Huber Unistat TR Series User manual

Unistat®
TR

OPERATION MANUAL
Unistat®
TR

OPERATION MANUAL
V2.3.0en/22.07.19//17.12 Unistat® TR
5
Unistat® TR
Pilot ONE®
This operation manual is a translation of the original operation manual.
VALID FOR:
Unistat® TR40x
Abbreviations used in model names:
Without = with air cooling, w HT = with HT water cooler

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

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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
1.3.2 Requirements for operators ...........................................................................15
1.3.3 Obligations of the operators...........................................................................15
1.4General information..................................................................................... 15
1.4.1 Description of workstation .............................................................................15
1.4.2 Safety devices to DIN 12876 ...........................................................................16
1.4.3 Further protective devices ..............................................................................17
1.4.3.1 Power interruption.....................................................................................17
1.4.3.2 Alarm functions ..........................................................................................17
1.4.3.3 Warning messages......................................................................................17
2Commissioning 18
2.1 In-plant transport......................................................................................... 18
2.1.1 Lifting and transporting the temperature control unit...................................18
2.1.1.1 Temperature control unit with lifting eyes ................................................18
2.1.1.2 Temperature control unit without lifting eyes...........................................18
2.1.2 Positioning the temperature control unit.......................................................19
2.1.2.1 Temperature control unit with casters ......................................................19
2.1.2.2 Temperature control unit without casters .................................................19
2.2 Unpacking.................................................................................................... 19
2.3 Ambient conditions...................................................................................... 19
2.3.1 EMC-specific notes..........................................................................................21
2.4 Installation conditions.................................................................................. 21
2.5 Recommended temperature control and cooling water hoses ...................... 22
2.6 Wrench sizes and torques............................................................................. 23
2.7 Temperature control units with water cooling.............................................. 23
2.8 Preparations for operation ........................................................................... 25
2.8.1 Unscrewing/activating the leveling feet (if any) .............................................25
2.8.2 Open/Close ball valve on >Drain< [8] .............................................................25
2.8.3 Check the knurled screw from the >Emptying of residues< [10]....................25
2.8.4 Connect the hose to the >Overflow< [12] ......................................................25
2.8.5 Connections for inert gas (nitrogen)...............................................................26
2.8.6 Connecting the temperature control unit with the controller (only TR401,
TR402).............................................................................................................26
2.9 Connecting externally closed application...................................................... 26
2.9.1 Connecting an externally closed application ..................................................27
2.10 Connecting to the power supply ................................................................... 27
2.10.1 Connection using socket with protective earth (PE).......................................27

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2.10.2 Connection via hard wiring .............................................................................28
2.10.3 Converting the power supply connection.......................................................28
2.10.4 Connecting the functional earth .....................................................................28
3Function description 29
3.1 Function description of the temperature control unit ................................... 29
3.1.1 General functions............................................................................................29
3.1.2 Other functions...............................................................................................29
3.2 Information on the thermal fluids ................................................................ 29
3.3 To be noted when planning the test ............................................................. 30
3.4 “Pilot ONE®” controller ................................................................................ 31
3.4.1 Functional overview of “Pilot ONE®” ..............................................................31
3.5 Clock/event function.................................................................................... 34
3.5.1 Rechargeable accumulator .............................................................................34
3.5.2 Programmable event function ........................................................................34
3.5.2.1 Event function “Alarm clock event” ...........................................................34
3.5.2.2 Event function “Program event” ................................................................34
3.6 Operation via the touch screen..................................................................... 34
3.7 Display instruments ..................................................................................... 35
3.7.1 The touchscreen [88] ......................................................................................35
3.8 Control instruments ..................................................................................... 35
3.8.1 The touchbuttons............................................................................................35
3.8.2 The categories.................................................................................................36
3.8.3 The sub-categories..........................................................................................36
3.8.4 The dialogs ......................................................................................................36
3.9 Function examples ....................................................................................... 36
3.9.1 Display of software version.............................................................................36
3.9.2 Start & Stop.....................................................................................................36
3.9.3 Copying the settings to a data carrier.............................................................37
3.9.3.1 Saving to a USB flash drive .........................................................................37
3.9.3.2 Loading from a USB flash drive...................................................................37
3.9.4 Restore factory settings ..................................................................................38
3.9.4.1 Restore to factory settings without overtemperature protection .............39
3.9.4.2 Restore to factory settings including overtemperature protection ...........39
4Setup mode 41
4.1 Setup mode ................................................................................................. 41
4.1.1 Turning on the temperature control unit .......................................................41
4.1.2 Turning off the temperature control unit .......................................................41
4.1.3 Setting the overtemperature protection ........................................................42
4.1.3.1 General information on the overtemperature protection .........................42
4.1.3.2 Setting “OT limit: heating” .........................................................................42
4.1.3.3 Setting “OT expansion vessel”....................................................................43
4.1.3.4 Setting “Process Safety” .............................................................................43
4.1.3.5Monitoring via “Display OT values”............................................................43
4.1.4 Testing overtemperature protection for functionality ...................................44
4.1.5 Adjusting the Delta T limiter ...........................................................................44
4.1.5.1 Changing the Delta T limiter.......................................................................44
4.2 The temperature control circuit.................................................................... 44
4.2.1 Select temperature control: Internal or process ............................................45
4.2.2 Temperature control to internal temperature ...............................................45
4.2.3Temperature control to process temperature................................................45
4.2.4 Delta T limiter .................................................................................................46

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4.2.5 Monitoring the Pt100 temperature sensors...................................................46
4.2.6 Optimum control parameters for optimum temperature control..................46
4.2.7 Sub-category: “Select auto/expert mode”......................................................47
4.2.8 Sub-category: “Configuration auto” ...............................................................47
4.2.8.1 Sub-category: “Find parameters”...............................................................47
4.2.8.2Sub-category: “Control Dynamics”.............................................................49
4.2.8.3 Sub-category: “Fluid Properties”................................................................50
4.2.8.4 Sub-category: “Display parameters” ..........................................................51
4.2.9 Sub-category: “Configuration manual”...........................................................51
4.2.9.1 Sub-category: “Change parameters”..........................................................51
4.2.9.2 Sub-category: “Display parameters” ..........................................................53
4.2.9.3 Sub-category: “Control structure”..............................................................53
4.2.10 Sub-category: “Reset parameters” .................................................................53
4.2.11 Sub-category: “Display parameters”...............................................................53
4.2.12 Setting the setpoint thresholds ......................................................................54
4.2.13 Setting the setpoint ........................................................................................54
4.3 Filling, venting, degassing and draining......................................................... 55
4.3.1 Externally closed application ..........................................................................55
4.3.1.1 Filling and venting externally closed application........................................55
4.3.1.2 Degassing externally closed applications ...................................................57
4.3.1.3 Draining externally closed applications......................................................59
5Normal operation 61
5.1 Automatic operation .................................................................................... 61
5.1.1 Temperature control.......................................................................................61
5.1.1.1 Starting the temperature control process..................................................61
5.1.1.2 Ending the temperature control process ...................................................61
5.1.2 Temperature control via a created temperature control program ................62
5.1.2.1 Starting the temperature control program ................................................62
5.1.2.2 Ending/cancelling the temperature control program ................................62
6Interfaces and software update 63
6.1 Interfaces at the “Pilot ONE®” controller ...................................................... 63
6.1.1 10/100 Mbps Ethernet for RJ45 network sockets ..........................................63
6.1.2 USB-2.0 interface ............................................................................................63
6.1.2.1 USB-2.0 interface, host...............................................................................64
6.1.2.2 USB-2.0 interface, device ...........................................................................64
6.2 Interfaces at the “Unistat® TR400” ............................................................... 64
6.2.1 Connection jack for Pt100 process controller sensor .....................................64
6.2.2 Service interface .............................................................................................65
6.2.3 Connector POKO (floating contact) alarm ......................................................65
6.2.4 Jack ECS (External Control Signal) standby .....................................................66
6.3 Interfaces at the “Unistat® TR401, TR402”.................................................... 67
6.3.1 Interfaces at the back of the “HT-Circulator” .................................................67
6.3.1.1 Connection jack for Pt100 process controller sensor.................................67
6.3.1.2 Service interface.........................................................................................67
6.3.1.3 Control connection HT-Circulator/Controller.............................................68
6.3.1.4 Unit connection HT-Circulator/Controller..................................................68
6.3.2 Interfaces at the back of the “Controller” ......................................................68
6.3.2.1 Service interface.........................................................................................68
6.3.2.2 Connector POKO (floating contact) alarm..................................................68
6.3.2.3 Jack ECS (External Control Signal) standby.................................................68
6.3.2.4 Power supply ..............................................................................................68

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6.3.2.5 Control connection HT-Circulator/Controller.............................................69
6.3.2.6 Unit connection HT-Circulator/Controller..................................................69
6.4 Interfaces at the Com.G@te® (optional) ....................................................... 69
6.4.1 Jack LEVEL (Com.G@te® external only) ..........................................................70
6.4.2 Connector POKO (floating contact) alarm ......................................................70
6.4.3 Jack AIF Reg-E-Prog.........................................................................................70
6.4.4 Jack ECS (External Control Signal) standby .....................................................71
6.4.5 Jack RS232/RS485 serial..................................................................................71
6.5 Firmware update.......................................................................................... 71
7Service/maintenance 72
7.1 Messages from the temperature control unit ............................................... 72
7.2 Replacing the “Pilot ONE®”........................................................................... 72
7.3 Maintenance................................................................................................ 72
7.3.1 Function check and visual inspection .............................................................73
7.3.2 Replacing temperature control or coolant hoses ...........................................74
7.3.2.1 Replacing temperature control hoses ........................................................74
7.3.2.2 Replacing coolant hoses .............................................................................74
7.3.3 Clean hat-type strainer (dirt trap) (water-cooled temperature control unit).74
7.3.4 Empty the drip tray .........................................................................................75
7.4Thermal fluid inspection, replacement and circuit cleaning........................... 75
7.4.1 Thermal fluid inspection .................................................................................76
7.4.2 Rinsing the thermal fluid circuit......................................................................76
7.5 Cleaning the surfaces ................................................................................... 78
7.6 Inspect the mechanical seal.......................................................................... 78
7.7 Plug contacts................................................................................................ 78
7.8 Decontamination/repairs ............................................................................. 79
8Shutting down 80
8.1 Safety instructions and basic principles ........................................................ 80
8.2 Switch-off .................................................................................................... 80
8.3 Draining the cooling water ........................................................................... 81
8.3.1 Draining process .............................................................................................81
8.4 Deinstalling the collecting container............................................................. 81
8.5 Packing ........................................................................................................ 81
8.6 Shipping....................................................................................................... 81
8.7 Disposal ....................................................................................................... 82
8.8 Contact data ................................................................................................ 82
8.8.1 Telephone number: Customer Support ..........................................................83
8.8.2 Telephone number: Sales ...............................................................................83
8.8.3 Email address: Customer Support...................................................................83
8.9 Certificate of Compliance ............................................................................. 83
9Annex 84