Huber Unichiller 400T User manual

Unichiller®

OPERATION MANUAL
Unichiller®

OPERATION MANUAL
V2.3.0en/07.06.19//17.12 Unichiller®
5
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

OPERATION MANUAL
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„Pilot ONE“
Layout of the “Home”
screen

OPERATION MANUAL
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Table of contents
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1Introduction 12
1.1 Details on the declaration of conformity....................................................... 12
1.2 Safety .......................................................................................................... 12
1.2.1 Symbols used for Safety Instructions..............................................................12
1.2.2 Representation of safety identifiers ...............................................................13
1.2.3 Proper operation.............................................................................................13
1.2.4 Reasonably foreseeable misuse......................................................................14
1.3 Responsible bodies and operators – Obligations and requirements............... 14
1.3.1 Obligations of the responsible body ...............................................................14
1.3.1.1 Proper disposal of resources and consumables .........................................15
1.3.1.2 Temperature control unit with natural refrigerants (NR) ..........................15
1.3.1.3 Temperature control units with fluorinated greenhouse gases/refrigerants17
1.3.2 Requirements for operators ...........................................................................17
1.3.3 Obligations of the operators...........................................................................18
1.4 General information..................................................................................... 18
1.4.1 Description of workstation .............................................................................18
1.4.2 Safety devices to DIN 12876 ...........................................................................18
1.4.2.1 Temperature control units (with heater) with electronic low level sensor18
1.4.3 Further protective devices..............................................................................19
1.4.3.1 Power interruption.....................................................................................19
1.4.3.2 Alarm functions ..........................................................................................19
1.4.3.3 Warning messages......................................................................................19
1.4.3.4 Emergency stop switch (optional)..............................................................19
1.5 Exemplary illustrations of the cooling variants.............................................. 20
1.5.1 Consequence of inadequate energy dissipation.............................................20
2Commissioning 22
2.1In-plant transport......................................................................................... 22
2.1.1 Lifting and transporting the temperature control unit...................................22
2.1.1.1 Temperature control unit with lifting eyes ................................................22
2.1.1.2 Temperature control unit without lifting eyes...........................................23
2.1.2 Positioning the temperature control unit.......................................................23
2.1.2.1 Temperature control unit with casters ......................................................23
2.1.2.2 Temperature control unit without casters .................................................23
2.2 Transportation lock ...................................................................................... 23
2.2.1 Transportation lock Type A.............................................................................24
2.2.1.1 Releasing the transportation lock (operating position)..............................24
2.2.1.2 Tightening the transportation lock (transport position) ............................24
2.2.2 Transportation lock Type B .............................................................................24
2.2.2.1 Releasing the transportation lock (operating position)..............................25
2.2.2.2 Tightening the transportation lock (transport position) ............................25
2.3 Unpacking.................................................................................................... 25
2.4 Ambient conditions...................................................................................... 25
2.4.1 EMC-specific notes..........................................................................................26
2.5 Installation conditions.................................................................................. 27
2.6 Recommended temperature control and cooling water hoses ...................... 27
2.7 Wrench sizes and torques............................................................................. 28

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2.8 Temperature control units with water cooling.............................................. 28
2.9 Temperature control unit for outdoor installation incl. winter operation ...... 29
2.10 Preparations for operation ........................................................................... 30
2.10.1 Unscrewing/activating the leveling feet (if any) .............................................30
2.10.2 Opening/closing valves ...................................................................................31
2.10.3 Emergency stop switch (optional): Check switching status ............................31
2.11 Connecting externally closed application...................................................... 31
2.11.1 Connecting an externally closed application ..................................................31
2.12 Connecting to the power supply ................................................................... 32
2.12.1 Connection using socket with protective earth (PE).......................................32
2.12.2 Connection via hard wiring .............................................................................32
2.12.3 Connecting the functional earth .....................................................................33
3Function description 34
3.1 Function description of the temperature control unit ................................... 34
3.1.1 General functions............................................................................................34
3.1.2 Other functions...............................................................................................34
3.2 Information on the thermal fluids ................................................................ 35
3.3 To be noted when planning the test ............................................................. 36
3.4 “Pilot ONE®” controller ................................................................................ 37
3.4.1 Functional overview of “Pilot ONE®” ..............................................................37
3.5 Clock/event function.................................................................................... 39
3.5.1 Rechargeable accumulator .............................................................................39
3.5.2 Programmable event function ........................................................................39
3.5.2.1 Event function “Alarm clock event” ...........................................................39
3.5.2.2 Event function “Program event” ................................................................39
3.6 Operation via the touch screen..................................................................... 40
3.7 Display instruments ..................................................................................... 40
3.7.1 The touchscreen [88] ......................................................................................40
3.8 Control instruments ..................................................................................... 40
3.8.1 The touchbuttons............................................................................................41
3.8.2 The categories.................................................................................................41
3.8.3 The sub-categories..........................................................................................41
3.8.4 The dialogs ......................................................................................................41
3.9 Function examples ....................................................................................... 41
3.9.1 Display of software version.............................................................................41
3.9.2 Start & Stop.....................................................................................................42
3.9.3 Copying the settings to a data carrier.............................................................42
3.9.3.1 Saving to a USB flash drive .........................................................................42
3.9.3.2 Loading from a USB flash drive...................................................................43
3.9.4 Restore factory settings ..................................................................................43
3.9.4.1 Restore to factory settings without overtemperature protection .............44
3.9.4.2 Restore to factory settings including overtemperature protection ...........44
4Setup mode 46
4.1 Setup mode ................................................................................................. 46
4.1.1 Emergency stop switch (optional): Activate / Deactivate...............................46
4.1.1.1 Emergency stop switch (optional): Activate...............................................46
4.1.1.2 Emergency stop switch (optional): Deactivate...........................................46
4.1.2 Turning on the temperature control unit .......................................................46
4.1.3 Turning off the temperature control unit .......................................................47
4.1.4 Setting the overtemperature protection ........................................................48
4.1.4.1 General information on the overtemperature protection .........................48

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4.1.4.2 Setting “OT limit: heating” .........................................................................48
4.1.4.3 Setting “Process Safety” .............................................................................49
4.1.4.4 Monitoring via “Display OT values”............................................................49
4.1.5 Testing overtemperature protection for functionality ...................................49
4.1.6 Adjusting the Delta T limiter ...........................................................................50
4.1.6.1 Changing the Delta T limiter.......................................................................50
4.2 The temperature control circuit.................................................................... 50
4.2.1 Select temperature control: Internal or process ............................................51
4.2.2 Temperature control to internal temperature ...............................................51
4.2.3 Temperature control to process temperature................................................51
4.2.4 Delta T limiter .................................................................................................52
4.2.5 Monitoring the Pt100 temperature sensors...................................................52
4.2.6 Optimum control parameters for optimum temperature control..................52
4.2.7 Sub-category: “Select auto/expert mode”......................................................52
4.2.8 Sub-category: “Configuration auto” ...............................................................53
4.2.8.1 Sub-category: “Find parameters”...............................................................53
4.2.8.2 Sub-category: “Control Dynamics”.............................................................55
4.2.8.3 Sub-category: “Fluid Properties”................................................................56
4.2.8.4 Sub-category: “Display parameters” ..........................................................57
4.2.9 Sub-category: “Configuration manual”...........................................................57
4.2.9.1 Sub-category: “Change parameters”..........................................................57
4.2.9.2 Sub-category: “Display parameters” ..........................................................58
4.2.9.3 Sub-category: “Control structure”..............................................................58
4.2.10 Sub-category: “Reset parameters” .................................................................59
4.2.11 Sub-category: “Display parameters”...............................................................59
4.2.12 Freeze protection for temperature control unit (optional) ............................59
4.2.13 Setting the setpoint thresholds ......................................................................60
4.2.14 Setting the setpoint ........................................................................................60
4.3 Filling, venting and draining ......................................................................... 61
4.3.1 Externally closed application ..........................................................................61
4.3.1.1 Filling and venting externally closed application........................................61
4.3.1.2 Draining externally closed applications......................................................63
5Normal operation 64
5.1 Automatic operation .................................................................................... 64
5.1.1 Temperature control.......................................................................................64
5.1.1.1 Starting the temperature control process..................................................64
5.1.1.2 Ending the temperature control process ...................................................64
5.1.2 Temperature control via a created temperature control program ................65
5.1.2.1 Starting the temperature control program ................................................65
5.1.2.2 Ending/cancelling the temperature control program ................................65
6Interfaces and software update 66
6.1 Interfaces at the “Pilot ONE®” controller ...................................................... 66
6.1.1 10/100 Mbps Ethernet for RJ45 network sockets ..........................................66
6.1.2 USB-2.0 interface ............................................................................................66
6.1.2.1 USB-2.0 interface, host...............................................................................67
6.1.2.2 USB-2.0 interface, device ...........................................................................67
6.2 Interfaces at the top side of the Unichiller. ................................................... 67
6.2.1 Female RS232 Serial (with adapter cable) ......................................................67
6.2.2 Connection jack for Pt100 process controller sensor .....................................67
6.2.3 Service interface .............................................................................................68
6.3 Interfaces at the Com.G@te® (optional) ....................................................... 68

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6.3.1 Jack LEVEL (Com.G@te® external only) ..........................................................69
6.3.2 Connector POKO (floating contact) alarm ......................................................69
6.3.3 Jack AIF Reg-E-Prog.........................................................................................70
6.3.4 Jack ECS (External Control Signal) standby .....................................................71
6.3.5 Jack RS232/RS485 serial..................................................................................72
6.4 Firmware update.......................................................................................... 72
7Service/maintenance 73
7.1 Messages from the temperature control unit ............................................... 73
7.2 Replacing the “Pilot ONE®”........................................................................... 73
7.3 Maintenance................................................................................................ 73
7.3.1 Function check and visual inspection .............................................................74
7.3.2 Replacing temperature control or coolant hoses ...........................................75
7.3.2.1 Replacing temperature control hoses ........................................................75
7.3.2.2 Replacing coolant hoses .............................................................................75
7.3.3 Clean liquefier fins (air-cooled temperature control unit) .............................75
7.3.4 Clean hat-type strainer (dirt trap) (water-cooled temperature control unit).76
7.3.5 Emergency stop switch (optional): Function test ...........................................76
7.4 Thermal fluid inspection, replacement and circuit cleaning........................... 77
7.4.1 Thermal fluid inspection .................................................................................77
7.4.2 Thermal fluid replacement .............................................................................77
7.4.2.1 Externally closed application......................................................................78
7.4.3 Rinsing the thermal fluid circuit......................................................................78
7.5 Cleaning the surfaces ................................................................................... 79
7.6 Inspect the mechanical seal.......................................................................... 80
7.7 Plug contacts................................................................................................ 80
7.8 Decontamination/repairs ............................................................................. 80
8Shutting down 81
8.1 Safety instructions and basic principles ........................................................ 81
8.2 Switch-off .................................................................................................... 81
8.3 Draining the cooling water ........................................................................... 82
8.3.1 Draining process .............................................................................................82
8.4 Transportation lock ...................................................................................... 82
8.5 Packing ........................................................................................................ 82
8.6 Shipping....................................................................................................... 82
8.7 Disposal ....................................................................................................... 83
8.8 Contact data ................................................................................................ 84
8.8.1 Telephone number: Customer Support ..........................................................84
8.8.2 Telephone number: Sales ...............................................................................84
8.8.3 Email address: Customer Support...................................................................84
8.9 Certificate of Compliance ............................................................................. 84
9Annex 85