with >Mains isolator< [36] (gray) and >Emergency stop switch< [70]
(red/yellow): Press the >Emergency stop switch< [70]. Then turn the >Mains isolator< [36] to the
“0” position!
Temperature control units with >Mains switch< [37]: Power supply via socket: Disconnect the
temperature control unit from the power supply. Then turn the >Mains isolator< [37] to the “0”
position! Power supply via hard wiring: Disconnect the power supply by means of the building’s
circuit breaker. Then turn the >Mains isolator< [37] to the “0” position!
Temperature control units without a switch or inside a protective housing: Connection via socket: Disconnect the temperature control unit from the power supply. Connection via hard wiring:
Disconnect the power supply by means of the building’s circuit breaker.
1.4.3.1
Power interruption
Following a power outage (or when switching on the temperature control unit), this function can be
used to determine how the temperature control unit is supposed to respond. This response can be
determined via “Pilot ONE”.
OFF/Standby (Default setting)
After turning the temperature control unit on, thermoregulation is started only after manual input.
ON / Temp. control active
After turning on the temperature control unit, thermoregulation is always started. An INFO appears
for a few seconds. This provides for suppressing the automatic start.
Only valid for temperature control units with an emergency stop switch (optional):
After installing the >Emergency stop switch< [70], automatic starting of the temperature control
process is not possible when turning on the temperature control unit.
Power Failure Auto
If temperature control is active during a power outage, the process will automatically continue after
the power outage.
Only valid for temperature control units with an emergency stop switch (optional):
After installing the >Emergency stop switch< [70], automatic continuation of the temperature control process is not possible after a power outage.
1.4.3.2
Alarm functions
An alarm is a system state that signals unfavorable process conditions. The temperature control unit
can be programmed so that the plant operator is warned when defined limit values are exceeded.
The response of the temperature control unit to an alarm can be determined. Possible responses
are: Switch off temperature control or control temperature to a safe setpoint (2nd setpoint).
1.4.3.3
Warning messages
Warning messages contain a message about the irregularity of the temperature control unit. These
messages have no further consequences. The plant operator evaluates the relevance of the message
and takes action where necessary.
1.4.3.4
Emergency stop switch (optional)
The >Emergency stop switch< [70] immediately disconnects all poles of the temperature control
unit. Further information on the >Emergency stop switch< [70] can be found on page 46 in Section
»Emergency stop switch (optional): Activate / Deactivate«.
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Introduction
OPERATION MANUAL
1.5
Chapter 1
Exemplary illustrations of the cooling variants
Example: Air and
water cooling
Air cooling: Air inlet
Water cooling: Water
connection
1.5.1
Consequence of inadequate energy dissipation
Room air/cooling water
Consequences of, for instance, contamination of the liquefier fins, inadequate clearance between
temperature control unit to wall/bath wall, room air/cooling water too warm, cooling water differential pressure too low, suction strainer contamination: The refrigerant in the coolant circuit can no
longer fully discharge the admitted energy to the room air/cooling water. Thus there is not sufficient
liquefied refrigerant available, the condensation temperature and the energy consumption to rise.
Coolant circuit
Consequences of inadequate refrigerant quantity/rising condensation temperature: Not all the
cooling capacity from the coolant circuit is available at the evaporator. This means reduced energy
transmission from the thermal fluid circuit.
Thermal fluid circuit
Consequence of inadequate energy dissipation from the thermal fluid: The thermal fluid can only
dissipate the energy from your application to a limited extent.
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OPERATION MANUAL
Application
Consequences of inadequate energy dissipation from the application: The energy created (exothermic) in the application can no longer be fully dissipated.
Temperature control unit
An electronically-controlled expansion valve is used in the temperature control unit to optimize the
power adjustment. The expansion valve always provisions the maximum possible cooling capacity
within the permissible ambient temperature range. The temperature control unit switches off when
the upper range is reached (maximum permissible ambient temperature).
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Commissioning
OPERATION MANUAL
Chapter 2
2
Commissioning
2.1
In-plant transport
Temperature control unit is not transported / moved according to the specifications in this operation manual
DEATH OR SERIOUS INJURY DUE TO CRUSHING
 Always transport / move the temperature control unit according to the specifications in this
operation manual.
 Wear personal protective equipment during transport.
 Always work with the specified number of persons when moving the temperature control unit
on casters (if any).
 If the temperature control unit is equipped with casters and parking brakes: 2 parking brakes
are always freely accessible when moving the temperature control unit. Activate the 2 parking
brakes in an emergency! If only one parking brake is activated on the casters in an emergency:
The temperature control unit is not stopped but rotates around the axis of the caster with the
activated parking brake!
Temperature control unit transported in a horizontal position
DAMAGE TO THE COMPRESSOR
 Only transport the temperature control unit in an upright position.
▪ If available, use the lugs on the top side of the temperature control unit for transportation.
▪ Use an industrial truck for transport.
▪ The casters (if present) on the temperature control unit are not suitable for transport. The casters
are symmetrically loaded with 25% of the total mass of the temperature control unit.
▪ Remove the packing material (e.g. the palette) only at the place of installation.
▪ Protect the temperature control unit from transport damage.
▪ Do not transport the temperature control unit alone and without aids.
▪ Check the load bearing capacity of the transportation route and the place of installation.
▪ The parking brakes must be activated at the casters (if any) and/or the leveling feet (if any) must
be unscrewed/activated before the temperature control unit is put into operation (see page 30,
section »Unscrewing/activating the leveling feet (if any)«).
▪ For temperature control units with transportation lock, strictly observe page 23, section
»Transportation lock«.
2.1.1
Lifting and transporting the temperature control unit
2.1.1.1
Temperature control unit with lifting eyes
The temperature control unit is raised at the lifting eyes without load handling attachments
DAMAGE TO THE TEMPERATURE CONTROL UNIT
 Always use load handling attachments when lifting and transporting the temperature control
unit.
 The lifting eyes are only designed for a load without inclination (0°).
 The load handling attachment used must be adequately dimensioned. Take the dimensions and
weight of the temperature control unit into account.
▪ Do not lift and transport the temperature control unit at the lifting eyes alone and without aids.
▪ Lift and transport the temperature control unit at the lifting eyes only with a crane or an industrial
truck.
▪ The crane or industrial truck must have a lifting force equal to or greater than the weight of the
temperature control unit. See the data sheet (from page 85 in section »Annex«) for the weight of
the temperature control unit.
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OPERATION MANUAL
2.1.1.2
Temperature control unit without lifting eyes
▪ Do not lift and transport the temperature control unit alone and without aids.
▪ Lift and transport the temperature control unit only with an industrial truck.
▪ The industrial truck must have a lifting force equal to or greater than the weight of the temperature control unit. See the data sheet (from page 85 in section »Annex«) for the weight of the
temperature control unit.
2.1.2
Positioning the temperature control unit
2.1.2.1
Temperature control unit with casters
▪ Do not use the casters for transportation to the place of installation. Observe page 22, section
»Lifting and transporting the temperature control unit« for the transport to the place of installation.
▪ Use the rollers only for positioning at the place of installation.
▪ Only ever move the temperature control unit on casters if the surface is level, without a gradient,
non-slip and stable.
▪ Do not move the temperature control unit alone.
▪ At least 2 persons are required to move the temperature control unit on casters. At least 5 persons are required to move the temperature control unit on casters if the total weight of the temperature control unit is over 1.5 tons.
▪ The parking brakes must be activated at the casters and/or the leveling feet (if any) must be unscrewed/activated before the temperature control unit is put into operation (see page 30, section
»Unscrewing/activating the leveling feet (if any)«).
2.1.2.2
Temperature control unit without casters
▪ An industrial truck must be used for positioning the temperature control unit.
▪ Do not move the temperature control unit alone.
▪ At least 2 persons are required to move the temperature control unit.
▪ The industrial truck must have a lifting force equal to or greater than the weight of the temperature control unit. See the data sheet (from page 85 in section »Annex«) for the weight of the
temperature control unit.
▪ The leveling feet (if any) must be unscrewed/activated before the temperature control unit is put
into operation (see page 30, section »Unscrewing/activating the leveling feet (if any)«).
2.2
Transportation lock
Commissioning with active transportation lock
DAMAGE TO THE TEMPERATURE CONTROL UNIT
 Check the position of the transportation locks.
 Prior to commissioning of the temperature control unit, bring the transportation locks of the
compressor into the operating position.
The temperature control units are listed in the table below are equipped with transportation locks
for the compressor. These transportation locks must be unlocked to commissioning the temperature
control unit or be reactivated during transport to another place of installation.
Special or temperature control unit variants may vary from those listed in the table. These temperature control units have a sticker next to the nameplate that indicates the type of transportation lock
used.
Overview of transportation locks
Temperature control units
Transportation lock
- All Unichiller table models
- Unichiller series: 0xxT(w)/(w) EO; 1xxT(w)/(w) EO; 2xxT(w)/(w) EO
without
- Unichiller series: 3xxT(w)/(w) EO; 4xxT(w)/(w) EO; 5xxT(w)/(w) EO
Type A
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OPERATION MANUAL
2.2.1
Chapter 2
Transportation lock Type A
Figures showing the
transportation lock
The transportation lock can not be reached in all temperature control units from below ([C] + [D]).
In this case, part of the cover panels must be removed and the transport lock released or engaged
from above ([A1] + [A2]). If the temperature control unit is water-cooled, the panel in the back
must be removed. In case of an air-cooled temperature control unit, the position of the transportation lock is located through the ventilating plate (perforated plate) so as to remove the appropriate panel.
To check the transportation lock, the cover panels must be removed from the temperature control
unit.
2.2.1.1
Releasing the transportation lock (operating position)
From below: >Hexagonal head bolts< [D] at the bottom of the temperature control unit, use a
socket wrench SW17 and turn it upward (counter-clockwise) and tighten it against the >weld nut<
[C] (hand-tight).
From top (after removing the panels): >Nut< [A2] must be turned upward, from above, with a socket wrench SW17 (counter-clockwise) and tightened against the >weld nut< [C] (hand-tight).
2.2.1.2
Tightening the transportation lock (transport position)
From below: >Hexagonal head bolts< [D] at the bottom of the temperature control unit, use a
socket wrench SW17 and turn it downwards (clockwise) and tighten it against both check nuts
(hand-tight).
From above (after removing the panels): >Nut< [A1] must be turned downward, from above, with a
socket wrench SW17 (clockwise) and tightened against the check nuts (hand-tight).
2.2.2
Transportation lock Type B
Picture of
transportation lock
Type B
Remove the side panel on the temperature control unit to loosen and tighten the transportation
locks.
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Chapter 2
OPERATION MANUAL
2.2.2.1
Releasing the transportation lock (operating position)
Loosen the >Self-locking nut< [A] until the >Slotted flat washer< [B] can be removed. Remove the
>Slotted flat washer< [B].
2.2.2.2
Tightening the transportation lock (transport position)
Insert a >Slotted flat washer< [B] under each >Self-locking nut< [A]. Tighten the >Self-locking nut<
[A] until the >Vibration damper< [C] is compressed by about 1 to 2 mm.
2.3
Unpacking
Starting up a damaged temperature control unit
MORTAL DANGER FROM ELECTRIC SHOCK
 Do not operate a damaged temperature control unit.
 Please contact the Customer Support. The telephone number can be found on page 84, section
»Contact data«.
PROCEDURE
 Check for damage to the packaging. Damage can indicate property damage to the temperature
control unit.
 Check for any transport damage when unpacking the temperature control unit.
 Always contact your forwarding agent regarding the settlement of claims.
 Follow the instructions on page 15, section »Proper disposal of resources and consumables« for
the disposal of packaging material.
2.4
Ambient conditions
Unsuitable ambient conditions/unsuitable installation
SERIOUS INJURY DUE TO CRUSHING
 Comply with the requirements under sections »Ambient conditions« and »Installation conditions«.
Make sure there is adequate fresh air available at the site for the circulation pump and the compressors. The warm exhaust air must be able to escape upwards unhindered.
Free-standing model
For the connection data, see the data sheet (from page 85 in section »Annex«).
Use of the temperature control unit is permitted only under normal ambient conditions in accordance with DIN EN 61010-1:2011:
▪ Use only indoors. The illuminance must be at least 300 lx.
▪ Installation altitude up to 2000 meters above sea level .
▪ Maintain wall and ceiling clearance for adequate air exchange (dissipation of waste heat, supply
of fresh air for the temperature control unit and work area). Ensure adequate floor clearance for
air-cooled temperature control units. Do not operate this temperature control unit from within
the box or with an inadequately dimensioned bath. This inhibits the exchange of air.
▪ Ambient temperature values are provided on the technical data sheet; compliance with the ambient conditions is mandatory, to ensure trouble-free operation.
▪ Relative humidity up to 32 °C max. 80% and decreasing linearly to 50% up to 40 °C.
▪ Short distance to supply connections.
▪ The temperature control unit must not be installed so as to hinder or prevent access to the isolator (to the power supply).
▪ Magnitude of the power supply fluctuations: see data sheet from page 85 in section »Annex«.
▪ Transient surges, as would normally occur in the power supply system
▪ Installation Class 3
▪ Applicable degree of soiling: 2.
▪ Surge category II.
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OPERATION MANUAL
Chapter 2
Observe page 20 of section »Exemplary illustrations of the cooling variants«.
Wall clearances
Clearance in cm (valid up to Unichiller 110T - air inlet on the right)
Air cooling
Water cooling
[A1] Top
free standing
free standing
[B] Left
min. 20
min. 10
[C] Right
min. 30
min. 20
[D] Front
min. 20
min. 10
[E] Rear
min. 20
min. 20
Side
Distance in cm (valid from Unichiller 130T - air inlet left, right and rear)
Air cooling
Water cooling
[A1] Top
free standing
free standing
[B] Left
min. 100
min. 20
[C] Right
min. 100
min. 20
[D] Front
min. 100
min. 20
[E] Rear
min. 100
min. 20
Side
2.4.1
EMC-specific notes
Connecting cables in general
Prerequisites for a failure-free operation of the temperature control units incl. their connections with
external applications: Installation and wiring must be carried out professionally. Topics affected: “Electrical safety“ and “EMC-compliant wiring“.
Cable lengths
For flexible/fixed cable routing longer than 3 meters, the following must amongst other things be observed:
- Equipotential bonding, grounding (see also technical data sheet “Electromagnetic compatibility EMC“)
- Compliance with “external“ and/or “internal“ lightning/overvoltage protection.
- Constructional protective measures, professional cable selection (UV resistance, steel pipe protection,
etc.)
Attention:
The operating company is responsible for compliance with national/international directives and laws.
This also includes the testing of the installation/wiring required by law or standards.
These devices are suitable for the operation in “industrial electromagnetic environments”. It meets
the “immunity requirements” of the currently applicable EN61326-1, which are required for this
environment.
It also meets the “interference emission requirements” for this environment. It is a Group 1 and
Class A unit according to the currently applicable EN55011.
Group 1 specifies that high frequency (HF) is only used for the function of a device. Class A specifies
the interference emission limits to be observed.
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2.5
OPERATION MANUAL
Installation conditions
Temperature control unit is connected to the power supply line
DEATH FROM ELECTRICAL SHOCK BY DAMAGE TO THE POWER CABLE.
 Do not put temperature control unit on power cable.
Operating the temperature control unit fitted with castors without brakes activated
CRUSHING OF LIMBS
 Activate brakes on the wheels.
▪ Allow the temperature control unit to acclimate for about 2 hours when changing from a cold to a
warm environment (or vice versa). Do not turn on the temperature control unit before!
▪ Install upright, stable and without tilt.
▪ Use a non-combustible, sealed subsurface.
▪ Keep environment clean: Prevent slip and trip hazards.
▪ Wheels must be locked after the installation, if installed!
▪ Spilled/leaked thermofluid must be disposed of immediately and properly. Follow the instructions
on page 15, section »Proper disposal of resources and consumables« for the disposal of thermofluid and material.
▪ Observe the floor load bearing capacity for large units.
▪ Observe the ambient conditions.
2.6
Recommended temperature control and cooling water hoses
Use of unsuitable/defective hoses and/or hose connections
INJURIES
 Thermal fluid
 Use appropriate hoses and/or hose connections.
 Check periodically for leaks and the quality of the hose and hose connections and take suitable
measures (replace) as required.
 Isolate and protect temperature control hoses against contact/mechanical load.
 Cooling water
 Reinforced hoses must be used to satisfy tougher safety requirements.
 Shut off the cooling water supply to the temperature control unit even for shorter downtimes
(e.g. overnight).
Hot or cold thermal fluid and surfaces
BURNS TO LIMBS
 Avoid direct contact with the thermal fluids or the surfaces.
 Wear your personnel protective equipment (e.g. temperature-resistant safety gloves, safety
goggles, safety footwear).
Uncontrolled formation of ice at the connections and hoses of the thermal fluid circuit
SLIP AND TRIP HAZARD
 If the temperature is controlled in the minus range, ice forms at the hoses and connections of
the thermal fluid circuit. This occurs by condensing and freezing of atmospheric humidity.
 Check the strength of the ice formation. If too much ice is formed, this increases the risk of the
temperature control unit tipping over. Secure the temperature control unit against tipping if
this is the case.
 Check the ground below the ice formation for condensation water. Collect the condensation
water with a suitable container or thoroughly remove it at regular intervals. You thus prevent
the danger of slipping caused by condensation.
To connect applications, use only temperature control hoses that are compatible with the thermal
fluid used. When selecting temperature control hoses, also pay attention to the temperature range
in which the hoses are to be used.
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OPERATION MANUAL
Chapter 2
▪ We recommend you use only temperature-insulated temperature control hoses with your temperature control unit. The responsible body is responsible for the insulation of connection valves.
▪ We exclusively recommend reinforced hoses for connecting to the cooling water supply. Cooling water
and insulated temperature control hoses can be found in the Huber catalogue under Accessories.
2.7
Wrench sizes and torques
Note the wrench sizes that result for the pump connection on the temperature control unit. The
following table lists the pump connections and the resulting wrench sizes, and torque values. A leak
test must always be performed, and the connections tightened if necessary. The values of the maximum torque (see table) must not be exceeded.
Overview
wrench sizes and
torques
Sleeve nut wrench
size
Connector wrench
size
Recommended
torques in Nm
Maximum torques
in Nm
M16x1
19
17
20
24
M24x1.5
27
27
47
56
36
32
79
93
36
36
79
93
46
46
130
153
Connection
M30x1.5
M38x1.5
G-thread (flatsealing)
2.8
Adapt the torque to the material of the flat seal used. First hand-tighten the temperature
control hose.
When using adapters, do not overtighten the G-thread on the pump connection when
connecting a temperature control hose. When connecting a temperature control hose to
the adapter piece, secure the G thread against overwinding.
Temperature control units with water cooling
Open electrical wires below the temperature control unit if the temperature falls below the dew point.
DEATH FROM ELECTRICAL SHOCK BY WATER ENTRY INTO THE ELECTRIC LINES.
 A temperature below the dew point may result in condensation in the temperature control unit
and at the cooling water connections. The condensation is caused by high humidity at the cooling water-bearing components. The condensation exists the temperature control unit at the
bottom.
 Electrical lines directly below the temperature control unit must be protected against liquid
ingress.
Use of unsuitable/defective hoses and/or hose connections
INJURIES
 Thermal fluid
 Use appropriate hoses and/or hose connections.
 Check periodically for leaks and the quality of the hose and hose connections and take suitable
measures (replace) as required.
 Isolate and protect temperature control hoses against contact/mechanical load.
 Cooling water
 Reinforced hoses must be used to satisfy tougher safety requirements.
 Shut off the cooling water supply to the temperature control unit even for shorter downtimes
(e.g. overnight).
No protection against corrosion
DAMAGE TO THE TEMPERATURE CONTROL UNIT
 The addition of anti-corrosion agents is mandatory if salts (chlorides, bromide) have been
added to the water circuit.
 Ensure that the materials used in the cooling water circuit are resistant with respect to the
cooling water. See the data sheet from page 85 in section »Annex« for information on the materials used.
 Take suitable measures to maintain the warranty conditions.
 For information about water quality, see www.huber-online.com.
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OPERATION MANUAL
Usage of un-filtered river/sea or ocean water as cooling water
DAMAGE TO THE TEMPERATURE CONTROL UNIT
 Un-filtered river or sea water is not suitable for use as cooling water due to its contaminants.
 Use drinking water or filtered river or sea water for cooling.
 Sea water must not be used for water cooling.
 For information about water quality, see www.huber-online.com.
To minimize cooling water consumption, Huber temperature control units with water cooling are
equipped with a cooling water regulator. It limits the flow of cooling water to the amount required
by the current load situation. If only a low cooling capacity is requested, only a small amount of
cooling water is consumed. It cannot be ruled out that cooling water flows when the machine is
switched off. Shut off the cooling water supply to the temperature control unit even for shorter
downtimes (e.g. overnight).
Connection diagram
Preparing the temperature control unit with water cooling:
In the event of outdoor installation, the operating company must ensure that the cooling water
supply and return lines are laid frost-protected. The cooling water temperature must not fall below
3 °C. At ambient temperatures below 3 °C, the cooling water supply must be heated.
The minimum pressure differential in the cooling water circuit and the recommended cooling
water inlet temperature can be found on the data sheet (from page 85 in Section »Annex«).
The illustration “connection diagram” can be found on page 85 in section »Annex«.
PROCEDURE
 Close (if fitted) the >Cooling water drain< [15].
 Connect the >Cooling water outlet< [14] to the water return flow. A seal must be used.
 Connect the >Cooling water inlet< [13] to the water supply. A seal must be used.
Leaking cooling water connections
DAMAGE BY ROOM FLOODING
 Slowly open the building-side shut-off valves of the cooling water supply and return line.
 If water leaks from the cooling water connections: shut off the cooling water supply and return
line immediately.
 Provide leakproof cooling water connections.
 Open the shut-off valves in the water line on the temperature control unit and on the building
side.
 Check the connections for leaks.
2.9
Temperature control unit for outdoor installation incl. winter
operation
Shut down temperature control unit with water cooling in outdoor operation
MECHANICAL DAMAGE CAUSED BY WATER FREEZING IN THE COOLING WATER LINE
 Leave the temperature control unit permanently enabled.
 Only turn off the temperature control unit permanently if the temperature control unit was
separated from the cooling water circuit and discharged at ambient temperatures below freezing point.
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Chapter 2
Switched off temperature control unit installed outdoors with water as thermal fluid
MECHANICAL DAMAGE CAUSED BY WATER FREEZING IN THE TEMPERATURE CONTROL UNIT
 The temperature control process must be permanently switched on.
 Only switch off the temperature control unit permanently at ambient temperatures below the
freezing point if the temperature control unit was completely discharged.
At temperatures below dew point, the temperature control unit is turned off and on again.
MATERIAL DAMAGE CAUSED BY SHORT CIRCUITS AS A RESULT OF CONDENSATION IN THE ELECTRICAL CABINET
 At ambient temperatures below dew point, leave the temperature control unit permanently
turned on.
 If the temperature control unit is turned off at ambient temperatures below dew point: Check
the interior of the electrical cabinet for condensation formation. Turn on the temperature control unit only after the condensate was removed.
The temperature control unit is switched on with a snow load on the unit or an ice-covered fan
DAMAGE TO THE TEMPERATURE CONTROL UNIT
 Do not switch on the temperature control unit with a snow load on the unit or an ice-covered
fan.
 Remove the snow from the unit before switching on the temperature control unit.
 Check the fan for freedom of movement before switching on the temperature control unit.
A heater and a fan are installed in the electrical cabinet of the temperature control unit for outdoor installation. This will prevent the formation of condensation in the electrical cabinet. If the
temperature control unit is turned off at an ambient temperature below dew point, the temperature difference between electrical cabinet and surrounding area cannot be compensated by the
heater/fan. This results in the formation of condensation inside the electrical cabinet. A short
circuit occurs in the electrical cabinet if the temperature control unit is then turned on again.
Applicable for models designed for winter operation and outdoor installations!
To operate the temperature control unit within a laboratory or office, the temperature control unit
is equipped with a remote control option. On the side of the temperature control unit is an opening
for the extension cable between “Unistat Control ONE” and “Pilot ONE”. Likewise, lines for the optional Com.G@te, external temperature sensor, etc. can be routed through this opening.
The responsible body must install a drip tray below the temperature control unit. The responsible
body must check whether national regulations require the mandatory installation of a drain tray for
the installation area of the temperature control unit/the entire system.
2.10
Preparations for operation
2.10.1
Unscrewing/activating the leveling feet (if any)
The leveling feet are not unscrewed/activated before switching on the temperature control unit
DEATH OR SERIOUS INJURY DUE TO CRUSHING
 The parking brakes must be activated at the casters (if any) and/or the leveling feet must be
unscrewed/activated before the temperature control unit is put into operation.
 The temperature control unit may move if the parking brakes of the casters (if any) are not
activated and/or the leveling feet are not unscrewed/activated.
Always unscrew/activate the leveling feet before switching on the temperature control unit.
Uneven floors can be compensated by adjusting these leveling feet.
PROCEDURE
 Verify that the parking brakes of the casters (if any) have been activated.
 Unscrew the leveling feet.
 Compensate uneven floors by adjusting these leveling feet, if necessary. Use a spirit level to
horizontally align the temperature control unit.
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OPERATION MANUAL
 Tighten the lock screws on the leveling feet after aligning the temperature control unit. This
prevents the leveling feet from changing their height during operation.
2.10.2
Opening/closing valves
Opening and closing
valves
Opening valves:
Open valves by turning them counterclockwise (turn 90° left as far as it will go).
Close valves:
close valves by turning them clockwise (turn 90° right as far as it will go).
PROCEDURE
 Check that all valves are closed.
 Close all valves by turning them clockwise (turn 90° right as far as it will go).
2.10.3
Emergency stop switch (optional): Check switching status
Exemplary layout of
the switches
PROCEDURE
 Check the >Emergency stop switch< [70].
This switch must not be pressed (activated) when taking the temperature control unit into operation.
 If required, release the >Emergency stop switch< [70] by turning it clockwise. A built-in spring in
the >Emergency stop switch< [70] returns it to its original state.
2.11
Connecting externally closed application
The illustration “connection diagram” can be found on page 85 in section »Annex«.
2.11.1
Connecting an externally closed application
Overpressure in the application (e.g. > 0.5 bar (g) with glass apparatus)
MATERIAL DAMAGE TO THE APPLICATION
 Provide an overpressure protective device to prevent damage to the application.
 Do not install valves/quick-release couplings in the feed/discharge lines from the temperature
control unit to the application and from the application to the temperature control unit.
 If valves/quick-release couplings are required:
 Install burst disks on the application itself (at the feed and discharge lines).
 Install a bypass upstream of the valves/quick-release couplings for the application.
 Matching accessories (e.g. bypasses to reduce pressure) can be found in the Huber catalog.
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Chapter 2
Example: Connecting
an externally closed
application
To enable your application to be operated correctly and eliminate air bubbles from the system, you
must ensure that the >Circulation flow< [1] connection from the temperature control unit is attached to the lower connection point of the application and the >Circulation return< [2] into the
temperature control unit is attached to the higher connection point of the application.
PROCEDURE
 Remove the screw plugs from the >Circulation flow< [1] and >Circulation return< [2] connections.
 Then connect your application to the temperature control unit using suitable thermal fluid hoses.
The corresponding wrench sizes can be found in the table on page 28 in section »Wrench sizes
and torques«.
 Check the connections for leaks.
2.12
Connecting to the power supply
Based on local circumstances, it may be that you need to use an alternative power cable instead of
the supplied original power cable. Have the mains cable only installed by a qualified electrician.
2.12.1
Connection using socket with protective earth (PE)
Connecting to a power socket without protective earth (PE)
MORTAL DANGER FROM ELECTRIC SHOCK
 Always connect the temperature control unit to safety sockets (PE).
Damaged power cable/power cable connection
MORTAL DANGER FROM ELECTRIC SHOCK
 Do not start up the temperature control unit.
 Isolate the temperature control unit from the power supply.
 Have the power supply cable/power supply connection replaced and inspected by an electrician.
Incorrect power supply connection
DAMAGE TO THE TEMPERATURE CONTROL UNIT
 Your building's existing power supply voltage and frequency must match the data provided on
the rating plate of the temperature control unit.
In case of uncertainties about an existing protective earth (PE), have the connection inspected by
an electrician.
2.12.2
Connection via hard wiring
Connection/adjustment to the power supply not carried out by an electrician
MORTAL DANGER FROM ELECTRIC SHOCK
 Have the connection/adjustment to the power supply carried out by an electrician.
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Damaged power cable/power cable connection
MORTAL DANGER FROM ELECTRIC SHOCK
 Do not start up the temperature control unit.
 Isolate the temperature control unit from the power supply.
 Have the power supply cable/power supply connection replaced and inspected by an electrician.
Incorrect power supply connection
DAMAGE TO THE TEMPERATURE CONTROL UNIT
 Your building's existing power supply voltage and frequency must match the data provided on
the rating plate of the temperature control unit.
2.12.3
Connecting the functional earth
PROCEDURE
 If required, connect the temperature control unit’s >Functional earth terminal< [87] to the
building’s grounding point. Use a ground strap for this purpose. For the exact position and thread
size please refer to the wiring diagram from page 85 in Section »Annex«.
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Function description
OPERATION MANUAL
Chapter 3
3
Function description
3.1
Function description of the temperature control unit
3.1.1
General functions
This temperature control unit is designed for externally closed applications. This controller generation is characterized by the fact that there is only a single hardware. For a license fee you will receive an activation key, which allows you to quickly expand the functionality of e.g. a simple temperature control unit (basic version) to its maximum functionality (professional version) at any time.
Thanks to the low internal volume and the efficient refrigeration technology, you will achieve
relatively short cooling rates.
3.1.2
Other functions
The self-optimizing cascade control delivers optimal controller results for regulating levels up and
down, both with setpoint changes and also with exothermic reactions. Temperature control can be
either a-periodic or with a slight overshoot (faster).
Your temperature control unit can be easily integrated into many laboratory automation systems.
This is provided for by the existing standard interfaces Ethernet, USB device and USB host at the
"Pilot ONE” as well as the interfaces Pt100 and RS232 at the Unichiller. The optional Com.G@te
allows you to expand your temperature control unit by digital interfaces (RS232 and RS485), an
analogue current loop interface (0/4 - 20 mA or 0 - 10 V) and various digital control options
(In/Out).
The removable control panel (“Pilot ONE”) can also be used as a remote control. Please contact
your dealer or Huber Sales Department if you need an extension cable. The telephone number of
the Huber Sales Department can be found on page 84 in Section »Contact data«.
A connection jack for Pt100 process controller sensor enables you to accomplish external temperature control tasks with ease (requires E-grade Exclusiv or Professional).
The temperature control unit can be retrofitted with an integrated temperature ramp function and
an internal temperature programmer via an “E-grade” upgrade. The “E-grade” upgrade “Exclusiv”
enables you to set and call 3 temperature control programs with 5 program steps each by using the
integrated programmer. The “E-grade” upgrade “Professional” enables you to set and call 10 temperature control programs with a total of 100 program steps by using the integrated programmer.
The temperature control unit has overtemperature protection to DIN EN 61010-2-010, independent of the control circuit itself (valid for temperature control units with heater).
Only valid for temperature control units with an emergency stop switch (optional):
By installing an >Emergency stop switch< [70], an additional protective device has been installed in
the temperature control unit. When the >Emergency stop switch< [70] is pressed (activated), all
poles of the temperature control unit are immediately disconnected.
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Chapter 3
3.2
OPERATION MANUAL
Information on the thermal fluids
Non-compliance with the safety data sheet for the thermal fluid to be used
INJURIES
 Risk of injury to the eyes, skin, respiratory tract.
 The safety data sheet for the thermal fluid to be used must be read prior to using it and its
content must be respected.
 Observe the local regulations/work instructions.
 Wear your personal protective equipment (e.g. temperature-resistant safety gloves, safety
goggles, safety footwear).
 Danger of slipping because floor and work area are contaminated. Clean the work station and
follow the instructions for the disposal of thermal fluid and material on page 15 in Section
»Proper disposal of resources and consumables«.
Non-compliance with the compatibility between the thermal fluid and your temperature control
unit
MATERIAL DAMAGE
 Observe the classification of your temperature control unit according to DIN 12876.
 Ensure the following materials are resistant with respect to the thermal fluid: Stainless steel
1.4301 (V2A)/1.4401 (V4A), copper, nickel, HNBR (Unichiller 017 to Unichiller 045), EPDM (from
Unichiller 055), red bronze/brass and silver solder.
 The maximum viscosity of the thermal fluid must not exceed 50 mm²/s at the lowest working
temperature!
 The maximum density of the thermal fluid may not exceed 1 kg/dm³!
Mixing different thermofluids in a thermal fluid circuit
PROPERTY DAMAGE
 Do not mix different types of thermofluid (such as mineral oil, silicone oil, synthetic oil, water,
etc.) in a thermofluid circuit.
 The thermal fluid circuit must be rinsed when changing from one type of thermal fluid to another. No residues of the previous type of thermal fluid may remain in the thermal fluid circuit.
Thermal fluid: Water
Designation
Specification
Calcium carbonate per liter
≤ 1.5 mmol/l; corresponds to a water hardness of: ≤ 8.4 °dH (soft)
PH value
between 6.0 and 8.5
Ultrapure water, distillates
Add 0.1 g of sodium carbonate (Na2CO3) per liter
Not approved water
Distilled, deionized, demineralized, chloric, ferruginous, ammoniacal, or
contaminated river water or sea water
Thermal fluid: Water without ethylene glycol
Operation without freeze protection*
do not use
Operation with freeze protection*
Please refer to the specifications in the data sheet in »Annex«. Additional
information on freeze protection is provided on page 59 in Section »Freeze
protection for temperature control unit (optional)«.
Thermal fluid: Water-ethylene glycol mixture
Thermal fluid composition
The mixture’s temperature must be 10 K below the permissible min. temperature. For the permissible temperature range, refer to the datasheet
from page 85 in Section »Annex«.
To find out whether your temperature control unit is equipped with a freeze protection, refer to the datasheet in
»Annex«.
We recommend the ethylene glycols listed in the Huber catalogue.
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Function description
OPERATION MANUAL
3.3
Chapter 3
To be noted when planning the test
Also observe page 13 in section »Proper operation«.
The focus is on your application. Bear in mind that system performance is influenced by heat transfer, temperature, thermal fluid viscosity, volume flow, and flow speed.
▪ Make sure that the electrical connection is adequately dimensioned.
▪ The installation location of the temperature control unit should be selected so as to ensure adequate fresh air, even with water-cooled chillers.
▪ The maximum forward flow pressure of a temperature control unit must be taken into account in
case of pressure-sensitive applications, such as glass reactors.
▪ Cross-section reduction or shut-off in the thermal fluid circuit must be avoided. Take corresponding measures to limit the pressure in the system; see data sheet from page 85 in the section
»Annex« and the data sheet for your glass apparatus.
▪ Check whether it is necessary to use an external bypass for temperature control units without
pressure limitation.
▪ In order to prevent the risk of overpressure in the system, the thermal fluid must always be adjusted to room temperature before switching off. This will prevent damage to the temperature
control unit or the application. Any isolating valves must remain open (pressure equalization).
▪ The temperature and the dynamics of the process are determined by the flow temperature. A
differential temperature (Delta T) forms between flow temperature and process temperature.
This temperature difference may have to be limited, because Delta T might exceed limits of the
application (glass apparatus) and cause bursting. Adjust the Delta T value to your application.
▪ Select the thermofluid to be used in such a way that it not only permits the minimum and maximum working temperature but is also suitable with regard to combustion point, boiling point, and
viscosity. In addition, the thermofluid must be compatible with all the materials in your system.
▪ Avoid bending the temperature control and cooling water hoses (if required). Use suitable angle
pieces and lay the hose connections with a large radius. Take the minimum bending radius from
the data sheet of the temperature control hoses used.
▪ The selected hose connections must be able to withstand the thermal fluid, the working temperatures and the admissible maximum pressure.
▪ Check the hoses at regular intervals for any material fatigue (e.g. cracks, leaks).
▪ Keep the temperature control hoses as short as possible
- The inside diameters of the temperature control hoses must correspond at least to the
pump connections. Select bigger inside diameters for longer line lengths to compensate
for pressure loss in the piping.
- The viscosity of the thermal fluid determines the pressure drop and influences the temperature control result, especially at low working temperatures.
- Too small connectors and couplers and valves can generate significant flow resistance.
Your application will therefore be slower to reach its design temperature.
▪ Basically, you should only use the thermofluid recommended by the manufacturer and only within the usable temperature and pressure range.
▪ The application should be roughly at the same height of or below the temperature control unit if
the thermoregulation is close to the boiling temperature of the thermofluid.
▪ Fill the temperature control unit slowly, carefully and evenly. Wear the necessary personal protective equipment, such as goggles, heat-proof and chemical-resistant gloves, etc.
▪ The temperature control circuit must be vented after filling and setting all required parameters.
This is required to ensure trouble-free operation of the temperature control unit and hence your
application.
For water-cooled temperature control units, please take the cooling water temperature necessary
for perfect operation and the required differential pressure from the data sheet from page 85
onward in the Section »Annex«.
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Chapter 3
3.4
OPERATION MANUAL
“Pilot ONE®” controller
The figure showing »“Pilot ONE”« can be found on page 6.
The basic version of “Pilot ONE” (Basic) can be upgraded in three stages (from “Basic” to “Exclusive”,
from “Exclusive” to “Professional”, and from “Professional” to “Explore”).
3.4.1
Functional overview of “Pilot ONE®”
You can verify, and optionally upgrade, the delivery version of your temperature control unit using
Pilot ONE, category “E-grade”.
Overview of the
E-grade variants
E-grade
Basic
E-grade
Exclusive
E-grade
Professional
Brewing thermostats
–
X
O
Unistat temperature control units
–
–
X
UniCAL
–
–
X
Other temperature control units
X
O
O
E-grade “Explore” (only for “Unistat”-series temperature control units)
The E-grade includes E-grade “Professional” functionalities.
In addition it includes:
– Sensor calibration for return sensor
– Return temperature display
– Display of performance (estimated or calculated from volume flow)
– Display mode “Explore” instead of “numerically large”
– PB commands correspond to DV-E-grade, except: Temperatures only
in 0.01 °C and volume flows only in 0.1 l/min.
–
–
O
E-grade “DV-E-grade”
– All interface commands are enabled.
– Temperatures in 0.001 C, volume flows in 0.001 l/min possible (cf. Egrade Explore)
Note: Only the interface commands are enabled, not the corresponding menu items in Pilot ONE!
O
O
O
E-grade “OPC-UA”
– OPC-UA interface via Ethernet.
This E-grade additionally includes DV-E-grade functionalities.
O
O
O
E-grade
Basic
E-grade
Exclusive
E-grade
Professional
X/–
–/X
–/X
–/–/X
X/X/–
X/X/–
2
5
5
X
X
X
X
X
X
X
X
X
Temperature control units / E-grade
X = Standard equipment, O = optional, – = not possible
Overview of
E-grade functions
Function
Temperature control
1
Controller parameterization: predefined / TAC
2
Find parameters: Fast Identification / With Preliminary Test / Estimate
Control Parameters
3
Sensor calibration for control sensor : x -point
Monitoring: Low level and overtemperature
Adjustable alarm thresholds
1
VPC (Variable Pressure Control)
4
1
TAC function available as a 30 day evaluation version.
True Adaptive Control.
3
Internal Pt100 and External Pt100.
4
For temperature control units with integrated overtemperature protection.
2
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Chapter 3
E-grade
Basic
E-grade
Exclusive
E-grade
Professional
Ventilation program
X
X
X
Automated compressor
X
X
X
Setpoint limitation
X
X
X
Program controller: x programs / max x steps
–/–
3/15
10/100
Ramp function: linear / non-linear
–/–
X/–
X/X
Temperature control mode: Internal and process
–
X
X
Adjustable max. heating and cooling capacity
–
X
X
X
X
X
Display mode: graphically / numerically large / Explore
–/X/–
–/X/–
X/X/–
Display resolution: 0.1 °C / 0.01 °C
X/–
X/X
X/X
Graphic display for temperature curves: Window, full screen and
scalable
X
X
X
Calendar, date and time
X
X
X
Language: CZ, DE, EN, ES, FR, IT, JP, KO, PL, PT, RU, TR, ZH
X
X
X
Temperature format switchable: °C, °F and K
X
X
X
Display mode (screen) can be switched by swiping
X
X
X
Favorites menu
X
X
X
User menu (Administrator Level)
–
–
X
2. Setpoint
–
–
X
Digital interface RS232
X
X
X
USB interfaces: Host und Device
X
X
X
Ethernet RJ45 interface
X
X
X
Pt100 external sensor connection
–
X
X
X
X
X
X
X
X
5
X
X
X
X
X
Visual / audible alarm signal
X
X
X
Autostart (Power Failure Auto)
X
X
X
Plug & Play technology
X
X
X
Technology glossary
X
X
X
Function
Display & operation
Temperature display: 5.7" Touchscreen
Connections
2
External control signal (ECS STANDBY )
3
Programmable potential-free contact (ALARM )
AIF (Analog Interface) 0/4–20 mA or 0–10 V
Digital interface RS485
6
4
X
Comfort & other
1
For units with variable-speed pump or external bypass.
Standard on Unistats, otherwise via optional Com.G@te or POKO/ECS interface.
3
Standard on Unistats, otherwise via optional Com.G@te or POKO/ECS interface.
4
Via optional Com.G@te.
5
Restricted, see entries under “Temperature Control”.
6
Via optional Com.G@te.
2
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OPERATION MANUAL
E-grade
Basic
E-grade
Exclusive
E-grade
Professional
Remote control / data visualization via Spy software
X
X
X
E-grade evaluation versions available (valid for 30 days)
X
X
X
Storage/loading temperature control programs onto USB stick
–
X
X
Copying settings
–
–
X
Service data recorders (flight recorder)
X
X
X
X
X
X
–
–
X
–/–/–
X/X/–
X/X/X
–
–
X
Function
PB commands
1
Communication Watchdog
Process data recording directly to a USB stick: Setpoint, Actual Value
Internal and Actual Value Process / Heating Capacity %, Cooling Capacity %, and Pump Pressure / Pump Speed, and VPC Pressure
Calendar start
3.5
Clock/event function
3.5.1
Rechargeable accumulator
“Pilot ONE” is fitted with a clock that continues to run even when the temperature control unit is
switched off. The energy required for this purpose is provided by a rechargeable accumulator, which
is automatically charged when the temperature control unit is switched on. The accumulator is
dimensioned so that the clock can also continue to run for prolonged switch-off intervals (up to
several months). If, after extremely prolonged switch-off time, time and date have been deleted,
leaving the temperature control unit switched on for a few hours will usually suffice (no temperature control required). During this time, you can reset the time and date.
If after switching the unit off and back on again, the previously set time and date re-appear, it can be
safely assumed that the rechargeable accumulator is defective. In this case, contact Customer Support. The telephone number can be found on page 84 in section »Contact data«.
3.5.2
Programmable event function
The “Calendar Start” offers a programmable event function. This enables you to enter a time at
which the event is repeatedly triggered on a daily basis (until the activity in the menu is reset). 2
event types are currently selectable:
3.5.2.1
Event function “Alarm clock event”
Several acoustic signals are used.
3.5.2.2
Event function “Program event”
After selecting “Program event” when configuring the event function, you will be prompted for the
number of the program to be started. The program will be started automatically when the programmed event time is reached. If the temperature control unit is not active, this will also be started.
1
See Data Communication Manual. Anything controllable via the graphical user interface of the Pilot
ONE can be controlled by PB commands.
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3.6
Chapter 3
Operation via the touch screen
The entire operation is via the >Touchscreen< [88]. These functions can be activated by tapping the
displayed text boxes/icons once. This also changes the display.
You can cancel the current dialog or dialog sequence at any time by pressing the “ESC” touch
button. When canceling a dialog or dialog sequence, it may be necessary to confirm the cancellation again. When canceling a dialog sequence, settings made earlier in the dialog sequence are
discarded. Check your already carried out settings and re-enter as needed.
3.7
Display instruments
Display instruments
The following meters are available:
▪ >Touchscreen< [88]
3.7.1
The touchscreen [88]
The most important display and operating instrument. Shows both standard variables (setpoint,
actual value, setpoint thresholds...), and also menu guidance, error information output and operation.
3.8
Control instruments
Example “Control
instruments”
To exit the “Categories Menu”, sub-categories, menu items, press the “Home” touch button
(house) or the arrow. After 2 minutes of inactivity, the category/ sub-category or the Favourites
menu is automatically closed and you return to the “Home” screen. Dialogs are not canceled/closed after 2 minutes of inactivity.
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3.8.1
OPERATION MANUAL
The touchbuttons
Depending on the situation, the touch buttons can be assigned different functions. For example:
▪ Select the “Home” screen (house)
▪ Back (arrow to left)
▪ Favourites (star)
▪ Add to favorites (star with a plus sign)
▪ Select the “Categories menu” (menu)
▪ Confirm entry
▪ Start/stop
etc.
3.8.2
The categories
For clarity we have grouped the Operation and Setting of Pilot ONE in various categories. A category
is selected by tapping it.
3.8.3
The sub-categories
The sub-categories are parts of a category. This is where you will find the entries that we have
grouped together for you in the selected category. Not all the categories also contain subcategories. Tap on a sub-category to select it.
3.8.4
The dialogs
Tapping on a category or sub-category displays its dialogs. Dialogues may appear e.g. as text, a
numeric or a alphanumeric keyboard. Dialogs allow you for example to enter settings or start created temperature control programs. Within a dialog, selection must always be confirmed with the
“OK” touch button. When cancelling a dialog with the “ESC” touch button it may be necessary to
confirm the cancellation again.
3.9
Function examples
3.9.1
Display of software version
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “System Settings”.
 Tap on the category “System Info”.
 Tap on the sub-category “Software Version”.
The software versions of the electronics will be displayed:
Display of
software versions
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 Tap either the “ESC” or “OK” touchbutton. You will be returned to the previous screen.
 Tap on the “Home” touchbutton (house) to return to the “Home” screen.
3.9.2
Start & Stop
How to start and stop the temperature control process. Prerequisites: You have entered a setpoint.
PROCEDURE
 Go to the “Home” screen.
Start
 Tap on the “Start” touchbutton.
 Confirm the start of temperature control by tapping on “OK”.
The correct selection will be displayed graphically and temperature control will start immediately. If tapping on “OK” is not correct, this is displayed graphically for 2 seconds. After this, the display will return to the “Home” screen again. Try to start the temperature control unit again.
Stop
 Tap on the “Stop” touchbutton.
 Confirm the stop of temperature control by tapping on “OK”.
The correct selection will be displayed graphically and temperature control will stop immediately
and the pump with overrun for about 30 seconds. Wait until the pump stops. If tapping on “OK”
is not correct, this is displayed graphically for 2 seconds. After this, the display will return to the
“Home” screen again. Try to stop the temperature control unit again.
With the “Stop” touchbutton, you can also stop Degassing, Venting and Circulation. The requirement for this is that the corresponding task is active.
3.9.3
Copying the settings to a data carrier
Only valid for E-grade Professional
The current settings of the temperature control unit are saved as a file to a connected USB flash
drive. Use this file to restore the settings of a temperature control unit or to copy them to another
temperature control unit. The models of the temperature control units used must be identical to
copy the settings between temperature control units. You cannot transfer data between different
models.
You can also transfer the set value of the overtemperature protection to another temperature control unit. You must always verify this value on the respective temperature control unit and adjust it
if necessary. Make sure that the value of the overtemperature protection has been adapted to the
thermal fluid used.
3.9.3.1
Saving to a USB flash drive
PROCEDURE
 Insert a USB flash drive into the “USB 2.0 interface host”. The USB flash drive must have at least
1 MB of free space.
 Go to the “Categories Menu”.
 Tap on the category “System Settings”.
 Tap on the category “Copy Settings”.
 Tap on the dialog entry “Save to USB flash drive”.
 Confirm your choice by tapping on “OK”. The content of the USB flash drive is displayed. If necessary, select the location (folder) on the USB flash drive.
 Confirm the selection of the memory location by tapping on “OK”.
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 Enter a name for the file to be saved. Confirm the entry by tapping on “OK”. Alternatively, you
can accept the proposed name by tapping on “OK”.
 Read the message and confirm by tapping on “OK”. The file with the settings was created on the
USB flash drive.
 Remove the USB flash drive from the temperature control unit.
3.9.3.2
Loading from a USB flash drive
PROCEDURE
 Insert a USB flash drive with the saved file into the “USB 2.0 interface host”.
 Go to the “Categories Menu”.
 Tap on the category “System Settings”.
 Tap on the category “Copy Settings”.
 Tap on the dialog entry “Load from USB flash drive”.
 Confirm your choice by tapping on “OK”. The content of the USB flash drive is displayed.
 Select the file you want to load.
 Confirm the selection of the file by tapping on “OK”.
 Select the setting group to be loaded from the list. A multiple selection is possible.
 Confirm your choice by tapping on “OK”.
 Read the message on the >Touchscreen< [88].
 Switch off the temperature control unit. The settings have been loaded to the temperature
control unit.
 Remove the USB flash drive from the temperature control unit.
3.9.4
Restore factory settings
Use this function to reset the temperature control unit to various basic states. This is useful if you
want to reverse various settings relatively quickly.
Restoring the factory settings is only possible if the temperature control unit is not carrying out a
task. If a task is active, do not switch off the temperature control unit until the application allows
this. Restoring the factory settings cannot be revoked. Depending on the type of resetting to factory settings performed you may have to enter parameters (process safety, thermal fluid used, cutout value etc.) again.
“X” = Value is reset, “–” = Value is not reset
(A) = All together; (B) = Device parameters without OT; (C) = Device Parameter; (D) Program Controller; (E) = Menu; (F) = Com.G@te
Description
(A)
(B)
(C)
(D)
(E)
(F)
Acoustics
X
X
X
–
–
–
Display functions
Warnings; Messages; Inactive Menu Items; Resolution Temperature
X
X
X
–
–
–
Display modes
X
X
X
–
–
–
AutoStart response
X
X
X
–
–
–
Limitations
DeltaT limit; max. heating variable; max. cooling variable; max. permissible current consumption (for 230 V temperature control units)
X
X
X
–
–
–
Meaning of AIF input; response on cable break; measurement range
setting
X
X
X
–
–
X
Calibration
–
–
–
–
–
X
In case of analog error; current / voltage switching; filter constant
X
X
X
–
–
X
Configuration Output
AIF output variable; Output range setting
X
X
X
–
–
X
Com.G@te (only if Com.G@te is connected)
Analog Interface (configuration input)
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Description
(A)
(B)
(C)
(D)
(E)
(F)
Calibration
–
–
–
–
–
X
RS232/RS485 (Hardware RS, Baud rate, device address); ECS Standby;
POKO Alarm
X
X
X
–
–
–
Properties (other)
Change thermal fluid (thermal fluid, liter indicator, bypass usage);
cooling bath / cooling (CC-E only)
X
X
X
–
–
–
Sensor calibration
–
–
–
–
–
–
Automated compressor
X
X
X
–
–
–
Enter program
X
–
–
X
–
–
Pump settings
Pump speed setpoint; Pump pressure setpoint; Control Mode
X
X
X
–
–
–
Fluid properties
Thermal fluid; liter indicator
X
X
X
–
–
–
Protective function
High Limit Alarm Internal; Low Limit Alarm Internal; High Limit Alarm
Process; Low Limit Alarm Process; Hydrostatic Correction; Warning
Time Limit (CC-E only); Min. Level (for temperature control units with
analogue level sensor); Max. Level (for temperature controllers with
analogue level sensor); Freeze Protection (optional)
X
X
X
–
–
–
Setpoint
X
X
X
–
–
–
Setpoint limitation
Min. Setpoint; Max. Setpoint
X
X
X
–
–
–
Language
X
X
X
–
–
–
Temperature format
X
X
X
–
–
–
Temperature control mode
X
X
X
–
–
–
Favourites menu
X
–
–
–
X
–
Pilot ONE Ethernet
IP address; Subnet Mask; Remote Access
X
X
X
–
–
–
Time format
X
X
X
–
–
–
2. Setpoint
X
X
X
–
–
–
Configuration manual parameters
3.9.4.1
Restore to factory settings without overtemperature protection
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “System Settings”.
 Tap on the category “Factory Settings”.
 Choose between the dialog entries “Unit Control Data without OT”, “Menu”, “Programmer” and
“Com.G@te”. These entries do not restore the overtemperature protection. Tap on the required
dialog entry.
 Tap on the “OK” touchbutton to confirm your choice.
 Read the message displayed. Tapping on “Yes” restores the factory settings, tapping on “No”
cancels the procedure. The message “Restart system!” appears on the >Touchscreen< [88].
 Switch the temperature control unit off. The selected control data have been reset.
3.9.4.2
Restore to factory settings including overtemperature protection
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “System Settings”.
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 Tap on the category “Factory Settings”.
 Choose between the dialog entries “Unit Control Data” and “All together”. These entries also
reset the overtemperature protection. Tap on the required dialog entry.
 Tap on the “OK” touchbutton to confirm your choice.
 Read the message displayed. Tapping on “Yes” restores the factory settings, tapping on “No”
cancels the procedure.
In the following dialog, enter the overtemperature protection suitable to the thermal fluid used.
To reset the cut-out values of the overtemperature protection to the factory setting from within
the controller of Pilot ONE, enter for “Heater” 35 °C and for the expansion vessel 45 °C. “Process
Safety” is factory set to “Stop” and is automatically reset to “Stop” when restoring the factory
settings.
 Enter the temperature unit you want to use with Pilot ONE. The available choices are “Celsius
(°C)”, “Kelvin (K)” and “Fahrenheit (°F)”.
 Confirm your choice by tapping on “OK”.
 Read the message and confirm by tapping on “OK”.
 Read the safety warning and confirm by tapping on “OK”.
 Read the Note and confirm by tapping on “OK”.
 Tap on the temperature format set by you in the controller (green text).
 Enter the displayed red safety code using the numeric keypad that appears.
 Enter the value 35 °C for the “Heating OT value” using the numeric keypad that appears.
 Confirm your entry by tapping on “OK”.
 Read the message and confirm by tapping on “OK”.
 Read the safety warning and confirm by tapping on “OK”.
 Tap on the temperature format set by you in the controller (green text).
 Enter the displayed red safety code using the numeric keypad that appears.
 Enter the value 45 °C for the “Exp. vessel OT value” using the numeric keypad that appears.
 Confirm your entry by tapping on “OK”. The message “Restart system!” appears on the
>Touchscreen< [88].
 Switch off the temperature control unit. The temperature control unit is reset.
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OPERATION MANUAL
Chapter 4
4
Setup mode
4.1
Setup mode
Moving the temperature control unit during operation
SERIOUS BURNS/FREEZING OF THE HOUSING PARTS/ESCAPING THERMAL FLUID
 Do not move temperature control units that are in operation.
4.1.1
Emergency stop switch (optional): Activate / Deactivate
Exemplary layout of
the switches
By activating the >Emergency stop switch< [70], all poles of the temperature control unit are
disconnected immediately.
4.1.1.1
Emergency stop switch (optional): Activate
PROCEDURE
 Press the >Emergency stop switch< [70].
All poles of the temperature control unit are disconnected immediately.
4.1.1.2
Emergency stop switch (optional): Deactivate
PROCEDURE
 Turn the >Mains isolator< [36] to the “0” position!
 Release the >Emergency stop switch< [70] by turning it clockwise. A built-in spring in the >Emergency stop switch< [70] returns it to its original state.
4.1.2
Turning on the temperature control unit
PROCEDURE
 Switch on the temperature control unit using the >Mains isolator< [36].
Only valid for temperature control units with an emergency stop switch (optional):
The safety relay is tested. Press the illuminated >Release button< [0]. The temperature control
unit is started and the illumination in the >Release button< [0] is turned off.
Then a system test is conducted to test the full functionality of the temperature control unit. All
sensors, the all-pole disconnecting power disconnect relay for the power supply and the power
electronics of the main heater and the main heater itself are checked. A message appears on the
>Touchscreen< [88] in case of an error or if a warning is issued. Contact Customer Support if in
doubt (the phone number can be found on page 84 in Section »Contact data«).
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The following data entry is required only for:
a) initial startup
b) reseting the temperature control unit to the factory settings
(see page 43, section »Restore factory settings«).
 After switching on the temperature control unit, tap on the required system language.
 Confirm your choice by tapping on “OK”.
 Tap on the thermal fluid used.
 Confirm your choice by tapping on “OK”.
 Read the message and confirm by tapping on “OK”.
 Enter the volume using the number keypad that appears.
 Confirm your entry by tapping on “OK”.
If your temperature control unit is not integrated into a network, confirm the preset IP address
(0.0.0.0) by tapping on “OK”. This skips the network settings.
 Enter the required IP address using the number keypad that appears.
 Confirm your entry by tapping on “OK”.
 Enter the required subnet mask using the number keypad that appears.
 Confirm your entry by tapping on “OK”.
 Tap on the required remote control mode.
 Confirm your choice by tapping on “OK”.
 Switch the temperature control unit on and off using the >Mains isolator< [36].
Only valid for temperature control units with an emergency stop switch (optional):
The safety relay is tested. Press the illuminated >Release button< [0]. The temperature control
unit is started and the illumination in the >Release button< [0] is turned off.
Only valid for temperature control units with an emergency stop switch (optional):
Proceed as follows, if the >Release button< [0] is not illuminated when turning on the temperature control unit via the >Mains switch< [36]:
Check whether the temperature control unit is properly connected to a functioning power supply.
Solution: Properly connect the temperature control unit to a working power supply.
Check whether the >Emergency stop switch< [70] has been activated (on page 46 see Section
»Emergency stop switch (optional): Activate / Deactivate«). Solution: Deactivate the >Emergency
stop switch< [70] as shown on page 46 in Section »Emergency stop switch (optional): Deactivate«.
If the illuminated >Release button< [0] does not turn off when pressed and/or the temperature
control unit still can’t be turned on:
Please contact our Customer Support (phone number, see page 84 in Section »Contact data«).
4.1.3
Turning off the temperature control unit
PROCEDURE
 Warm the thermofluid to room temperature.
 Stop the thermoregulation.
 Switch off the temperature control unit using the >Mains switch< [36].
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4.1.4
Chapter 4
Setting the overtemperature protection
The overtemperature protection is not correctly set to the thermal fluid used
MORTAL DANGER FROM FIRE
 The overtemperature protection must be correctly set to the thermal fluid you are using.
 Always observe the safety data sheet of the thermal fluid.
 Different working temperature ranges may apply for open and closed systems.
 For Huber thermal fluids:
 For Huber thermal fluids, the maximum usable working temperature range is already indicated.
 Set the cut-out value of the overtemperature protection to the upper temperature limit of the
working range of the thermal fluid.
 For thermal fluids of other manufacturers:
 Set the cut-out value of the overtemperature protection at least 25 K below the combustion
point of the thermal fluid.
The maximum settable cut-out value of the OT corresponds, for Huber thermal fluids, to the specified upper working temperature of the thermal fluid. The usable working temperature range may
be less, if the overtemperature protection is correctly set. When controlling the temperature at
the upper working temperature limit, the OT may be triggered due to tolerances.
4.1.4.1
General information on the overtemperature protection
The overtemperature protection is a device in the temperature control unit that works independently of the controller. The software and hardware is designed to test key functions and operating
states during a self-test after the power supply has been switched on. If faults are detected, the
enabling of the electrical assemblies in the temperature control unit is blocked. During operation,
the sensors are tested for short-circuit and interruption.
The bath or flow temperature is monitored to ensure the safety of your system. It is set immediately
after you have filled the system with thermal fluid.
Our temperature control units not only offer the possibility to specify the cut-out value of the overtemperature protection but also provide the possibility to specify the shutdown mode of the temperature control unit. In a typical setting the temperature control unit switches off both the temperature control as well as the circulation (stop according to DIN EN 61010) after reaching the cut-out
value. This monitors a possible defect in the control of the heater. A strong exothermic reaction near
the cut-out value can also, under certain circumstances, result in a shutdown of the temperature
control unit. In this case, however, a shutdown would be fatal.
Our temperature control units provide the possibility to work with the shutdown mode Process
Safety. In this mode, temperature control (cooling) and circulation work as always. This is therefore
a possibility to respond to exothermic reactions.
The default shutdown mode of the overtemperature protection is “Stop according to
DIN EN 61010”. When resetting to factory settings, the overtemperature protection is reset to the
default shutdown mode “Stop according to DIN EN 61010”!
Upon delivery, the cut-out value of the overtemperature protection is set to 35 °C. An alarm is triggered by the temperature control unit shortly after turning on the power if the temperature of the
thermal fluid just filled is higher than the cut-out value set for the overtemperature protection. Set
the overtemperature protection to the thermal fluid you are using.
When setting a new cut-out value for the overtemperature protection, you will be prompted to
enter a randomly generated and displayed code via the numeric keypad displayed. Only after successful entry will you be able to change the cut-out value.
4.1.4.2
Setting “OT limit: heating”
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Safety”.
 Tap on the category “Overtemperature”.
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 Read the safety warning and confirm by tapping on “OK”.
 Read the Note and confirm by tapping on “OK”.
 Tap on the dialog entry “OT limit: heating”.
 Confirm your choice by tapping on “OK”.
 Tap on the temperature format set by you in the controller (green text).
 Enter the displayed red safety code using the number keypad that appears.
 Enter the value for the “Heating OT value” using the numeric keypad that appears. This value
must be 25 K below the combustion point of the thermal fluid you are using.
 Confirm your entry by tapping on “OK”.
4.1.4.3
Setting “Process Safety”
You have two options.
“Stop” in accordance with DIN EN 61010
Once the overtemperature protection cut-out value is reached, the temperature control unit (heating, cooling circuit and circulation pump) switches off (default setting).
“Process Safety”
Once the overtemperature protection cut-out value is reached, the heater switches off and the
cooling circuit and circulation pump continue to operate. In case of an emergency (possible exothermic reaction), the full cooling capacity is thus available. Please make sure that the automated
compressor is set to Permanently ON ([System Settings] > [Power/ECO Settings] > [Compressor
ON/OFF/AUTO] > [Permanently ON]).
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Safety”.
 Tap on the category “Process Safety”.
 Read the safety warning and confirm by tapping on “OK”.
 Choose between the modes “Stop” and “process safety”.
 Confirm your choice by tapping on “OK”.
4.1.4.4
Monitoring via “Display OT values”
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Safety”.
 Tap on the category “Display OT values”.
You will receive an overview of the current measured temperature value of the overtemperature
protection sensor, the set cut-out values and the set cut-out mode (Process Safety). Some temperature control units have 2 overtemperature protection sensors, and so 2 values are shown for
these temperature control units.
 Tap on the “OK” touchbutton after you have read/checked the information.
4.1.5
Testing overtemperature protection for functionality
Overtemperature protection (OT) does not trip
MORTAL DANGER FROM FIRE
 Test the response of the device every month and after each change of the thermal fluid in
order to assure proper functioning.
The steps below are carried out without permanent monitoring of the temperature control unit
DAMAGE TO AND IN THE VICINITY OF THE TEMPERATURE CONTROL UNIT
 The following actions may only be carried out while constantly monitoring the temperature
control unit and the application!
Run the test only if the temperature of the thermal fluid used is about 20 °C. You must NOT leave
the temperature control unit unattended during the entire test of the overtemperature protection.
The Pilot ONE controller contains a description for carrying out the overtemperature protection test.
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Chapter 4
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Safety”.
 Tap on the category “OT Test”.
The description for carrying out the overtemperature protection test is displayed.
 Tap on the “OK” touch button after you have read the information.
4.1.6
Adjusting the Delta T limiter
The Delta T limiter has not been adjusted to the used glass apparatus
DAMAGE CAUSED BY GLASS APPARATUS BURSTING
 Adjust the Delta T value to your application.
The temperature dynamics inside the reactor/process temperature are dictated by the flow temperature. A differential temperature (Delta T) occurs between the flow temperature and the temperature inside the reactor. The greater the permitted Delta T, the better the energy transmission
and hence the faster the speed reaches the setpoint. However, damage could result if the temperature difference limits are exceeded (bursting of the application e.g. glass apparatus). This difference in temperature may have to be restricted depending on the application (glass apparatus).
4.1.6.1
Changing the Delta T limiter
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Protection Options”.
 Tap on the sub-category “Delta T limiter”.
 Set the value of Delta T in line with the glass apparatus.
 Confirm your entry by tapping on the “OK” touchbutton.
4.2
The temperature control circuit
Every temperature control unit with a Pilot ONE control panel has its own PID controller for internal
and process temperature control. For many temperature control tasks it is sufficient to use the
factory-set control parameter. Our years of experience and current developments in control technology are used in these control parameters.
If a process control system is used, ideally send the specification of the temperature setpoint digitally to the
temperature control unit. For this purpose, an Ethernet and USB port is available at the Pilot ONE and a RS232
interface at the temperature control unit. With the optional Com.G@te, an additional RS485 interface is added
to your temperature control unit. Optionally you can integrate the temperature control unit in a Profibus environment. For more information, see the pages from 66, section »Interfaces and software update«.
The capacity adjustment of the temperature control unit is optimized so that the specified processes are run through in the fastest possible time. This increases the productivity of the system as
a whole and thus saves energy in the long term.
Diagram of temperature control circuit
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4.2.1
OPERATION MANUAL
Select temperature control: Internal or process
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “Process/Internal”.
 Choose between the entries “Internal” and “Process (Cascade)”.
 Confirm your choice by tapping on “OK”.
4.2.2
Temperature control to internal temperature
With internal temperature control, a control circuit is used to control the temperature at the internal Pt100 temperature sensor. This Pt100 temperature sensor is built into the device and is located
close to thermal fluid outlet (forward flow) or in the bath tank.
Representation of an
optimum internal
temperature control
4.2.3
Temperature control to process temperature
Certain temperature control tasks require that the temperature is recorded elsewhere for best
results than described. Setting the temperature to process temperature makes alternatives available. When setting the temperature to process temperature, an additionally connected external
Pt100 temperature sensor is used in conjunction with a master controller (cascade controller). The
internal sensor at the supply line is integrated with the slave controller. This temperature control
method is used e. g. for the thermostatic control of jacket vessels. The setpoint setting is valid for
the process controller. It in turn calculates a target value for the internal controller to optimally
adjust the process setpoint.
Incorrect installation of the process sensor (Pt100)
MATERIAL DAMAGE CAUSED BY FAULTY TEMPERATURE CONTROL
 Disruption of measured value recording due to static build-up.
 The process sensor (Pt100) must have a screened supply cable.
 If the sensor tube is metallic, take care to avoid ground loops.
 The connection cable should not be unnecessarily long.
 Make sure that the process sensor is properly attached at the measurement point and that
there is good thermal coupling
 The sensor itself must have good insulation from the screen or the protective grounding (R > 20
MΩ).
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Chapter 4
Representation of an
optimum process
temperature control
4.2.4
Delta T limiter
The Delta T limiter is a part of the temperature control which protects the system or the process.
The Delta T limiter is given a limit value. The Delta T limiter then reacts when the limit value is
reached during heating or cooling.
The temperature control mode “Process (Cascade)” evaluates the temperature difference between
the flow temperature and the process temperature. The default setting of the limit value is 100 K. If
the limit value and the temperature sensor are set properly, the load limits, e.g. from a glass apparatus, are not exceeded. As the limit value is approached, the cooling or heating capacity is adjusted.
The DeltaT limiter is not a safety device.
4.2.5
Monitoring the Pt100 temperature sensors
The Pt100 temperature sensors are constantly monitored for their electrical status. If the status
“Sensor faulty” occurs during temperature control, the temperature control process is stopped
immediately and a device message is displayed. This applies for all temperature sensors connected
within the temperature control unit.
4.2.6
Optimum control parameters for optimum temperature control
If the adjustment of the temperature does not correspond to the quality of the illustrations shown
above, you can adjust the control parameters. With Huber temperature control units, there are
various ways of finding the optimum control parameters. Depending on the facilities of the temperature control unit, you can choose the following processes:
▪ Use ex-factory parameters
(standard)
▪ Estimate Control Parameters
(only useful for bath thermostats with E-grade Basic and
internal control)
▪ Fast Identification
(from E-grade Exclusive)
▪ With Preliminary Test
(from E-grade Exclusive)
4.2.7
Sub-category: “Select auto/expert mode”.
Use of the “Expert mode” without a thorough knowledge of I&C technology.
MATERIAL DAMAGE TO THE APPLICATION
 Only use this mode if you have a thorough knowledge of I&C technology.
Here you can select whether the control parameters are set in the “Automatic mode” or in the
“Expert mode”. To enter settings in “Expert mode” requires in-depth knowledge of process measuring and control technology. Incorrect or insufficient settings can severely impair the function of the
temperature control unit.
In “Expert mode”, “Configuration auto” is deactivated and only “Configuration manual” is possible.
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This is how to change mode:
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “TAC/Manual”.
 Tap on the sub-category “Select auto/expert”.
 Choose between the dialog entries “Automatic mode” and “Expert mode”.
 Confirm your choice by tapping on “OK”.
4.2.8
Sub-category: “Configuration auto”
You can only select this menu entry if “Automatic mode” is set.
4.2.8.1
Sub-category: “Find parameters”
4.2.8.1.1
Dialog entry: “Fast Identification”
Considering the small effort, the “Fast Identification” function of the controlled system provides you
with very quick and reliable adapted control parameters. These control parameters achieve a fast
and very accurate tuning performance. The more complex but also more precise identification “With
Preliminary Test” is only very rarely required.
Do not make any changes to the temperature control unit and to the application (temperature
control unit / external application) after your system has been started. Changes include e.g. filling /
draining process chamber, changing the mixer speed, change of position of Pt100 process control
sensor etc.
PROCEDURE
 Before setting the control parameters, make sure that the temperature control unit has reached
the set setpoint and has been controlling the temperature at this setpoint for a few minutes. Do
not stop the temperature control.
 Do not make any changes to the temperature control unit and the application during parameter
determination.
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “TAC/Manual”.
 Tap on the sub-category “Configuration auto”.
 Tap on the sub-category “Find parameters”.
 Tap on the dialog entry “Fast Identification”.
 Confirm your choice by tapping on “OK”.
 Read the message displayed and confirm it by tapping on “OK”.
 Select the thermal fluid used from the list.
 Confirm your choice by tapping on “OK”.
 Choose between the dialog entries “Internal” and “Process (Cascade)”.
 Confirm your choice by tapping on “OK”.
 Enter a new setpoint using the number keypad that appears. This should be at least 10 K away
from the current setpoint.
 Confirm your entry by tapping on “OK”. Setting of the control parameters using “Fast Identification” starts and after a while a message appears on the display.
 Read the message displayed and confirm it by tapping on “OK”.
4.2.8.1.2
Dialog entry: “With Preliminary Test”
In some complex applications, the “Fast Identification” of the control circuit may not yet lead to
optimum control. This can happen, in particular, if the hydraulic build-up cannot be adjusted to the
necessary circulation volumes. Further information on this is provided on page 36 in the Section »To
be noted when planning the test«.
A further optimization of control behavior can be achieved if you select the control parameterization
“With Preliminary Test”. With this, the control parameters within the set limits of the minimum and
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maximum setpoint are determined. Temperature control is then also carried out to the setpoint
limits in some circumstances.
Before starting the automatic controller parameterization, verify the correct setting of the minimum and maximum setpoint. A limitation to the actually used operating temperaturerange is
advantageous. Do not make any changes to the temperature control unit and to the application
(temperature control unit / external application) after your system has been started. Changes
include e.g. filling / draining process chamber, changing the mixerspeed, change of position of
Pt100 process sensor etc.
Since the working temperature range can sometimes be very large, finding the parameters takes
correspondingly longer in this mode. The control defines up to three temperature setpoints and
automatically processes them one after another. One of these is below room temperature, one
roughly at room temperature and one above room temperature, if the setpoint limits allow this.
PROCEDURE
 Before setting the control parameters, make sure that the temperature control unit has reached
the set setpoint and has been controlling the temperature at this setpoint for a few minutes. Do
not stop the temperature control.
 Do not make any changes to the temperature control unit and the application during parameter
determination.
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “TAC/Manual”.
 Tap on the sub-category “Configuration auto”.
 Tap on the sub-category “Find parameters”.
 Tap on the dialog entry “With Preliminary Test”.
 Confirm your choice by tapping on “OK”.
 Read the message displayed and confirm it by tapping on “OK”.
 Select the thermal fluid used from the list.
 Confirm your choice by tapping on “OK”.
 Choose between the dialog entries “Internal” and “Process (Cascade)”.
 Confirm your choice by tapping on “OK”. Setting the control parameters using “With Preliminary
Test” starts and a message appears on the touchscreen after a while.
 Read the message displayed and confirm it by tapping on “OK”.
4.2.8.1.3
Dialog entry: “Estimate Control Parameters”
Even with the simple temperature control units, we offer a further advantage in comparison with
comparable bath thermostats available on the market. You can modify an existing control parameter
by entering the thermal fluid used and the quantity of thermal fluid. This version is available with
bath thermostats without connected external application.
All the necessary technical data for the thermal fluids listed for Pilot ONE are stored in the controller. If the thermal fluid that you use is not shown in the list, choose the most similar thermal fluid
with regard to temperature range and viscosity. Further information about this is provided on page
35 in the Section »Information on the thermal fluids«.
PROCEDURE
 Before setting the control parameters, make sure that the temperature control unit has reached
the set setpoint and has been controlling the temperature at this setpoint for a few minutes. Do
not stop the temperature control.
 Do not make any changes to the temperature control unit and the application during parameter
determination.
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “TAC/Manual”.
 Tap on the sub-category “Configuration auto”.
 Tap on the sub-category “Find parameters”.
 Tap on the dialog entry “Estimate Control Parameters”.
 Confirm your choice by tapping on “OK”.
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 Read the message and confirm it by tapping on “Yes”. The current control parameters will be overwritten.
 Select the thermal fluid used from the list.
 Confirm your choice by tapping on “OK”.
 Read the message displayed and confirm it by tapping on “OK”.
 Enter the filling volume using the number keypad that appears.
 Confirm your entry by tapping on “OK”.
 Tap twice on the “Arrow” touchbutton to return to the category “Temperature Control”.
 Tap on the category “Process/Internal”.
 Choose between the dialog entries “Internal” and “Process (Cascade)”.
 Tap on “OK” to confirm your choice.
4.2.8.2
Sub-category: “Control Dynamics”
You can choose between a faster tuning performance with a possible and accepted small temperature overshoot and a tuning performance without temperature overshoot. The default setting is
“Fast, small overshoot”.
The overshoot always refers to the leading temperature. Example: The process temperature, if activated, is the
leading temperature. In contrast, the bath or flow temperature must always be leading the process temperature. In order to achieve the best possible energy transfer, the greatest possible temperature difference between the bath or flow temperature and the process temperature is necessary (see figure "»Representation of
an optimum process temperature control« from page 51 in section »Temperature control to process temperature«). This always requires the maximum possible thermal fluid flow rate. In the setting “Faster, small overshoot”, the combination of high thermal fluid flow rate and the superbly designed control electronics hardly ever
results in an overshoot of the process temperature, while reaching the setpoint as quickly as possible. The opposite to the mode “Faster, small overshoot” is available in the setting “Without overshoot”. The target temperature is approached more cautiously and thus aperiodic. It takes longer to adjust to the selected setpoint. The
statement “without overshooting” is only valid with little external disturbance influence. Please note the specifications on page 36 in section »To be noted when planning the test«.
The adjustment behavior can be selected at any time without reactivating the “Find control parameters”.
Internal, aperiodic
temperature control
Internal, dynamic
temperature control
with possible overshooting of the temperature
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PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “TAC/Manual”.
 Tap on the sub-category “Configuration auto”.
 Tap on the sub-category “Control Dynamics”.
 Choose between the dialog entries “Fast, small overshoot” and “Without overshoot”.
 Confirm your choice by tapping on “OK”.
4.2.8.3
Sub-category: “Fluid Properties”
4.2.8.3.1
Sub-category “Select Fluid”
Under this entry, you can select the thermal fluid used from a list.
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “TAC/Manual”.
 Tap on the sub-category “Configuration auto”.
 Tap on the sub-category “Fluid Properties”.
 Tap on the sub-category “Select Fluid”.
 Select the thermal fluid used from the list.
 Confirm your choice by tapping on “OK”.
4.2.8.3.2
Sub-category: “Bath/Circulation Volume”
Under this entry, you can enter the filling volume of the thermal fluid in your bath/circuit.
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “TAC/Manual”.
 Tap on the sub-category “Configuration auto”.
 Tap on the sub-category “Fluid Properties”.
 Tap on the sub-category “Bath/Circulation Volume”.
 Read the message and confirm it by tapping on “OK”.
 Enter the filling volume using the number keypad that appears.
 Confirm your entry by tapping on “OK”.
4.2.8.3.3
Sub-category: “VPC/Bypass”
Under this entry, you can specify whether you use a bypass or not.
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “TAC/Manual”.
 Tap on the sub-category “Configuration auto”.
 Tap on the sub-category “Fluid Properties”.
 Tap on the sub-category “VPC/Bypass”.
 Choose between the dialog entries “Bypass used” and “Bypass not used”.
 Confirm your choice by tapping on “OK”.
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4.2.8.3.4
OPERATION MANUAL
Sub-category: “Show Fluid”
This entry provides you with an overview of the settings entered.
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “TAC/Manual”.
 Tap on the sub-category “Configuration auto”.
 Tap on the sub-category “Fluid Properties”.
 Tap on the sub-category “Show Fluid”.
 Tap on “OK” after you have read/checked the entries.
4.2.8.4
Sub-category: “Display parameters”
Here you can display the set parameters in “Automatic mode”.
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “TAC/Manual”.
 Tap on the sub-category “Configuration auto”.
 Tap on the sub-category “Display parameters”.
 Tap on “OK” after you have read/checked the parameters.
4.2.9
Sub-category: “Configuration manual”
Use of the “Expert mode” without a thorough knowledge of I&C technology.
MATERIAL DAMAGE TO THE APPLICATION
 Only use this mode if you have a thorough knowledge of I&C technology.
In “Expert mode”, “Configuration auto” is deactivated only “Configuration manual” is possible.
To enter settings in “Expert mode” requires in-depth knowledge of process measuring and control
technology. Incorrect or insufficient settings can severely impair the function of the temperature
control unit.
4.2.9.1
Sub-category: “Change parameters”
In this menu you manually configure the control parameters. If only the internal temperature is used
as a target value, the control parameters are entered only under “Internal”. If the process temperature is used as the target value, also the internal controller can be used, for example, when reaching
the set point limit or in case of a Delta T limit. Consequently, parameter sets must be entered under
all three items (“Internal”, “Jacket” and “Process”) when using the process temperature as a target
value.
4.2.9.1.1
Sub-category: “Internal”
Enter the new values for “KP”, “Tn” and “Tv” here one after the other.
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “TAC/Manual”.
 Tap on the sub-category “Configuration manual”.
 Tap on the sub-category “Change parameters”.
 Tap on the sub-category “Internal”.
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 Enter the new “KP” value using the number keypad that appears.
 Confirm your entry by tapping on “OK”.
 Enter the new “Tn” value using the number keypad that appears.
 Confirm your entry by tapping on “OK”.
 Enter the new “Tv” value using the number keypad that appears.
 Confirm your entry by tapping on “OK”.
4.2.9.1.2
Sub-category: “Jacket”
Enter the new value for “KP” here.
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “TAC/Manual”.
 Tap on the sub-category “Configuration manual”.
 Tap on the sub-category “Change parameters”.
 Tap on the sub-category “Jacket”.
 Enter the new “KP” value using the number keypad that appears.
 Confirm your entry by tapping on “OK”.
 Read the message and confirm it by tapping on “OK”.
4.2.9.1.3
Sub-category: “Process”
Enter the new values for “KP”, “Tn” and “Tv” here one after the other.
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “TAC/Manual”.
 Tap on the sub-category “Configuration manual”.
 Tap on the sub-category “Change parameters”.
 Tap on the sub-category “Process”.
 Enter the new “KP” value using the number keypad that appears.
 Confirm your entry by tapping on “OK”.
 Enter the new “Tn” value using the number keypad that appears.
 Confirm your entry by tapping on “OK”.
 Enter the new “Tv” value using the number keypad that appears.
 Confirm your entry by tapping on “OK”.
4.2.9.2
Sub-category: “Display parameters”
In this function, the set manual parameters are displayed.
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “TAC/Manual”.
 Tap on the sub-category “Configuration manual”.
 Tap on the sub-category “Display parameters”.
 Tap on “OK” after you have read/checked the parameters.
4.2.9.3
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Sub-category: “Control structure”
With this function, you have two different control structures available.
“Huber PID controller”: Default setting
“Classic PID controller”:This setting is exclusively used by Huber service engineers for service purposes.
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PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “TAC/Manual”.
 Tap on the sub-category “Configuration manual”.
 Tap on the sub-category “control structure”.
 Choose between the dialogue entries “Huber PID controller” and “Classic PID controller”.
 Confirm your choice by tapping on “OK”.
4.2.10
Sub-category: “Reset parameters”
With this function, you can reset the control parameters to the factory setting.
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “TAC/Manual”.
 Tap on the sub-category “Reset parameters”.
 Read the message and confirm it by tapping on “Yes”. The control parameters are reset/deleted.
The temperature control unit can only be operated again after a complete restart.
 To do so, switch the temperature control unit off and back on again. The parameters have been
reset.
4.2.11
Sub-category: “Display parameters”
In this function, the set parameters are displayed. Depending on the previous setting, these will be
the “Automatic control parameters” or the “Manual control parameters”.
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “TAC/Manual”.
 Tap on the sub-category “Display parameters”.
 Tap on “OK” after you have read/checked the parameters.
4.2.12
Freeze protection for temperature control unit (optional)
Non-compliance with the compatibility between the thermal fluid and your temperature control
unit
MATERIAL DAMAGE
 Observe the classification of your temperature control unit according to DIN 12876.
 Ensure the following materials are resistant with respect to the thermal fluid: Stainless steel
1.4301 (V2A)/1.4401 (V4A), copper, nickel, HNBR (Unichiller 017 to Unichiller 045), EPDM (from
Unichiller 055), red bronze/brass and silver solder.
 The maximum viscosity of the thermal fluid must not exceed 50 mm²/s at the lowest working
temperature!
 The maximum density of the thermal fluid may not exceed 1 kg/dm³!
Operation without freeze protection activated
COMPLETE DESTRUCTION OF THE TEMPERATURE CONTROL UNIT
 When using water as a thermal fluid, freeze protection must be activated in the category “protective devices”.
Temperature control units with freeze protection option can use water as the only thermal fluid.
Possible danger: Freezing of the heat exchanger at < 5 °C. An ice crystal (green flashing) indicates the
activation of the freeze protection on the touch display. To find out whether your temperature
control unit is equipped with a freeze protection, refer to the datasheet from page 85 in section
»Annex«.
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PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Protection Options”.
 Tap on the category “Freeze Protection”.
 Either tap on the dialog entry “off” or “on” to turn the freeze protection on or off.
 Confirm your choice by tapping on “OK”.
4.2.13
Setting the setpoint thresholds
Overview of the
temperature thresholds
The limits for the minimum and maximum setpoints serve for the safety of your system. They should
be set for the application field of the thermal fluid before starting the first temperature control and
when changing the thermal fluid. The maximum setpoint limit limits the setpoint setting for the bath
or flow temperature. The minimum setpoint limit protects against high viscosity or freezing at low
temperatures. Setpoint settings are only available in the temperature range between the minimum
and maximum setpoint limit.
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Protection Options”.
 Tap on the category “Setpoint Limits”.
 Tap on the sub-category “Minimum Setpoint”.
 Enter the new value, using the numeric keypad that appears.
 Confirm your entry by tapping on “OK”.
 In the display that follows, confirm your entry again by tapping on “OK”.
The correct selection will be displayed graphically and the “Min. setpoint” will be changed
promptly. If tapping on “OK” is not correct, it will be displayed graphically for 2 seconds. The display will then return to the category “Setpoint Limits”. Try changing the “Min. Setpoint” again.
 Tap on the sub-category “Maximum Setpoint”.
 Enter the new value, using the numeric keypad that appears.
 Confirm your entry by tapping on “OK”.
 In the display that follows, confirm your entry again by tapping on “OK”.
The correct selection will be displayed graphically and the “Max. Setpoint” will be changed
promptly. If tapping on “OK” is not correct, it will be displayed graphically for 2 seconds. The display will then return to the category “Setpoint Limits”. Try changing the “Max. Setpoint” again.
Check the set values for the minimum and maximum setpoint at any system change, especially
when changing the thermal fluid.
4.2.14
Setting the setpoint
PROCEDURE
 Go to the “Home” screen.
 Tap on the keypad symbol next to “TSetpoint”.
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 Enter a new setpoint using the number keypad that appears.
The following must apply:
[Minimum setpoint limit] ≤ [Setpoint] ≤ [Maximum setpoint limit].
If these conditions are not met, a message will appear on the >Touchscreen< [88] and the entry
will be ignored. In this case, delete the value just entered either with the “Arrow” key or with the
“clear” key. Enter the setpoint again.
 Confirm your entry by tapping on “OK”.
 In the display that follows, confirm your entry again by tapping on “OK”.
The correct selection will be displayed graphically and the setpoint will be changed immediately.
If tapping on “OK” is not correct, this is displayed graphically for 2 seconds. After this, the display
will return to the “Home” screen again. Try changing the setpoint again.
4.3
Filling, venting and draining
The illustration “connection diagram” can be found on page 85 in section »Annex«.
Extremely hot / cold surfaces, connections and thermal fluids
BURNS/FREEZING OF LIMBS
 Surfaces, connections and tempered thermal fluids can be extremely hot or cold depending on
the operating mode.
 Avoid direct contact with surfaces, connections and thermal fluids!
 Wear your personnel protective equipment (e.g. temperature-resistant safety gloves, safety
goggles).
During an active circulation, the thermal fluid circuit is shut off by shut-off valves
MATERIAL DAMAGE TO THE CIRCULATING PUMPS INSTALLED IN THE TEMPERATURE CONTROL
UNIT
 Do not close the thermal fluid circuit during an active circulation by means of shut-off valves.
 Warm the thermal fluid to room temperature before stopping the circulation.
4.3.1
Externally closed application
4.3.1.1
Filling and venting externally closed application
Non-compliance with the safety data sheet for the thermal fluid to be used
INJURIES
 Risk of injury to the eyes, skin, respiratory tract.
 The safety data sheet for the thermal fluid to be used must be read prior to using it and its
content must be respected.
 Observe the local regulations/work instructions.
 Wear your personal protective equipment (e.g. temperature-resistant safety gloves, safety
goggles, safety footwear).
 Danger of slipping because floor and work area are contaminated. Clean the work station and
follow the instructions for the disposal of thermal fluid and material on page 15 in Section
»Proper disposal of resources and consumables«.
Semi-automatic venting
DAMAGE TO THE TEMPERATURE CONTROL UNIT
 An elevated tolerance time for the pressure drop can damage the pump if the thermal fluid
level in the system is also too low.
 Constantly observe the thermal fluid level on the >Touchscreen< [88]. Refill thermal fluid as
needed, so that the thermal fluid level does not fall below 20%.
Calculate whether the capacity of the >Expansion vessel< [18] can absorb the expansion volume
during operation. Assume the following volumes for this calculation: [Minimum filling capacity of
the temperature control unit] + [Volume of the thermal fluid hoses] + [Jacket volume of your application] + [10% / 100 K].
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Thermal fluid level on
the >Touchscreen<
[88]
▪ During the fill process, ensure any necessary measures, such as earthing the tanks, funnels and
other aids, have been taken.
▪ Fill to the lowest possible height.
PROCEDURE
 Open the >Expansion vessel cap< [22] by hand.
 Carefully pour suitable thermofluid, using the filling accessories (funnel and/or beaker) into the
>Filling port< [17]. The thermofluid flows from the >Expansion vessel< [18] into the temperature
control unit and over the hose connection to the external application. You can see the thermofluid level on the Pilot ONE >Touchscreen< [88]. Follow the instructions on page 15 , section
»Proper disposal of resources and consumables« for the cleaning of the filling accessories.
 Before starting the venting process, fill the >Expansion vessel< [18] from 50 to 70%.
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “Start/Stop”.
 Tap on the Dialog entry “Start air-purge”.
 Confirm your choice by tapping on “OK”.
 Using the number keypad that appears, enter the time interval for the ventilation. The default is
0.5 minutes.
 Confirm your entry by tapping on “OK”. Venting will start.
If, with externally closed applications (reactors), the fluid level in the fill level display remains the
same when the pump is running and when the pump has stopped, the application has been vented.
 Stop venting. To do this, go to the category “Temperature Control”.
 Tap on the category “Start/Stop”.
 Tap on the dialog entry “Stop air-purge”.
 Confirm your choice by tapping on “OK”. Venting is stopped and the pump continues to run for
approx. 30 seconds. Wait until the pump stops.
 Close the >Expansion vessel cap< [22] by hand.
Venting must be performed especially during commissioning and after thermal fluid. This is the
only way to ensure trouble-free operation.
Note that the volume expansion of the thermal fluid depends on the working temperature range
you wish to work in. At the “lowest” working temperature, do not go beyond the minimum mark
of the >Sight glass< [23] and at the “highest” working temperature there should be no overflow
from the >Expansion vessel< [18]. In case of overfilling, drain the excess amount of thermal fluid
(see page 63 in Section »Draining externally closed applications«). Check if the thermal fluid can
be reused. On page 15 observe Section »Proper disposal of resources and consumables«.
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Draining externally closed applications
Hot or very cold thermal fluid
SERIOUS BURNS/FREEZING OF LIMBS
 Before draining, ensure that the thermal fluid has room temperature (20 °C).
 If, at this temperature, the thermal fluid is too viscous to be drained: Control the temperature
of the thermal fluid for a few minutes until the viscosity will allow drainage. Never control the
temperature of the thermal fluid when the Drain is open.
 Danger of burns when draining thermal fluids at temperatures above 20 °C.
 Wear your personal protective equipment when carrying out the drain operation.
 Only drain with a suitable draining hose and container. These must be resistant to the thermal
fluid and the temperature.
PROCEDURE
 Connect a suitable drain hose to the >Drain< [8].
 Place the other end of the hose in a suitable container.
Free-standing models
 Open the >Drain valve thermal fluid< [3] by turning it counterclockwise (turn 90° left as far as it
will go). The thermal fluid will flow from the external application via the pump chamber and the
draining hose into the container. Check if the thermal fluid can be reused. On page 15 observe
Section »Proper disposal of resources and consumables«.
 Drain your externally closed application. The description for the drainage procedure can be
found in the documents you received with the application. Check if the thermal fluid can be reused. On page 15 observe Section »Proper disposal of resources and consumables«.
 First open the >Circulation flow< [1] connection.
 Then open the connection >Circulation return< [2]. Leave the temperature control unit open for
a while to dry out (without screw caps) and with the >Drain valve thermal fluid< [3]) open.
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OPERATION MANUAL
Chapter 5
5
Normal operation
5.1
Automatic operation
Extremely hot / cold surfaces, connections and thermal fluids
BURNS/FREEZING OF LIMBS
 Surfaces, connections and tempered thermal fluids can be extremely hot or cold depending on
the operating mode.
 Avoid direct contact with surfaces, connections and thermal fluids!
 Wear your personnel protective equipment (e.g. temperature-resistant safety gloves, safety
goggles).
During an active circulation, the thermal fluid circuit is shut off by shut-off valves
MATERIAL DAMAGE TO THE CIRCULATING PUMPS INSTALLED IN THE TEMPERATURE CONTROL
UNIT
 Do not close the thermal fluid circuit during an active circulation by means of shut-off valves.
 Warm the thermal fluid to room temperature before stopping the circulation.
5.1.1
Temperature control
5.1.1.1
Starting the temperature control process
The temperature control process can be started after filling and complete venting.
PROCEDURE
 Go to the “Home” screen.
 Tap on the “Start” touchbutton.
 Confirm the start of temperature control by tapping on “OK”.
The correct selection will be displayed graphically and temperature control will start immediately. If tapping on “OK” is not correct, this is displayed graphically for 2 seconds. After this, the display will return to the “Home” screen again. Try to start the temperature control unit again.
5.1.1.2
Ending the temperature control process
When the temperature control unit is switched off, the thermal fluid temperature is higher/lower than room temperature
DAMAGE TO THE TEMPERATURE CONTROL UNIT AND THE GLASS APPARATUS/APPLICATION
 Bring the thermal fluid up to room temperature using the temperature control unit.
 Do not close the shut-off valves in the thermal fluid circuit.
The temperature control can be ended at any time, the pump continues to run for approx. 30 seconds. The compressor is switched off after the stepper motor valve has reached a defined position
to control the cold output.
PROCEDURE
 Go to the “Home” screen.
 Tap on the “Stop” touchbutton.
 Confirm the stop of temperature control by tapping on “OK”.
The correct selection will be displayed graphically and temperature control will stop immediately
and the pump with overrun for about 30 seconds. Wait until the pump stops. If tapping on “OK”
is not correct, this is displayed graphically for 2 seconds. After this, the display will return to the
“Home” screen again. Try to stop the temperature control unit again.
The compressor is not switched off until the stepper motor valve has reached a defined position.
The status line [Field 10] displays the relevant information.
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OPERATION MANUAL
5.1.2
Temperature control via a created temperature control program
5.1.2.1
Starting the temperature control program
A temperature control program can be started after filling and complete venting.
PROCEDURE
 Go to the “Categories Menu”.
 Tap on the category “Programmer/Ramp”.
 Tap on the category “Start/stop Program”.
 Tap on the dialog entry of the temperature control program to be started.
 Confirm your choice by tapping on “OK”.
 Read the message and confirm it. You temperature control unit will start the temperature control program and the temperature control programmed in it will start.
 Read the Note and confirm by tapping on “OK”.
5.1.2.2
Ending/cancelling the temperature control program
When the temperature control unit is switched off, the thermal fluid temperature is higher/lower than room temperature
DAMAGE TO THE TEMPERATURE CONTROL UNIT AND THE GLASS APPARATUS/APPLICATION
 Bring the thermal fluid up to room temperature using the temperature control unit.
 Do not close the shut-off valves in the thermal fluid circuit.
You can either end the temperature control automatically using the parameters predefined in the
temperature control program or end/interrupt the temperature control at any time manually. The
temperature control is switched off immediately after, the pump continues to run for approx. 30
seconds. The compressor is switched off after the stepper motor valve has reached a defined position to control the cold output.
Manual ending/cancelling
PROCEDURE
 Go to the “Home” screen.
 Tap on the “Stop” touchbutton.
 Confirm the stop of temperature control by tapping on “OK”.
The correct selection will be displayed graphically and temperature control will stop immediately
and the pump with overrun for about 30 seconds. Wait until the pump stops. If tapping on “OK”
is not correct, this is displayed graphically for 2 seconds. After this, the display will return to the
“Home” screen again. Try to stop the temperature control unit again.
The compressor is not switched off until the stepper motor valve has reached a defined position.
The status line [Field 10] displays the relevant information.
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6
Chapter 6
Interfaces and software update
The specifications of the interface used are not being met.
PROPERTY DAMAGE
 Only connect components that meet the specifications of the interface used.
The use of PB commands is described in our “Data communications PB” manual. This manual can
be downloaded from www.huber-online.com.
6.1
Interfaces at the “Pilot ONE®” controller
The Pilot ONE controller is not operated behind a firewall
PROPERTY DAMAGE
 Operate the controller Pilot ONE exclusively behind a firewall, if the local subnet is connected
to the Internet or another risk-prone network.
 The best available technology is to be applied in order to provide sufficient security for the
LAN!
Standard interfaces at
the “Pilot ONE” top
side
6.1.1
10/100 Mbps Ethernet for RJ45 network sockets
This is a fast and flexible interface. Standard 10/100 Mbps interface (Fast Ethernet), can be connected to any existing Ethernet network. Because this interface can also be connected to very large
networks, the IT “Best Practices” (firewall) must be observed.
Usage:
Also - to be able to communicate with the “Pilot ONE” controller - the communication enable must
be issued. This is an additional safety feature that prevents persons - possibly unintentionally - connecting to the wrong machine and implementing incorrect temperature control specifications. The
following restrictions are possible:
▪ Deactivated
▪ Always on (PLC)
▪ 12h Inactivity Timer
▪ 10min Inactivity Timer
If, for example, “10min Inactivity Timer” is selected, the connection must be made within 10
minutes after confirmation at the control. If this does not happen, the connection is refused.
Communication with the Pilot ONE is via TCP (Transmission Control Protocol),
Port 8101. The interfaces used must meet the specifications of the generally accepted standards.
6.1.2
USB-2.0 interface
The interfaces used must meet the specifications of the generally accepted standards.
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6.1.2.1
USB-2.0 interface, host
USB-2.0 connection (for connector A), e.g. for data memories.
6.1.2.2
USB-2.0 interface, device
USB-2.0 connection (for Mini-B connector) for communicating with a computer.
6.2
Interfaces at the top side of the Unichiller.
Connecting to the interfaces at the temperature control unit during operation
DAMAGE TO THE INTERFACES
 When devices in operation are connected with interfaces of the temperature control unit,
interfaces may get damaged.
 Before connecting, ensure the temperature control unit and the device to be connected are
turned off.
Standard interfaces at
the top side of the
Unichiller.
6.2.1
Female RS232 Serial (with adapter cable)
A PC, a SPS or a Process Control System (PCS) can be connected to this jack for remote control of the
controller electronics. Before plugging in the cable, check the settings in the “Interfaces” category
and adjust if necessary.
The interfaces used must meet the specifications of the generally accepted standards.
Pin assignment (front
view)
Pin assignment
6.2.2
Pin
Signal
Description
2
RxD
Receive Data
3
TxD
Transmit Data
5
GND
Signal GND
Connection jack for Pt100 process controller sensor
A temperature sensor located in the connected application (Pt100, 4-wire technology, Lemosa connector) is connected to the Pt100 connection jack. The external actual temperature is then recorded
and the operating temperature of the temperature control unit is permanently calculated and adjusted.
Depending on the operating temperature, isolation losses and exothermic heat, the operating
temperature (flow temperature) of the application can be significantly less than the setpoint of the
application. In this context, safety-critical thresholds for the temperature control fluid must be
strictly observed.
The control results contained in the data sheet can only be achieved with shielded sensor leads.
We recommend the external Pt100 process control sensor from the Huber accessories program.
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Pin assignment (front
view)
Pin assignment
6.2.3
Pin
Signal
1
I+
2
U+
3
U−
4
I−
Service interface
This interface is exclusively used by Huber service engineers for service purposes.
6.3
Interfaces at the Com.G@te® (optional)
Connecting to the interfaces at the temperature control unit during operation
DAMAGE TO THE INTERFACES
 When devices in operation are connected with interfaces of the temperature control unit,
interfaces may get damaged.
 Before connecting, ensure the temperature control unit and the device to be connected are
turned off.
Com.G@te external
interfaces:
LEVEL, POKO, AIF,
ECS,RS232/RS485
(left to right).
Com.G@te internal
interfaces:
POKO, AIF, ECS,
RS232/RS485
(left to right).
If the >Com.G@te< [46] is not connected, proceed as follows.
PROCEDURE
 Switch off the temperature control unit.
 Plug the >Com.G@te< [46] into the slot provided.
 Switch on the temperature control unit. “Unistat Control ONE” detects the new component. The
>Com.G@te< [46] is operable.
Note that you may only change >Com.G@te< [46] when the temperature control unit is turned off.
In the category “Interfaces” you can change the settings of each function such as PoKo, analog
interface and RS232/RS485.
You may order >Com.G@te< [46] with Order No. 6915. You can extend an existing >Com.G@te<
[46] via a connecting cable (Order No. 16160).
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6.3.1
OPERATION MANUAL
Jack LEVEL (Com.G@te® external only)
For level monitoring in the >Sight glass< [23].
This connection enables you to connect an external float switch (Order No. 6152), which is positioned in the >Sight glass< [23], for monitoring the level of your externally closed application. Activation via a potential-free contact.
The interface is specified as a digital input. Do not apply voltage or current.
Pin assignment (front
view)
Pin assignment
6.3.2
Pin
Description
1
Level test (bypass via contact 2 → “absence”)
2
Level – (GND)
3
Level + (normally open contact)
Connector POKO (floating contact) alarm
Signal contact for external monitoring.
Notice the functions provided by PoKo in the category “Interfaces”. The potential-free contact
(PoKo) signals the state of the temperature control unit via the contact position. A closed operating
contact means readiness for operation. If a fault or an error occurs, the operating contact is opened
(this applies to the make contact between pin 1 and pin 2).
The following settings are offered:
▪ “Off”: The POKO displays the OK state whenever the temperature control unit is ready for operation. The unit is ready for operation about 30 seconds after switching on, once the internal controller check has been completed. The OK status is terminated by switching off the unit or in case
a fault occurs.
▪ “Internal temperature relative": Set the upper and lower limit of a temperature range around
the setpoint by using the POKO “min. value” and the POKO “max. value”.
The potential-free contact indicates the condition, that the setpoint differs from the actual value
by a smaller difference than was defined by the temperature range. Exceeding the set range only
results in the potential-free contact to switch (away from the OK state), but does not result in further reactions of the temperature control unit. The contact returns to the OK status if the actual
value is within that range.
▪ “External alarm”: The POKO relay becomes active (OK state) in this function only, if the temperature control unit is switched on and is in “Fault” mode. The advantage is that the alarm will not be
triggered if the temperature control unit is switched off. Please use the POKO function “OFF” if
the alarm function is wanted together with the operating current principle.
▪ “Unipump/PCS”: This POKO function and the enable contact of the pump guarantee that the
external pump runs synchronously with the pump in the temperature control unit if an external
pressure booster pump is used in your temperature control circuit / cooling water circuit, i.e. the
POKO assumes the OK state as soon as the internal pump is started up.
PCS: The POKO is used to communicate the state of the temperature control unit to the process
control system.
POKO condition ON means the pump is running.
POKO condition OFF means the pump is not running, the temperature control unit is in stand-by
mode.
▪ “External control”: The PB commands “vPoKoExtMode” and “vPoKoState” use an external interface (Ethernet, RS232, TS485, USB device) to switch the POKO on and off. Please also refer to the
software offered by us and the Data Communication Manual.
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▪ “Process temperature relative”: Set the upper and lower limit of a temperature range around the
setpoint by using the POKO “min. value” and the POKO “max. value”.
The potential-free contact indicates the condition, that the setpoint differs from the actual value
by a smaller difference than was defined by the temperature range. Exceeding the set range only
results in the potential-free contact to switch (away from the OK state), but does not result in further reactions of the temperature control unit. The contact returns to the OK status if the actual
value is within that range.
▪ “Unipump with Echo”: This function is used to check whether the Unipump controlled by the
POKO runs synchronous with the Unistat pump. For this purpose, the operating mode of the
Unipump is applied via a make contact to the “LEVEL” socket. A fault is generated if asynchronous. This mode is useful if a Unipump is to be monitored - either to guarantee the desired circulation or to prevent an unintended heating of the thermal fluid.
▪ “Programmer”: This activates the individual segments associated during program creation with
the POKO switching states.
▪ “Internal temperature absolute”: This enables you to set a temperature range relative to the
internal sensor (absolute temperature). The POCO is active outside of this range; the POCO is inactive inside of this range.
▪ “Process temperature absolute”: This enables you to set a temperature range relative to the
process temperature (absolute temperature). The POCO is active outside of this range; the POCO
is inactive inside of this range.
▪ “Solenoid valve flow / return flow”: This function is used to control a connected solenoid valve. It
takes 60 seconds before the POKO switches on after you have started the pump in the temperature control unit. For example, the POKO is switched off before the pump has been completely
stopped when the temperature control process / circulation is stopped. Thus, the POKO is
switched on only as long as the full pump pressure exists.
▪ “Cooling”: This function is used to open the cooling water supply with a solenoid valve only when
the temperature control unit requires cooling water. The POKO is switched on when the temperature control unit is cooling.
▪ “Message available”: The POKO switches on when a message is available at the Pilot ONE. This
message can be a fault, warning or general message.
▪ “Automatic filling”: The POKO switches on when the level has dropped below the minimum
value. The POKO is switched off after 20 seconds when the level has risen above the minimum
value. The POKO switches off immediately when the maximum value has been reached.
With the floating contact, use only sheathed lines! The interface is specified as a digital output.
Pin assignment (front
view)
The connection is designed as a potential-free changeover contact.
Closing contact between pin 1 and pin 2.
Opening contact between pin 2 and pin 3.
Contact load: 1 A at 24 V DC.
6.3.3
Jack AIF Reg-E-Prog
The analog interface has a programmable input channel and 3 output channels.
The analog interface of Com.G@te® is programmed in the category “Interfaces”.
Pin assignment (front
view)
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Pin assignment
OPERATION MANUAL
Pin
Description
Signal
1
Current output, T external
0 /4 - 20 mA or 0 - 10 V
2
Current output, setpoint
0 /4 - 20 mA or 0 - 10 V
3
GND for analog outputs
GND
a)
a)
a)
4
Analog input (programmable)
0 /4 - 20 mA or 0 - 10 V
5
Current output, freely programmable
0 /4 - 20 mA or 0 - 10 V
6
GND for analog input
GND
a)
If using 0 - 10 V, integrate a
500 Ω resistor.
Power input: 200 Ω working
resistance
Voltage input: 100 kΩ input
resistance
If using 0 - 10 V, integrate a
500 Ω resistor.
a)
Consult with our Customer Support.
6.3.4
Jack ECS (External Control Signal) standby
Enable signal ECS (external control signal) for starting/stopping the temperature control process.
Activation via a potential-free contact. Contacts 1 and 3 are internally bypassed. ECS is energized
when E1 and E2 are connected by an external floating contact. Contact specification: min. 0.1 A /
24 V DC.
The functionality of the ECS is determined via the “Interfaces” category.
The following variants are offered:
▪ “No Action”: Switching the contacts open/closed or closed/open has no effect.
▪ “Switching to second setpoint”: A change from a closed to an open contact replaces the set
setpoint with the value of the second setpoint. This altered setpoint is not fixed to the second
setpoint but can be changed by the operator at the temperature control unit at any time. A
change from an open to a closed contact does not cause any change and the temperature control
process is not reset to the original setpoint.
▪ „2. setpoint selective”: An open contact causes a thermoregulation to its original setpoint. A
closed contact causes a thermoregulation to the second setpoint.
▪ “Internal / Process”: If the contact is open, the device-internal temperature sensor is used for
control. If the contact is closed, the additionally connected external temperature sensor is used
for control. Switching the contacts open/closed or closed/open switches between these two temperature sensors.
▪ “Temperature control on/off”: The temperature control process starts when switching from an
open to a closed contact. The temperature control process switches off when switching from a
closed to an open contact.
▪ “Release”: The temperature control process switches off, if the temperature control process is
active and the contact is switched from closed to open. The temperature control process is not
switched on, if contact is further switched from open to closed!
▪ “Reset Messages”: All messages in the Pilot ONE are reset (if possible) if the enable signal changes from “open” to “closed”. Resetting is delayed in the event of a fault until the temperature control unit is in stand-by mode. Messages can be reset as often as required, but faults can be reset
only 3 times.
▪ “Program 1 Start/Stop”: The temperature control program 1 is started if the enable signal changes from “open” to “closed”. The temperature control program is stopped when changing from
“closed” to “open”.
▪ “Fill level alarm”: When switching from closed to open contact, an alarm is triggered if the fill
level is too low. For this purpose, a level sensor must be connected and placed in the > sight
glass< [23] or in the external application.
▪ “Fill level warning”: When switching from closed to open contact, a warning is generated if the fill
level is too low. For this purpose, a level sensor must be connected and placed in the > sight
glass< [23] or in the external application.
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The interface is specified as a digital input. Do not apply voltage or current.
Pin assignment (front
view)
Pin assignment
6.3.5
Pin
Signal
1.3
E2
2
E1
Jack RS232/RS485 serial
A PC, a SPS or a Process Control System (PCS) can be connected to this jack for remote control of the
controller electronics. Alternatively, a connection to a RS485 bus is possible. Before plugging in the
cable, check the settings in the “Interfaces” category and adjust if necessary.
The interfaces used must meet the specifications of the generally accepted standards.
Pin assignment (front
view)
Pin assignment
Pin
Signal
Description
Wiring RS232
2
RxD
Receive Data
3
TxD
Transmit Data
5
GND
Signal GND
Wiring RS485
6.4
6
A with 120-Ω terminating resistor
–
7
A
–
8
B
–
Firmware update
An instruction for running a firmware update can be found at www.huber-online.com.
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Chapter 7
OPERATION MANUAL
7
Service/maintenance
7.1
Messages from the temperature control unit
Messages output by the temperature control unit can be divided into various classes.
Follow the instructions displayed on the >Touchscreen< [88]. Once a message has been acknowledged, a symbol is output on the >Touchscreen< [88]. Tapping the symbol takes you to an overview
of all messages in chronological order.
Displayed symbol:
7.2
Replacing the “Pilot ONE®”
Replacing the electronics while the temperature control unit is operating
MORTAL DANGER FROM FIRE
 Stop an ongoing temperature control process.
 Turn off the temperature control unit.
 Also disconnect the temperature control unit from the power supply.
In case of fault, you can replace the “Pilot ONE” yourself. If you have questions or difficulties, please
contact your dealer, your local office or our Customer Support.
Replacing the
“Pilot ONE”
PROCEDURE
 Turn off the temperature control unit.
 Disconnect the temperature control unit from the power supply.
 Release the >Fixing screw for Pilot ONE< [89] at the front of the housing.
 Carefully pull the “Pilot ONE” away upwards.
 Carefully insert the replacement “Pilot ONE”.
 Close the >Fixing screw for Pilot ONE< [89] at the front of the housing.
 Connect the temperature control unit to the power supply.
 Turn on the temperature control unit.
7.3
Maintenance
Cleaning/maintenance while the temperature control unit is operating
MORTAL DANGER FROM ELECTRIC SHOCK
 Stop an ongoing temperature control process.
 Turn off the temperature control unit.
 Also disconnect the temperature control unit from the power supply.
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Chapter 7
Carrying out maintenance work not described in this operation manual
DAMAGE TO THE TEMPERATURE CONTROL UNIT
 For maintenance work not described in the operation manual, contact the Huber company.
 Maintenance work not described in this operation manual is reserved for qualified specialists
trained by Huber.
 Only perform the following maintenance work on the temperature control unit yourself.
7.3.1
Monitoring interval
74
Unichiller®
Function check and visual inspection
Cooling*
Description
Maintenance
interval
Comment
Person responsible
Responsible
body and/or
operators
L/W
Visually inspect
hoses and hose
connections
Prior to switching
on the temperature control unit
Exchange leaking hoses and hose
connections prior to switching on
the temperature control unit. On
page 75 see Section »Replacing
temperature control or coolant
hoses«.
L/W
Inspection in accordance with the
F-Gas Directive
In accordance
with the F-Gas
Directive
On page 17 see Section
»Temperature control units with
fluorinated greenhouse gases/refrigerants«
Responsible
body
L/W
Inspect power
supply cable
Prior to switching
on the temperature control unit
or on relocation
Do not start the temperature
control unit if the power cable is
damaged.
Qualified
electrician
(BGV A3)
L
Clean air inlet grille
As required
Clean the perforated sheet of the
temperature control unit with a
damp cloth
Responsible
body
L/W
Thermal fluid
inspection
As required
L/W
Inspect the mechanical seals
Monthly
On page 80 see Section »Inspect
the mechanical seal«
Responsible
body and/or
operators
L
Check liquefier fins
As required, after
3 months at the
latest
On page 75 see Section »Clean
liquefier fins (air-cooled temperature control unit)«
Responsible
body and/or
operators
W
Check suction
strainer (dirt trap)
As required, after
3 months at the
latest
On page 76 see Section »Clean
hat-type strainer (dirt trap) (water-cooled temperature control
unit)«
Responsible
body and/or
operators
L/W
Overtemperature
protection (OT) functional check
Every month or
after changing the
thermal fluid
On page 49 see Section »Testing
overtemperature protection for
functionality«
Responsible
body and/or
operators
L/W
Emergency stop
switch (optional):
Function test
Every 6 months or
after a change of
location
On page 76 see Section
»Emergency stop switch (optional): Function test«
Responsible
body and/or
operators
L/W
Inspect temperature control unit for
damage and stability
Every 12 months
or after a change
of location
W
Inspect cooling
water quality
Every 12 months
Responsible
body and/or
operators
Responsible
body and/or
operators
Descale the cooling water circuit
as required. Documentation on
water quality available at:
www.huber-online.com
Responsible
body and/or
operators
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Service/maintenance
Chapter 7
OPERATION MANUAL
Cooling*
Description
Maintenance
interval
Comment
Person responsible
L/W
Check air filter mats
Determine according to ambient
conditions.
Check all air filter mats of the
temperature control unit. Clean
the air filter mats as needed or
replace.
Responsible
body and/or
operators
*L = Air cooling; W = Water cooling; U = Applicable only for Unistats
7.3.2
Replacing temperature control or coolant hoses
Replace defective temperature control and/or coolant hoses before turning on the temperature
control unit.
7.3.2.1
Replacing temperature control hoses
PROCEDURE
 Drain the temperature control unit as described on page 63 in section »Draining externally
closed applications«.
 Replace defective temperature control hoses. When disposing of them, observe page 15, section
»Proper disposal of resources and consumables«.
 Reconnect your external application as described on page 31 in section »Connecting externally
closed application«.
 Fill the temperature control unit with thermofluid as described on page 61 in section »Filling and
venting externally closed application«.
 Vent the temperature control unit as described on page 61 in section »Filling and venting externally closed application«.
 Restart the temperature control unit in normal mode.
7.3.2.2
Replacing coolant hoses
PROCEDURE
 Drain the cooling water as described on page 82 in section »Draining the cooling water«.
 Replace the defective coolant hoses. When disposing of them, observe page 15, section »Proper
disposal of resources and consumables«.
 Reconnect the temperature control unit to the building’s cooling water supply. Proceed as described on page 28 in section »Temperature control units with water cooling«.
 Restart the temperature control unit in normal mode.
7.3.3
Clean liquefier fins (air-cooled temperature control unit)
Manual cleaning
RISK OF BEING CUT ON THE LIQUEFIER FINS
 Wear suitable cut-resistant gloves for cleaning work.
 Depending on the ambient conditions, use cleaning equipment such as vacuum cleaners and/or
a hand brush/brush. Follow the local regulations when cleaning. Do not clean the liquefier fins
in a clean room with items like a brush and do not use a vacuum cleaner without an extra-fine
particle filter.
Cleaning using pointed or sharp-edged tools
DAMAGE TO THE LIQUEFIER FINS
 Clean the liquefier fins using suitable cleaning appliances.
Make sure there is adequate ventilation (removal of waste heat, fresh air supply) for the temperature control unit, in case of air cooling, maintain wall clearance (see page 20, section »Exemplary
illustrations of the cooling variants« and page 25, section »Ambient conditions«).
The liquefier fins must be cleaned (dust) from time to time as only then will the temperature control unit perform at its maximum cooling capacity.
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Identify the position of the ventilation grille, usually located on the front. With some temperature
control units, the ventilation grilles on the side wall, rear or on the underside (table units) of the
temperature control unit.
PROCEDURE
Ventilation grille on the front/rear or on a side wall
 Turn off the temperature control unit.
 Disconnect the temperature control unit from the power supply.
 Remove the ventilation grille to create unhindered access to the liquefier fins.
 Clean the liquefier fins using suitable cleaning appliances. Observe the local regulations and
ambient conditions when selecting cleaning appliances.
 Make sure the liquefier fins are not damaged or deformed as this will impair the air flow.
 Re-mount the ventilation grille after cleaning work.
 Connect the temperature control unit to the power supply.
 Turn on the temperature control unit.
7.3.4
Clean hat-type strainer (dirt trap) (water-cooled temperature control unit)
Building side shut-off valves are not closed
DAMAGE BY ROOM FLOODING
 Close the building’s shut-off valves in the cooling water supply and return lines.
 For table-top models, place a collection container below the >Cooling water drain< [15] (see
connection diagram page 85, section »Annex«).
The strainer at the cooling water inlet must be inspected and cleaned on a regular basis, depending on water quality.
PROCEDURE
Free-standing models:
 Turn off the temperature control unit.
 Disconnect the temperature control unit from the power supply.
 Close the customer’s shut-off valves in the cooling water supply and return lines.
 Remove the panel around the >Cooling water inlet< [13] and >Cooling water outlet< [14]. Information: Located immediately behind the >Cooling water inlet< [13] is the dirt trap.
 Place a collecting container below the >Cooling water inlet< [13].
 Carefully detach the cover (hexagonal).
 Remove and clean the metal strainer located below.
 Clean the metal strainer under running water.
 Re-insert the metal strainer after cleaning work.
 Carefully fasten the cover (hexagonal).
 Remove the collecting container from below the >Cooling water inlet< [13].
 Re-mount the panel around the >Cooling water inlet< [13] and >Cooling water outlet< [14].
 Open the customer’s shut-off valves in the cooling water supply and return lines.
 Connect the temperature control unit to the power supply.
 Turn on the temperature control unit.
We also provide service training. Please contact the Customer Support. The telephone number can
be found on page 84, section »Contact data«.
7.3.5
Emergency stop switch (optional): Function test
Important: Perform the function test only when the temperature control unit is not controlling the
temperature. All poles of the temperature control unit are switched off immediately during a
function test!
Immediately take the temperature control unit out of use if the function test doesn’t turn off the
temperature control unit. Please contact Customer Support, if this is the case. The telephone
number can be found on page 84, section »Contact data«.
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PROCEDURE
 Press the >Emergency stop switch< [70].
All poles of the temperature control unit are disconnected immediately.
 Restart the temperature control unit in normal mode after a successful function test. Please see
page 46, section »Turning on the temperature control unit«.
7.4
Thermal fluid inspection, replacement and circuit cleaning
The illustration “connection diagram” can be found on page 85 in section »Annex«.
Extremely hot / cold surfaces, connections and thermal fluids
BURNS/FREEZING OF LIMBS
 Surfaces, connections and tempered thermal fluids can be extremely hot or cold depending on
the operating mode.
 Avoid direct contact with surfaces, connections and thermal fluids!
 Wear your personnel protective equipment (e.g. temperature-resistant safety gloves, safety
goggles).
During an active circulation, the thermal fluid circuit is shut off by shut-off valves
MATERIAL DAMAGE TO THE CIRCULATING PUMPS INSTALLED IN THE TEMPERATURE CONTROL
UNIT
 Do not close the thermal fluid circuit during an active circulation by means of shut-off valves.
 Warm the thermal fluid to room temperature before stopping the circulation.
7.4.1
Thermal fluid inspection
Thermal fluid is not inspected on a regular basis
BURNS DUE TO REDUCED BOILING POINT
 Regularly check your thermal fluid whether it meets the specifications in the safety data sheet.
Thermal fluid is not inspected on a regular basis
DAMAGE TO THE HEAT EXCHANGER AND/OR ELECTROMECHANICAL PARTS.
 Regularly check your thermal fluid whether it meets the specifications in the safety data sheet.
Oxidation
Oxidation ages the thermal fluid and changes its characteristics (e.g. reduces its boiling point).
When controlling high temperatures, a reduced boiling point may cause overflow of very hot
thermal fluids at the >Expansion vessel< [18]. It may cause serious burns of the limbs.
Hygroscopy
When continuously thermoregulating below room temperature, hygroscopy causes the thermal
fluid to accumulate water in the course of time. Such a liquid mixture causes the evaporator to
burst when thermoregulating in the minus range. This is caused by the water in the liquid mixture,
which forms ice crystals on the evaporator. When thermoregulating high temperatures with such a
liquid mixture, the boiling point is reduced. When controlling high temperatures, a reduced boiling
point may cause overflow of very hot thermal fluids at the >Expansion vessel< [18]. It may cause
serious burns of the limbs.
Hygroscopy can change the mixing ratio of a water-ethylene-glycol mixture.
7.4.2
Thermal fluid replacement
Mixing different thermofluids in a thermal fluid circuit
PROPERTY DAMAGE
 Do not mix different types of thermofluid (such as mineral oil, silicone oil, synthetic oil, water,
etc.) in a thermofluid circuit.
 The thermal fluid circuit must be rinsed when changing from one type of thermal fluid to another. No residues of the previous type of thermal fluid may remain in the thermal fluid circuit.
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7.4.2.1
Externally closed application
To replace the thermal fluid, proceed as described from page 61 in section »Externally closed application«. The draining and filling operations are described in this section.
7.4.3
Rinsing the thermal fluid circuit
Setpoint and overtemperature protection are not adjusted to the thermofluid
MORTAL DANGER FROM FIRE
 The cut-out value of the overtemperature protection must be adapted to the thermofluid. Set
the cut-out value of the overtemperature protection 25 K below the combustion point of the
thermofluid.
 The setpoint set during rinsing must be adjusted to the thermofluid used.
Non-compliance with the safety data sheet for the thermal fluid to be used
INJURIES
 Risk of injury to the eyes, skin, respiratory tract.
 The safety data sheet for the thermal fluid to be used must be read prior to using it and its
content must be respected.
 Observe the local regulations/work instructions.
 Wear your personal protective equipment (e.g. temperature-resistant safety gloves, safety
goggles, safety footwear).
 Danger of slipping because floor and work area are contaminated. Clean the work station and
follow the instructions for the disposal of thermal fluid and material on page 15 in Section
»Proper disposal of resources and consumables«.
Mixing different thermofluids in a thermal fluid circuit
PROPERTY DAMAGE
 Do not mix different types of thermofluid (such as mineral oil, silicone oil, synthetic oil, water,
etc.) in a thermofluid circuit.
 The thermal fluid circuit must be rinsed when changing from one type of thermal fluid to another. No residues of the previous type of thermal fluid may remain in the thermal fluid circuit.
Example: Connecting a
short circuit hose
The inner components of the temperature control unit must be dried out Need to avoid boiling
retardation during future uses (e.g. use of a silicone oil at temperatures above about 100 °C).
PROCEDURE
 Drain the temperature control unit as described on page 63 in section »Draining externally
closed applications«.
Residual thermal fluid can remain in the pump chamber and the internal lines after draining. Leave
the temperature control unit with open valves for a while.
 Leave the drain hose mounted to the >Drain< [8].
 Check the fill level in the collecting container at the end of the drain hose. Follow the instructions on
page 15, section »Proper disposal of resources and consumables« for the disposal of thermofluid.
 Close the drain valves on the temperature control unit by turning them clockwise (turn 90° right
as far as it will go).
 Connect the >Circulation flow< [1] with the >Circulation return< [2] to the temperature control
using a bypass hose.
Perform the following steps without attaching a short circuit hose, if the application used by you
(externally closed) is also dirty. In this case, leave your externally closed application connected to
the temperature control unit. This rinses the temperature control unit and your application at the
same time.
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 Fill the system (minimum fill level) with the thermofluid you wish to use. The description can be
found on page 61 in section »Filling and venting externally closed application«.
 Vent the system as described on page 61 in section »Filling and venting externally closed application«.
 Adjust the setpoint and the cut-out value of the overtemperature protection to the thermofluid
used. This procedure can be found on page 60 in section »Setting the setpoint« and on page 48
in section »Setting the overtemperature protection«.
 Go to the “Categories Menu”.
 Tap on the category “Temperature Control”.
 Tap on the category “Start/Stop”.
 Tap on the dialog entry “Start temperature control process”.
 Confirm your choice by tapping on “OK”. The length of rinsing depends on the level of soiling.
 Tap on the category “Start/Stop”.
 Tap on the dialog entry “Stop temperature control process”.
 Confirm your choice by tapping on “OK”. The temperature control process is stopped.
 Open the >Drain< [8] and >Emptying of residues< [10] (if present) and drain the thermofluid
through the draining hose into a suitable container (such as the original canister, which is compatible with the thermofluid). Follow the instructions for the disposal of thermofluid on page 15 ,
section »Proper disposal of resources and consumables«.
 Repeat the steps “Filling”, “Venting”, “Start/Stop temperature control process” and “Draining”
until the drained thermofluid remains clear.
 Remove the bypass hose.
Leave an application connected, if you have simultaneously rinsed a used application (externally
closed).
 Leave the >Drain< [8] open for a while to allow the thermofluid to evaporate in the temperature
control unit.
 Close the >Drain< [8] once the residual thermofluid has evaporated.
 Dismount the drain hose.
 Remove the collecting container.
 Discard the collecting container, including its contents, properly. Follow the instructions for the
disposal of thermofluid on page 15 , section »Proper disposal of resources and consumables«.
 Re-connect your application. (Only if you have rinsed the thermofluid circuit using a bypass
hose.)
 Fill the temperature control unit with thermofluid, as described on page 61 in section »Filling
and venting externally closed application«.
 Vent the temperature control unit as described on page 61 in section »Filling and venting externally closed application«. An externally open application does not need to be vented.
 Restart the temperature control unit in normal mode.
7.5
Cleaning the surfaces
Extremely hot / cold surfaces, connections and thermal fluids
BURNS/FREEZING OF LIMBS
 Surfaces, connections and tempered thermal fluids can be extremely hot or cold depending on
the operating mode.
 Avoid direct contact with surfaces, connections and thermal fluids!
 Wear your personnel protective equipment (e.g. temperature-resistant safety gloves, safety
goggles).
Exposed plug contacts
DAMAGE CAUSED BY FLUID INGRESS
 Protect unused plug contacts with the protective caps supplied.
 Clean surfaces only with a damp cloth.
A standard stainless steel cleaning agent is suitable for cleaning the stainless steel surfaces. Carefully
clean painted surfaces (damp only) using a solution of sensitive-fabrics detergent. Follow the instructions on page 15, section »Proper disposal of resources and consumables« for the disposal of
cleaning agents and material.
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7.6
Chapter 7
Inspect the mechanical seal
No visual inspection of the mechanical seals
MATERIAL DAMAGE IN THE TEMPERATURE CONTROL UNIT CAUSED BY LEAKING MECHANICAL
SEALS
 Check the mechanical seals once a month.
 If case of leakage, stop the temperature control unit and contact Customer Support. The telephone number can be found on page 84, section »Contact data«.
Expect drop formation at the mechanical seal when operating with thermal fluids that evaporate
only very slowly, as mechanical seals are never absolutely tight. These drops must be removed if
necessary (see page 74, section »Function check and visual inspection«). The tightness of the mechanical seal must be visually checked. In case of a leakage, more thermal fluid exits at the bottom
of the temperature control unit. Follow the instructions on page 15, section »Proper disposal of
resources and consumables« for the disposal of thermofluid.
7.7
Plug contacts
Exposed plug contacts
DAMAGE CAUSED BY FLUID INGRESS
 Protect unused plug contacts with the protective caps supplied.
 Clean surfaces only with a damp cloth.
Protective caps are supplied for all plug contacts. Make sure that any plug contacts not required are
protective with the caps.
7.8
Decontamination/repairs
Returning a not decontaminated temperature control unit for repair
PHYSICAL INJURY AND PROPERTY DAMAGE CAUSED BY HAZARDOUS MATERIALS IN OR ON THE
TEMPERATURE CONTROL UNIT
 Carry out appropriate decontamination.
 The decontamination process depends on the type and quantity of the materials used.
 Consult the relevant safety data sheet.
 You will find a prepared return receipt at www.huber-online.com.
As the responsible body you are responsible for carrying out decontamination before third-party
personnel come into contact with the temperature control unit / accessory. Decontamination must
be carried out before the temperature control unit / accessory is returned for repair or inspection.
Attach a clearly visible written notice stating that the temperature control unit / accessory has been
decontaminated.
To simplify the process, we have prepared a form for you. This is available for download at
www.huber-online.com.
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8
Shutting down
8.1
Safety instructions and basic principles
Connection/adjustment to the power supply not carried out by an electrician and/or connection
to a power socket without protective earth (PE)
MORTAL DANGER FROM ELECTRIC SHOCK
 Have the connection/adjustment to the power supply carried out by an electrician.
 Always connect the temperature control unit to safety sockets (PE).
Damaged power cable/power cable connection
MORTAL DANGER FROM ELECTRIC SHOCK
 Do not start up the temperature control unit.
 Isolate the temperature control unit from the power supply.
 Have the power supply cable/power supply connection replaced and inspected by an electrician.
Risk of tipping due to unstable temperature control unit
SERIOUS INJURY AND PROPERTY DAMAGE
 Avoid risk of tipping due to unstable temperature control unit.
Non-compliance with the safety data sheet for the thermal fluid to be used
INJURIES
 Risk of injury to the eyes, skin, respiratory tract.
 The safety data sheet for the thermal fluid to be used must be read prior to using it and its
content must be respected.
 Observe the local regulations/work instructions.
 Wear your personal protective equipment (e.g. temperature-resistant safety gloves, safety
goggles, safety footwear).
 Danger of slipping because floor and work area are contaminated. Clean the work station and
follow the instructions for the disposal of thermal fluid and material on page 15 in Section
»Proper disposal of resources and consumables«.
Hot or very cold thermal fluid
SERIOUS BURNS/FREEZING OF LIMBS
 Before draining, ensure that the thermal fluid has room temperature (20 °C).
 If, at this temperature, the thermal fluid is too viscous to be drained: Control the temperature
of the thermal fluid for a few minutes until the viscosity will allow drainage. Never control the
temperature of the thermal fluid when the Drain is open.
 Danger of burns when draining thermal fluids at temperatures above 20 °C.
 Wear your personal protective equipment when carrying out the drain operation.
 Only drain with a suitable draining hose and container. These must be resistant to the thermal
fluid and the temperature.
All safety instructions are important and must be followed accordingly during working operations!
8.2
Switch-off
PROCEDURE
 Turn off the temperature control unit.
 Disconnect the temperature control unit from the power supply connection.
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8.3
Chapter 8
Draining the cooling water
This section must be observed when using water-cooled temperature control units.
8.3.1
Draining process
Pressurized cooling water connections
RISK OF INJURY
 Wear your personnel protective equipment (e.g. safety goggles).
 Carefully open the cooling water connection. Open slowly (1-2 signal edges) and drain the
cooling water slowly.
Building side shut-off valves are not closed
DAMAGE BY ROOM FLOODING
 Close the building’s shut-off valves in the cooling water supply and return lines.
 For table-top models, place a collection container below the >Cooling water drain< [15] (see
connection diagram page 85, section »Annex«).
PROCEDURE
 Close the building’s shut-off valves in the cooling water supply and return lines.
 Place a collecting container below the >Cooling water outlet< [14] and >Cooling water drain<
[15].
 Undo the screw cap on the >Cooling water drain< [15]. The cooling water will begin to drain out.
Allow all the cooling water to drain out to prevent the risk of freezing during transport and storage!
8.4
Transportation lock
Not checking the position of the transportation locks prior to transport
DAMAGE TO THE TEMPERATURE CONTROL UNIT
 Prior to packaging and transport of the temperature control unit, bring the transportation locks
of the compressor into the transport position.
To tighten the transportation locks, observe page 24, section »Tightening the transportation lock
(transport position)«.
8.5
Packing
Use the original packaging wherever possible! Further information can be found on page 25 in section »Unpacking«.
8.6
Shipping
Temperature control unit transported in a horizontal position
DAMAGE TO THE COMPRESSOR
 Only transport the temperature control unit in an upright position.
Temperature control unit transported incorrectly
PROPERTY DAMAGE
 Do not transport by truck on the castors or feet.
 Comply all requirements in this section to avoid damage to the temperature control unit.
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Pallet with squared
timber for freestanding units
Transport using the lugs, if fitted, on the top of the temperature control unit. Do not transport the
temperature control unit alone and without aids.
▪ Always use the original packaging for transport.
▪ Always transport the temperature control unit upright on a pallet!
▪ Protect attachments from damage during transport!
▪ During transport, place the temperature control unit on squared timber to protect the castors/feet.
▪ Secure with tensioning belts/lashing straps rated for the weight concerned.
▪ Additionally secure (depending on model) with plastic film, cardboard and straps.
For temperature control units with transportation lock, strictly observe on page 23 the section
»Transportation lock«.
8.7
Disposal
Uncontrolled or incorrect opening of the coolant circuit
RISK OF INJURY AND ENVIRONMENTAL DAMAGE
 Work on the coolant circuit and disposal of the refrigerant must be carried out by approved
refrigeration/air-conditioning system contractors.
 Also see page 17, section »Temperature control units with fluorinated greenhouse gases/refrigerants«.
Improper disposal
ENVIRONMENTAL DAMAGE
 Spilled/leaked thermofluid must be disposed of immediately and properly. Follow the instructions on page 15, section »Proper disposal of resources and consumables« for the disposal of
thermofluid and material.
 To avoid environmental damage, have “old” temperature control units disposed of exclusively
by approved waste management companies (e.g. refrigeration and air conditioning companies).
 Also see page 17, section »Temperature control units with fluorinated greenhouse gases/refrigerants«.
Huber temperature control units and Huber accessories are made of high quality, recyclable materials. For example: Stainless steel 1.4301 / 1.4401 (V2A), copper, nickel, FKM, Perbunan, NBR, ceramic, carbon, Al‐Oxid, red brass, brass, nickel-plated brass and silver solder. Proper recycling of the
temperature control unit and accessories can actively help reduce CO2 emissions in the production
of these materials. Follow the laws and regulations of your jurisdiction when disposing material.
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8.8
Chapter 8
Contact data
Contact your supplier or local specialist retailer prior to returning the temperature control unit.
The contact data can be found on our homepage www.huber-online.com under the heading „Contact“. Please keep the serial number of the temperature control unit ready. The serial number can
be found on the nameplate of the temperature control unit.
8.8.1
Telephone number: Customer Support
If your country is not mentioned in the list below: The responsible service partner can be found on
our homepage www.huber-online.com under the heading „Contact“.
▪ Huber Deutschland: +49 781 9603 244
▪ Huber China: +86 (20) 89001381
▪ Huber India: +91 80 2364 7966
▪ Huber Ireland: +44 1773 82 3369
▪ Huber Italia: +39 0331 181493
▪ Huber Swiss: +41 (0) 41 854 10 10
▪ Huber UK: +44 1773 82 3369
▪ Huber USA: +1 800 726 4877 | +1 919 674 4266
8.8.2
Telephone number: Sales
Telephone: +49-781-9603-123
8.8.3
Email address: Customer Support
Email: [email protected]
8.9
Certificate of Compliance
Please read page 80, section »Decontamination/repairs«.
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Chapter 9
9
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Annex
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Inspired by temperature
designed for you
Peter Huber Kältemaschinenbau AG
Werner-von-Siemens-Str. 1
77656 Offenburg / Germany
Telefon +49 (0)781 9603-0
Telefax +49 (0)781 57211
[email protected]
www.huber-online.com
Technischer Service: +49 (0)781 9603-244
-125 °C ...+425 °C
Inspired by
temperature
Betriebsanleitung · Operation manual · Manual de
instrucciones · Manuel d‘utilisation · Manuale de d‘uso
· 사용 설명서 · Manual de instruções · Инструкция
по Эксплуатации · Kullanım talimatı · 操作说明书 ·
Betriebsanleitung · Operation manual · Manual de
instrucciones · Manuel d‘utilisation · Manuale de d‘uso
· 사용 설명서 · Manual de instruções · Инструкция
по Эксплуатации · Kullanım talimatı · 操作说明书
· Betriebsanleitung · Operation manual · Manual de
instrucciones · Manuel d‘utilisation · Manuale de d‘uso
· 사용 설명서 · Manual de instruções · Инструкция
по Эксплуатации · Kullanım talimatı · 操作说明书