Julabo PRESTO A80 Installation instructions

02.09.2019
Original Operating Manual
Highly Dynamic Temperature Control System
A80, A80t, W80, W80t
1.951.3044-V7 09/19
See Operating
instructions „User
Interface“, 1951.3041,
for additional
information.
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A80, A80t, W80, W80t Operating Manual
28.08.2019 3
Congratulations!
You have made an excellent choice.
JULABO would like to thank you for the trust you have placed in our company and products.
This Operating Manual will help you become acquainted with the use of our temperature control
systems. Read this manual carefully before bringing the unit into operation!
The JULABO Quality Management System
Temperature control devices for research and industry are developed,
produced, and distributed according to the requirements of ISO 9001 and
ISO 14001. Certificate Registration No. 01 100044846
Unpacking and Inspection
After unpacking the units and accessories, carefully inspect them for any damage. If the packaging
has been damaged, you must notify the freight forwarder, railway company, or postal service so they
can file a damage report.
Printed in Germany Changes without prior notification reserved
Important: keep operating manuals for future use
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Table of Contents
4 28.08.2019
Table of Contents
Table of Contents ....................................................................................................................... 4
1. Proper Use ........................................................................................................................ 7
1.1. Description.................................................................................................................... 7
2. Operator Responsibilities - General Safety Notices ........................................................... 8
2.1. Personnel ..................................................................................................................... 8
2.2. Handling guidelines ...................................................................................................... 8
3. Safety Notices ................................................................................................................... 9
3.1. Explanation of safety notices ........................................................................................ 9
3.2. Descriptions of other notices......................................................................................... 9
3.3. Safety instructions for operation.................................................................................. 10
3.5. Operation.................................................................................................................... 12
3.6. Transporting and properly locating the device............................................................. 14
3.6.1. Transport................................................................................................................ 14
3.6.2. Properly locating the device, Earthquake anchorage.............................................. 15
3.7. Connecting to power supply........................................................................................ 16
3.7.1. Unit for hard-wired installation ................................................................................ 16
4. Operating and functional elements .................................................................................. 17
4.1. Front side of the unit ................................................................................................... 17
4.1.1. Electrical connections on the front side of the device (upper section)..................... 18
4.1.2. Drain elements on the front side of the device (lower section)................................ 19
4.2. Rear of unit ................................................................................................................. 20
4.2.1. A80, A80t, air-cooled.............................................................................................. 20
4.2.2. W80, W80t, water-cooled ....................................................................................... 21
5. Preparations.................................................................................................................... 22
5.1. Cooling water connections at W80 and W80t.............................................................. 22
5.2. Bath fluids................................................................................................................... 24
5.3. Temperature control tubing ......................................................................................... 25
5.4. Connecting an external vessel .................................................................................... 26
5.5. Diagram: Device structure and mechanical connections ............................................. 27
5.6. Accessories ................................................................................................................ 27
5.6.1. Connectors, Valves, Adapters, etc. ........................................................................ 27
5.7. Filling .......................................................................................................................... 28
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5.7.1. Sample Calculation: Determining whether an external exp. reservoir is needed ..... 28
5.7.2. Filling a closed, external system............................................................................. 29
5.8. “Empty the unit” menu................................................................................................. 30
5.9. Additional thermal adjustment and electrical connection elements.............................. 34
5.9.1. Adjustable high temperature cut-off........................................................................ 34
5.9.2. Electrical connections............................................................................................. 35
6. Electrical connection pin assignments .................................................................................. 37
6.1. Accessories ................................................................................................................ 37
6.1.1. Alarm output........................................................................................................... 37
6.1.2. Connection for the external Pt100 sensor............................................................... 38
6.2. Options (on the rear side) ........................................................................................... 38
6.2.1. Analog module ....................................................................................................... 39
6.2.2. Module with Pt100 connector ................................................................................. 39
6.2.3. Connecting to the STAND-BY socket ..................................................................... 40
6.2.4. Connecting to the REG+E-PROG socket ............................................................... 41
6.2.5. Connecting to the JULABO Pressure / Flow Sensor socket.................................... 42
7. Remote operation, laboratory automation........................................................................ 43
7.1. Preparing for remote control ....................................................................................... 43
7.2. Communication with PC or higher priority data system ............................................... 43
7.3. Status messages / Error messages ............................................................................ 44
7.3.1. Alarms.................................................................................................................... 44
7.3.2. Warnings................................................................................................................ 44
8. Technical Data ................................................................................................................ 45
8.1. Cooling water connection, cooling water quantity........................................................
49
8.2. Connections................................................................................................................ 49
8.3. Safety ......................................................................................................................... 50
8.4. Ambient conditions for proper operation according to EN 61 010-1............................. 50
8.5. Materials of Construction of the wetted Parts .............................................................. 52
9. Pump characteristic curves (using water) ........................................................................ 53
9.1. Medium with a density of 1 kg/dm3 [8.35 lb/gal] .......................................................... 53
10. Cleaning the unit ............................................................................................................. 54
10.1. External cleaning ........................................................................................................ 54
10.2. Internal cleaning ......................................................................................................... 54
10.3. Cleaning the reservoir, tubing system and heat exchanger: ........................................ 55
10.4. Removing residual cleaning liquid:.............................................................................. 56
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10.5. Shut-down and storage............................................................................................... 56
11. Maintenance/repair of the unit ........................................................................................ 57
11.1. Repair service............................................................................................................. 57
11.2. Warranty ..................................................................................................................... 58
11.3. Disposal...................................................................................................................... 58
12. EC compliance ................................................................................................................ 59
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1. Proper Use
is a highly dynamic temperature control system designed for
controlling the temperature of certain liquids in a closed, external system.
The temperature-controlled external system is attached to the protruding
pump connections on the rear of the .
JULABO temperature control systems are not suitable for direct
temperature control of food or other items intended for human
consumption, pharmaceutical products, or medical products.
Direct temperature control means: The temperature-controlled object
has unprotected contact with the bath fluid.
1.1. Description
•In addition to the refrigeration unit, the main functional elements are
the heater, circulation pump, and control electronics. When used
with an external Pt100 control sensor, the auto-optimizing electronic
PID controller will automatically adjust to the requirements of the
external vessel.
•The pump’s powerful output can be reduced for use with pressure-
sensitive vessels by altering the motor speed in four stages or by
controlling via pressure.
•The refrigeration systems are cooled
- A80, A80t with air from the ambient surroundings
- W80, W80t with water.
•The unit is operated via the TFT user interface.
•Remote control through the digital RS232, USB, and ethernet
interfaces according to NAMUR enable advanced process control
without an additional interface card.
•The high temperature cut-off is a safety device that is independent
from the control circuit. The cut-off temperature is adjustable and is
displayed on the TFT user interface.
•The integrated programmer lets you store and retrieve setpoints and
times for eight different temperature profiles.
•Interfaces available on the right side of the housing:
- SD card for datalogging
- USB host interface.
•Analog interfaces:
- Alarm output for an external signal
- Ext. Pt100 connection for an external control
- Connection for JULABO pressure or flow sensor
•An analog module is optionally available, it consists of:
A STAND-BY input for remote shutoff with an external switch.
REG+E-PROG connection for specifying the setpoint with an
external analog setpoint device or programmer. Three analog
outputs for datalogging are also integrated.
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Operator Responsibilities - General Safety Notices
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2. Operator Responsibilities - General Safety Notices
Products from JULABO GmbH are safe when installed, operated, and
maintained according to generally accepted rules of safety. This chapter
explains the potential hazards that can arise in conjunction with operation
of the temperature control system and describes safety measures for
eliminating these hazards when possible.
2.1. Personnel
•The owner/operator is responsible for the qualifications of the
operating personnel.
•Make sure that anyone who will operate the temperature control
system has been instructed regarding the relevant tasks.
•The operators must be trained on a regular basis on the hazards that
may occur during their activities and on measures for mitigating
these hazards.
•Make sure that anyone entrusted with operation, maintenance, and
installation has read and understood the safety information and the
operating manual.
•When using hazardous materials or materials that may become
hazardous, allow only persons with complete knowledge of the
materials and the circulator to bring the unit into operation. These
persons must have the ability to evaluate potential dangers in their
entirety.
2.2. Handling guidelines
•Avoid impacts to the housing, vibrations, damage to the keypad
(keys, display), or heavy soiling.
•Regularly check, at least once every two years, to ensure proper
condition of the safety, warning, and prohibition symbols.
•Ensure that the mains power network exhibits low impedance in
order to avoid influencing units that are operated on the same
network.
•Magnetic radiation may affect other devices that contain components
that are sensitive to magnetic fields, such as a monitor. We advise
maintaining a min. distance of 1 m from such devices.
•The ambient temperature may not exceed 40 °C [104 °F], nor fall
below 5 °C [41 °F].
•Rel. humidity should not exceed 50% at 40 °C, [104 °F].
•Do not store or use the unit in aggressive (corrosive) atmospheres.
Protect the unit from contamination.
•Do not place the device in direct sunlight.
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3. Safety Notices
3.1. Explanation of safety notices
The Operating Manual contains additional safety notices. They are
identified by a triangle with exclamation point.
"Caution, warning of a dangerous condition."
The significance of the danger is categorized in conjunction with a
signal word. Carefully read and observe the instructions!
Designates a potentially threatening danger to life and health. Failure
to observe these notices can result in serious health consequences,
including life-threatening injuries.
Designates a potentially hazardous situation. If not avoided, they
may result in slight or minor injuries. The text may also warn against
potential property damages.
Designates the potential for property damage. If not avoided, the
product or something in its vicinity may be damaged.
Designates a possibly harmful situation. If it is not prevented, the
system or something near it may be damaged.
3.2. Descriptions of other notices
TIPP
This symbol draws attention to important information.
Important!
Refers to usage tips and other useful information.
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Operator Responsibilities - General Safety Notices
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3.3. Safety instructions for operation
It is essential that you read the operating manuals before initial
operation.
It is important that you follow all safety instructions in order to avoid
personal injury and property damage. These instructions supplement
workplace safety regulations.
•This device may be connected to grounded (protected earth, PE)
mains power outlets only!
•These tasks may be performed by properly trained personnel only.
•The mains plug serves as a reliable way to disconnect the unit from
its power supply for safety reasons and must be readily accessible
at all times.
•Install the unit on a level, noncombustible surface
•Adjust the high temperature cut-off before operating the unit.
•Never operate the unit without bath fluid!
•Observe expansion of the bath oil as the bath temperature rises.
•Do not allow water to enter hot bath oil.
•Do not drain bath fluid while it is hot!
Check the temperature of the bath fluid before draining; this may be
done by briefly switching on the unit.
•Use tubing suitable for temperature-control purposes.
•Avoid kinking the external tubing.
•Secure tubing connections to prevent slipping.
•Regularly check tubing for material fatigue, such as cracks.
•Never operate a damaged or leaking unit.
•Do not attempt to use the unit if the power cable is damaged!
•Before performing service or repair tasks or moving the unit, switch
the unit off and remove the power plug from the socket.
•Allow only authorized technicians to perform service and repair
tasks.
•Always switch off the device and disconnect it from its power supply
before attempting to clean it.
•Completely drain the unit before moving it.
•Transport the unit carefully.
•Do not tilt or lay the unit during transport.
•Shaking or falls may damage the inside of the unit.
•Observe all safety labels!
•Do not remove safety labels!
Hot or cold parts.
Risk of burns or frostbite.
Use gloves.
Dangerous electrical voltage
Discharging of internal capacitors takes 5 sec. Do not touch plug pins
for 5 sec. after pulling the power plug.
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3.4. Safety instructions for properly locating and installing the device
Danger of burns and property damage if unsuitable bath fluid is
used.
Proper use of the temperature control system includes controlling the
temperature of a liquid in a reactor or similar vessel.
We do not know which substances you will need to use.
Many substances are:
•combustible, flammable, or explosive
•hazardous to health
•hazardous to the environment
•in other words: dangerous.
The user bears sole responsibility for handling these materials!
The following questions are meant to help recognize potential
hazards and minimize risks.
•Are all tubes and electrical cables securely attached and laid?
Watch for:
sharp edges, hot surfaces during operation, moving mechanical
parts, etc.
•Will hazardous vapors or gases be produced during heat-up?
Is it necessary to work under a fume hood?
•What must be done if a hazardous substance is spilled onto or into
the unit?
Obtain information about the substance before beginning work and
define decontamination methods.
Escaping vapors/gases
•Vapors/gases may develop, especially at higher working
temperatures. The unit will vent these vapors/gases to ensure
optimum performance. Operation under a fume hood is
recommended.
Ensure good ventilation and airflow at the place of installation.
It is advisable to continue circulation for a certain amount of time after
you are finished working with the temperature control system. You
should also set the working temperature to approximately 20 °C [68 °F]
in order to uniformly drop the temperature in the closed loop. This will
avoid overheating of the bath fluid and dangerous draining conditions.
Inspect safety devices at least twice per year:
•High temperature cut-off device.
Use a screwdriver to turn the adjustable high temperature cut-off
down to the current bath temperature (this will shut off the unit).
•Low-level safety
The float switch on this unit cannot be activated manually for the
purpose of checking functionality. Therefore, you should observe the
five-stage level indicator each time you refill the unit.
If the bath fluid becomes thick or cracks during operation, the
temperature control system must be cleaned by qualified personnel.
This can be avoided by changing the fluid regularly. Refer to chapter
5.9. “Empty the unit” menu.
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Operator Responsibilities - General Safety Notices
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3.5. Operation
The unit may only be configured, installed, maintained, and repaired by
qualified personnel.
Persons who operate the circulator must be trained in the particular tasks
by qualified personnel. Please call us if you have any questions about
operating the unit or the operating manual.
The bath may be filled with flammable liquids. Fire hazard!
Some bath fluids may represent a chemical hazard.
Observe all warning notices on the materials used (bath fluids) and in
their associated instructions (safety data sheets).
Potentially explosive mixtures may be formed if adequate ventilation is
not provided. Use the units only in well ventilated areas. The units are not
suitable for use in potentially explosive atmospheres.
Proper use includes limitations on the types of materials (bath fluids)
used. Do not use toxic, acidic, or corrosive bath fluids.
If using hazardous materials or materials that may become hazardous,
the operator must apply the enclosed safety labels to the front side of the
unit where they are easily visible.
Switch off the temperature control system if the cooling circuit is
disconnected for an extended time period.
Warns against a dangerous condition. Important! Please observe the
documentation. (operating instructions, safety data sheet).
You must read the operating manual before switching on the unit.
Valid in: EU
You must read the operating manual before switching on the unit.
Valid in: USA, NAFTA
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Special diligence and care are essential due to the wide operating
temperature range.
There are heat- and cold-related hazards: burns, scalding, superheated
steam, frostbite.
Hot and cold parts and surfaces that could cause burns or frostbite when
touched.
Warns against hot or cold surfaces.
Disconnect the unit from the power supply prior to opening.
Dangerous electrical voltage. Discharging of internal capacitors.
Observe the notices in the instructions for third-party units that you attach
to the JULABO unit, especially any safety notices.
The pin assignment of the plugs and the technical data of the products
must be observed of all times.
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Operator Responsibilities - General Safety Notices
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3.6. Transporting and properly locating the device
Risk of explosion by explosive mixtures
Danger of burns
The unit is not suitable for use in potentially explosive atmospheres
Tipping hazard!
Unit may tip if pushed from the side with more than 180 N of force.
Incorrect lifting techniques and/or lifting equipment can lead to
overloading of one or more of the eye bolts (pictured below), which
could destroy it/them. As a result, all of the support points used for
lifting could become overloaded, leading to a drop that could cause
harm to bystanders and/or damage to the device.
When selecting lifting equipment, please take into account the weight
of the temperature control system.
Danger of suspended loads
Risk of impact and crushing
- Do not step beneath the suspended unit.
- Wear personal protective equipment e.g.
safety shoes, safety helmet.
3.6.1. Transport
•Fasten lifting gear to the
four eye bolts.
•Transport unit to
installation site and
place in position.
•Remove lifting gear.
•Remove eye bolts and
retain.
•Suggestion: Close the
tapped bores with the
plastic caps included in
delivery.
To transport and position the unit with lifting gear there are four lifting
points with eye bolts.
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3.6.2. Properly locating the device, Earthquake anchorage
•Transport the unit on a
firm, level surface.
Avoid shocks, e.g. floor
grates.
•For longer distances,
securely strap the unit
to a trolley or cart before
transport.
•Position the unit at the
desired location and
lock the castors.
•Install the unit on a
level, noncombustible
surface.
•Do not install the unit in
the immediate vicinity of
a heat source and do
not place it in direct
sunlight.
•Keep the ventilation
grids clear (front and
rear)! Maintain
clearance of at least 8
inches (20 cm) from
objects, walls, etc. in
both the front and rear
of the unit.
•Clean the ventilation
grids (front and rear) at
least once every 2-3
weeks. In dirty
environments, clean the
ventilation grids more
often.
•When using an external
reservoir, additional
space is needed at the
rear.
Ensure adequate air conditioning at the installation location.
The installation location should be air conditioned to prevent the
exhaust heat of the unit from increasing the ambient temperature too
much (maximum ambient temperature 40 °C [104 °F]). Furthermore,
standard EN 378 requires a minimum room size for each kilogram of
refrigerant in the event of a leak in the refrigeration circuit. Refer to the
type label for the refrigerant volume.
0.49 kg of refrigerant R507 requires 1 m3of space.
0.68 kg of refrigerant R23 requires 1 m3of space.
Mounting holes for Earthquake anchorage (in mm)
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Operator Responsibilities - General Safety Notices
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3.7. Connecting to power supply
Danger of electric shock.
Risk of injury from electric power.
•This device may be attached to grounded (protected earth, PE)
mains power outlets only!
•The mains plug serves as a reliable way to disconnect the unit from
its power supply for safety reasons and must be readily accessible
at all times.
•Do not attempt to use the unit if the power cable is damaged!
•Regularly inspect the power cable for damage.
•JULABO assumes no liability for improper power connection!
Compare the available mains voltage and mains frequency with the
specifications on the type label.
See technical data section for information on allowable voltage
tolerances.
Connect the mains plug to a grounded (protected earth, PE) power
supply socket!
For 60 Hz devices: Since the device is protected by a circuit breaker of
characteristic K, the loop impedance of the circuit used must not exceed
0.55 ohms.
3.7.1. Unit for hard-wired installation
Units for hard-wiring are delivered with a mains power cable but without a
plug. These units are A80t and W80t units with the voltage
3x208 V / 60 Hz.
When installed in a building, provisions must be made for a circuit
breaker of 32-A as separator.
In addition it is recommended to fuse the unit in the building installation
with 32-A-with C-characteristic.
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4. Operating and functional elements
4.1. Front side of the unit
1 User Interface
2 Removable ventilation
grid
3 High temperature cut-
off adjustment
4 Power switch (at the
side of the housing)
5 USB Host (Type A)
connection and SD
Card slot.
Operation of the user
interface is described in a
separate document (see
page 1).
Fig.: A80
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Operating and functional elements
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4.1.1. Electrical connections on the front side of the device (upper section)
Remove the ventilation
grid (front panel at W80)
as follows in order to
access the electrical
connections:
•Grasp the bottom
edge of the ventilation
grid (front panel), lift
slightly (1), and tilt it
forwards (2).
•Remove the
ventilation grid (front
panel) from the
housing frame.
Included connections:
1 Ethernet connection.
2 USB device (Type B
plug).
3 RS232 interface
4 Alarm socket for ext.
alarm signal.
5 Socket for external
measurement and
control sensor
(Pt100).
6 Connection for
draining residual bath
fluid.
7 Sensor for ambient
temperature
measurement.
Using tubing and a
suitable vessel, open the
connection (6), about
every 2-3 weeks, to
release any built-up
deposits
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4.1.2. Drain elements on the front side of the device (lower section)
The drain nozzle (7) with
outer diameter ∅12 mm and
the drain screw (8) are
located near the bottom of
the unit behind the
ventilation grid.
On the W80 it is possible to
completely drain the cooling
water system via the sealing
plug M10x1 (9).
Details are given in chapter
5.8. “Empty the unit”
menu.
A80
W80
Replace the ventilation grid
(front panel) as follows:
•Slide the venting grid
below the upper unit
cover. Set the
ventilation grid onto the
angled metal piece at
the bottom of the unit.
•Tilt the ventilation grid
towards the unit until it
touches the mounting
pins.
•Lift the grid slightly and
onto the mounting pins.
•Slide the ventilation grid
downward.
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Operating and functional elements
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4.2. Rear of unit
4.2.1. A80, A80t, air-cooled
1 Circuit breakers for
mains supply
1a at A80t
2 Mains cable with plug
2a at A80t
3 Overflow connection,
M16x1 male
4 Pump connection
(supply ),
M24x1.5 male
5 Pump connection,
(return IN ),
M24x1.5 male
6 Connection for
external
expansion reservoir,
M16x1 male
Options
7 Socket for connection
of optional accessory
analog connections
(Order No. 8900105).
8 Socket for connection
of Pt100 module with
connector (Order No.
8900106).
9 JULABO Pressure /
Flow Sensor socket.
More information regarding
these connections can be
found in chapter 6.
Electrical connection pin
assignments, page 37
Safety cutouts and mains cable at A80t
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4.2.2. W80, W80t, water-cooled
1 Circuit breakers for mains
supply
1a at W80t
2 Mains cable with plug
2a at W80t
3 Overflow connection,
M16x1 male
4 Pump connection
(supply ),
M24x1.5 male
5 Pump connection
(return, ),
M24x1.5; male
6 Cooling water outlet,
(OUT ) G3/4“ barbed
fittings for ½” inner
diameter
7 Cooling water inlet,
(IN ) G3/4“ barbed
fittings for ½” inner diameter
8 Connection for external
expansion reservoir,
M16x1 male
Options
9 Socket for connection of
optional accessory analog
connections (Order No.
8900105).
10 Socket for connection of
Pt100 module with
connector (Order No.
8900106)
11 JULABO Pressure / Flow
Sensor socket
More information reg. these
connections can be found in
chapter 6. Electrical connection
pin assignments, page 37
Safety coutouts and mains cable at W80t
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