Lauda INTEGRAL XT User manual

Operating instructions
Flow controller with integrated bypass for
Valid from approval for the following software:
Analogue module 3.12
Command 3.39
Ethernet 2.21
Profibus 3.22
LAUDA DR. R. WOBSER GMBH & CO.KG
Laudaplatz 1
97922 Lauda-Königshofen
Germany
Phone: [phone]
Fax : [phone]
E-mail [e-mail]
Website http://www.lauda.de
6.2.2 Read commands
The right temperature worldwide
English
Translation of the original operating instructions
Q4DA_E_13-001-EN issue 04
replaces issues 03, 02

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Table of contents
1. Safety.................................................................................................................................................................. 5
1.1 Safety instructions ............................................................................................................................................. 5
1.2 General safety instructions ................................................................................................................................ 6
2. General............................................................................................................................................................... 7
2.1 Description of the device ................................................................................................................................... 7
2.2 Intended use...................................................................................................................................................... 7
2.3 Non-intended use .............................................................................................................................................. 7
2.4 Personnel qualification....................................................................................................................................... 8
2.5 Owner's responsibility........................................................................................................................................ 8
2.6 EC conformity .................................................................................................................................................... 8
3. Controls................................................................................................................................................................ 9
3.1 Function elements of the flow controller............................................................................................................ 9
3.2 Deviating command function elements............................................................................................................ 10
4. Installation.......................................................................................................................................................... 11
4.1 Unpacking........................................................................................................................................................ 11
4.2 Contents of package........................................................................................................................................ 11
4.3 Recommended accessories ............................................................................................................................ 12
4.4 Placement........................................................................................................................................................ 12
4.5 Connecting device components....................................................................................................................... 13
4.6 Establishing a power supply............................................................................................................................ 15
5. Operation ........................................................................................................................................................... 16
5.1 Filling, venting and degassing the application................................................................................................. 17
5.2 Operation ......................................................................................................................................................... 17
5.2.1 Switching on.................................................................................................................................................. 17
5.2.2 Setting the target flow rate............................................................................................................................ 17
5.2.3 Settings for the higher-pressure pump ......................................................................................................... 18
5.2.4 Setting the control parameters...................................................................................................................... 18
5.2.5 Setting the bypass ........................................................................................................................................ 19
5.2.6 Standby......................................................................................................................................................... 19
5.2.7 Switching off.................................................................................................................................................. 19
6. Interface commands .......................................................................................................................................... 20
6.1 Additional commands for RS 232/485 and Ethernet interface ........................................................................ 20
6.1.1 Write commands........................................................................................................................................... 20
6.2 Additional commands for Profibus interface.................................................................................................... 21
6.2.1 Write commands........................................................................................................................................... 21
6.2.2 Read commands........................................................................................................................................... 21
7. Error messages for flow controller..................................................................................................................... 22
8. Service............................................................................................................................................................... 23
9. Maintenance and repair..................................................................................................................................... 24

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9.1 Maintenance intervals...................................................................................................................................... 24
9.2 Fuses ............................................................................................................................................................... 24
10. Technical data.................................................................................................................................................. 25
10.1 Ambient conditions ........................................................................................................................................ 25
10.2 Technical characteristics of flow measurement............................................................................................. 26
Appendix:
- Declaration of clearance for service or repair jobs.

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1.Safety
1.1 Safety instructions
Danger!
Type and source
Consequences in the case of non-compliance
Measure 1
Measure...
“DANGER”indicates an immediately hazardous situation which can result in death or severe,
irreversible injuries if the safety regulations are disregarded.
Warning!
Type and source
Consequences in the case of non-compliance
Measure 1
Measure...
“WARNING”indicates a potentially hazardous situation which can result in death or severe, irreversible
injuries if the safety regulations are disregarded.
Caution!
Type and source
Consequences in the case of non-compliance
Measure 1
Measure...
“CAUTION”indicates a possibly hazardous situation which can result in minor irreversible injuries if
the safety regulations are disregarded.
Note
Type and source
Consequences in the case of non-compliance
Measure 1
Measure...
“NOTE”warns about possible property or environmental damage.
“Reference”refers to information in other chapters.

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1.2 General safety instructions
Read this operating manual carefully. It contains important information about how to handle this device. In
addition to these operating instructions, the operating instructions of the main device Integral XT are also to
be given full consideration. If you have any questions, please contact the LAUDA service department
(chapter 8.2).
Follow all instructions in this operating manual. That is the only way to ensure that you handle the device
correctly.
Ensure that the device is only operated by trained personnel (chapter 2.4).
The device may not be operated without heat transfer liquid.
Use suitable protective equipment when working on the device or connected components.
Use the integrated bypass to ensure that there is a constant flow rate of heat transfer liquid
(chapter 5.2.5).
Never operate the device if:
- Damage has been ascertained on device components or
- the device is leaking.
Switch off the device and unplug the mains plug:
- for service and repair work,
- when moving the device,
- if there is danger.
Do notmake technicalchanges to the device. In the case of infringement, anywarranty claim is void.
Only allow service and repair work to be performed by specialists.
Addition for devices with an additional pump:
The additional pump may not have fluid flowing through it when at a standstill, as this may
damage the pump.
The additional pump, together with the process thermostat from the LAUDA XT series, is a
system requiring monitoring in accordance with §14 of the German Industrial Health and Safety
Ordinance¹. (Classification in accordance with Pressure Equipment Directive 97/23/EC: Category I). Before
commissioning, the system must be subjected to an inspection of the installation, order and functions by
qualified personnel (chapter 2.4) Certification of this inspection shall be created, documenting the scope
and result of the inspections.
¹ The national regulations of the country in which the system is set up must be followed.

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2.General
2.1 Description of the device
The flow controller complements the function of the Integral XT process thermostat by receiving the flow of
heat transfer liquid and regulating it by means of a valve. At the pressure output of the flow meter, there is
an internal temperature sensor that allows temperature control at this point or allows the values to be read
out.
In the case of devices with a higher-pressure pump, it is also possible to increase the flow pressure and
thus the flow within the device parameters.
The flow controller is equipped with a bypass as the Integral XT process thermostat requires a minimum
flow rate of 5 L of heat transfer liquid per minute for optimum heating and cooling capacity. If the flow in the
flow meter is lower, the bypass must be opened to ensure that there is a sufficient quantity of heat transfer
liquid flowing back into the Integral XT before flow measurement.
2.2 Intended use
The device is an accessory for the Integral XT process thermostat and has the function of regulating the
flow quantity in the range of 0.2 to 20 L/min. The heat transfer liquid must have a minimum conductivity of
1 µS/cm and be operated within its working temperature range. Silicone oils and mineral oils are not
suitable.
Devices with an additional pump offer the ability to increase the flow pressure.
The device may only be operated in accordance with the intended procedures and under the conditions
specified by these operating instructions and the operating instructions of the Integral XT process
thermostat. Any other type of operation is considered to be unintended can impair the protection provided
by the device.
LAUDA does not accept liability in the case of damage caused by improper use of the device.
2.3 Non-intended use
The device may not be used:
for medical or pharmaceutical applications.
in potentially explosive areas.
with combustible, flammable, highly flammable or explosive heat transfer liquid or silicone oil.
if the permissible working temperature range of the heat transfer liquid is exceeded.
in outdoor installation.
to heat or cool food.

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2.4 Personnel qualification
Operating personnel
Operating personnel are personnel who have been instructed by specialist personnel about the intended
use of the device according to the operating manual, about the hazards posed by the heat transfer liquid,
about the working temperature ranges and the pressures within the application as well as the necessary
protective measures.
Specialist personnel
Specific activities on the device must be carried out by technical staff. Technical staff is personnel that can
evaluate functions and risks of the device and the application based on their training, skills and experience.
Typically, this personnel has had appropriate training or third-level education in a relevant technical area.
Specialist personnel must be able to judge the hazard posed by the heat transfer liquid, the working
temperature ranges and the pressures within the application and to determine the necessary protective
measures and the effectiveness thereof.
2.5 Owner's responsibility
The owner is responsible for the qualification of the specialist and operating personnel.
The thermostat may only be configured, installed, maintained and repaired by specialist personnel.
Persons who operate the device must have been instructed in their duties by specialist personnel.
Ensure that specialist personnel and operators have read and understood the operating instructions.
The device is to be used in the intended manner (chapter 2.2).
2.6 EC conformity
The device complies with the applicable basic occupational health and safety
requirements of the Directives listed below:
Manufacturer
LAUDA DR. R. WOBSER GMBH & CO. KG
Laudaplatz 1
97922 Lauda-Königshofen
Germany
Low Voltage Directive 2014/35/EU
EMC Directive 2004/108/EC
Safety requirements for electrical equipment
for measurement, control and laboratory use
DIN EN 61010-1

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3. Controls
3.1 Function elements of the flow controller
,
Position
Designation
Function
1
Connection socket return XT
Connection socket between return and process
thermostat
2
Main switch
Flip to switch the device on/off
3
Lemo connection socket
Output of the internal temperature probe
4
LiBus connection socket
Receives control signals from the Integral XT
5
Setting wheel for bypass
Turn to set the degree of bypass opening
6
Outlet
To drain the device
7
Connection socket outflow
XT
Connection of pressure side of process thermostat
8
Lever for outlet
Flip to open the outlet
9
Connection socket outflow
user
Connection socket of the application’s pressure side
10
Connection socket return
user
Connection socket of application return

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3.2 Deviating command function elements
Here, function elements that deviate from the standard command operating unit are described.
Command
Position
Designation
Function
1
Flow
Access to flow meter settings.
L2 0,00
Flow Menu End Tset Tfix

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4. Installation
Note
Falling down / tipping over of the device
Damage to property
- Only place the device upright and on a level surface.
- Do not tilt the device.
4.1 Unpacking
Unpacking procedure
1. Open the package at the top.
2. Keep the original packaging of your device for later storage or transport.
3. Inspect the device and the accessories immediately after unpacking for completeness and
transport damage.
4. If there is unexpected damage to the device or accessories, inform the carrier immediately
so that a damage report is produced and a check of the transport damage can be made by the
LAUDA service department (chapter 8.2).
4.2 Contents of package
Figure
(not to scale)
Designation
Quantity
Flow controller
1
No figure
Declaration of clearance for service or repair jobs.
1

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4.3 Recommended accessories
(Not included in the scope of delivery)
Article number
Designation
Quantity
UK 246
Connecting cable 2.5 m with 2 Lemo connectors
1
If you have questions about accessories you can contact our LAUDA service department (
chapter 8) or visit our website lauda.de. Under the tab “Product solutions/temperature control
devices/accessories”you will find a wide selection of different accessories including connecting
materials.
4.4 Placement
Note
Errors during placement
Damage to property
Observe the minimum clearance on all sides and do not
cover the ventilation openings.
The device may not be operated if its temperature has
dropped below the dew point during transport or storage.
We recommend that the devices by placed as described. Other placement options are possible, but
the type of heat dissipation of the Integral XT, the temperature change if bridging paths are too long
and the ambient conditions of the placement location(s) must be taken into account.
Figure
(not to scale)
Placement procedure
1. Select a suitable location for the devices.
2. Position the flow meter on the right-hand side of the Integral
XT.
3. Ideally, the application is to the right of the flow meter.

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4.5 Connecting device components
Caution!
Use unsuitable connecting materials
Material damage and injuries
Note the requirements that the expected temperature and
pressure ranges place on the hose material.
Only use hose material that is suitable for the chemical
makeup of the heat transfer liquid.
Note the requirements that the expected temperature range
places on the insulation of the connecting hoses and
connection elements.
Note
Contamination/damage to the connections or the piping
Damage to property
Before connecting, ensure that the connections are clean
and free of foreign objects.
When connecting the hoses to the connectors, use a second
spanner to counter the tightening torque.
Ensure that the nipple does not turn when tightening.
Do not tighten the connections more tightly than is
necessary.
Note
Consumer overflow
Damage to property/contamination
Only connect closed consumers.

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Figure
(not to scale)
Procedure when connecting the device components
1. Connect the outlet connector on the pressure side of the
Integral XT to the pressure input connector on the flow
controller (1).
2. Connect the outlet connector on the pressure side of the flow
controller to the input connector on the application (2).
3. Connect the outlet connector on the return of the application to
the input connector for the return on the flow meter (3).
4. Connect the outlet connector on the return side of the flow
controller (4) to the input connector for the return on the Integral
XT.
5. Connect the LiBus cable of the flow meter (5) to the LiBus
socket of the Integral XT.
6. Option when using the internal temperature sensor:
Connect the Lemo socket of the flow meter (6) with the Lemo
socket of the Integral XT. To do so, use a connecting cable.
This is available as an accessory (chapter 4.3).

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4.6 Establishing a power supply
Caution!
Contact with live parts
Electric shock
Check the device and the accessories for damage before
switching it on.
Never put the device into operation if you have discovered
any damage.
Note
Use of unauthorised mains voltage or mains frequency
Damage to property
Compare the type plate of the power supply with available
mains voltage and mains frequency.
Procedure for establishing a power supply
1. Connect the plug of the flow meter to the power supply using earthing.

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5. Operation
Caution!
Improper operation
Scalding, freezing, burning
Only use heat transfer liquid that is suitable for the
application’s temperature range.
Ensure that no substance or material that comes into
contact with heat energy during operation exceeds or falls
below the working temperature range.
Ensure that all components are designed for the pressures
encountered during operation.
Never use the application outside of its specification range
(chapter 9).
Caution!
Contact with heat transfer liquid or device or connection
components
Corrosion, poisoning, scalding, freezing
Use suitable protective equipment.
Avoid contact with hot, cold, corrosive or poisonous
temperature control fluid or sample fluid.
Avoid contact with hot or cold device components.
During operation, ensure that device and connection
components are appropriately insulated.
Bring the heat transfer liquid to room temperature before
draining.
Only carry out work on device, socket or connection
components when the device is empty.
Note
Change the fill level
Damage to property
Note the heat expansion and/or drop in volume of the heat
transfer liquid when regulating its temperature.
Note that, before continuous operation of the application, the
air in the piping must be allowed to escape in order to avoid
damage or incorrect measurements. This can lead to the fill
level dropping below the minimum fill level.
Note that, during longer temperature control, the heat
transfer liquid can evaporate. This can lead to the fill level
dropping below the minimum fill level.

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5.1 Filling, venting and degassing the application
To do so, follow the operating instruction of the LAUDA Integral XT (chapter 7.6).
5.2 Operation
5.2.1 Switching on
Note
Error when switching on/off
Damage to property
Always switch the flow controller on first
Ensure that the device has been filled with heat transfer
liquid before it is switched on.
Procedure for switching on
1. Set the mains switch of the flow controller to position 1.
2. Set the mains switch of the main device to position 1.
3. Select the soft key “Flow”.
4. Use the “up”and “down”arrow buttons to move the cursor to the “Status”menu item and press
“Enter”or the “right”arrow button to confirm.
5. Use the “up”and “down”arrow buttons to move the cursor to “On”and press “Enter”or the “right”
arrow button to confirm.
If the status “On”has been selected, the valve regulates to the desired flow rate. This setting is
active until you set the status to “Off”. Note that the flow through the flow controller is highest
when the position “Off”is selected.
5.2.2 Setting the target flow rate
Procedure for setting the target flow rate
1. Select the soft key “Flow”.
2. Use the “up”and “down”arrow buttons to move the cursor to the “Target flow rate”menu item and
press “Enter”or the “right”arrow button to confirm.
3. The input field is now above the current value of the target flow rate. Now press “Enter”.
4. Now use the soft keys to enter a value between 0 and 20 L per min and confirm the value with
“Enter”.
Example: Inputting a target value of 7.53 L per min.
Use the soft keys to enter 00753 and confirm by pressing “Enter”.

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5.2.3 Settings for the higher-pressure pump
If your device has a higher-pressure pump, the existing LiBus software connection is detected
and the setting automatically switches from Aux. Pump OFF to Aux. Pump ON . When the
flow controller of the Integral XT is dismantled, the automatic setting described above must be
undone manually on the command remote control unit of the Integral XT.
Procedure for deregistering the flow controller
1. Select the soft key “Menu“.
2. Use the “up”and “down”arrow buttons to move the cursor to the “Pump”menu item and press
“Enter”or the “right”arrow button to confirm.
3. Use the “up”and “down”arrow buttons to move the cursor to the “Aux. Pump ON”menu item and
press “Enter”or the “right”arrow button to deregister the pump of the flow controller.
5.2.4 Setting the control parameters
For flow rate control, the actuating signals are a continuous valve and the pump speed.
The two actuating signals can be parameterised using separate PI controllers.
Procedure for setting the control parameters
1. Select the soft key “Flow”.
2. Use the “up”and “down”arrow buttons to move the cursor to the “Control parameters”menu item
and press “Enter”or the “right”arrow button to confirm.
3. Use the “up”and “down”arrow buttons to move the cursor to the desired control parameter and
press “Enter”to confirm.
4. Now use the soft keys to enter a value between 0 and 10 and confirm the value with “Enter”.
Control parameters
Meaning
Basic setup (default)
Valve Kp
Proportional share, controller valve
5.0
Valve Ki
Integral share, controller valve
1.25
Pump Kp
Proportional share, controller pump
0.8
Pump Ki
Integral share, controller pump
0.1

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5.2.5 Setting the bypass
In order to protect the main device, the Integral XT, from damage, a continuous flow rate of heat
transfer liquid must be guaranteed. In order to guarantee this for applications in which the flow is
interrupted, the device has an internal bypass.
Procedure for setting the bypass
1. Switch the flow rate control function “off”.
2. Open the bypass fully.
3. Set the pump level such that the flow is sufficient to maintain the desired minimum flow rate.
4. If the flow rate is not attained, closed the bypass slowly until the flow rate is set.
5.2.6 Standby
Procedure for switching device to standby
1. Press the standby button on the Command remote control unit.
When the standby button is pressed, the pump(s) of the Integral XT and the flow meter (for
devices with an additional pump) is/are switched off. The heating and cooling unit are also
switched off. The operating unit remains active, meaning that status displays can be viewed and
settings can be made.
5.2.7 Switching off
Procedure for switching off
1. Press the standby button on the Command remote control unit in order to place the device in
standby mode.
2. Set the mains switch of the main device to position 0.
3. Set the mains switch of the flow meter to position 0.

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6. Interface commands
The following interface commands are valid for flow rate control. Input is via the selected
interface on the Integral XT.
6.1 Additional commands for RS 232/485 and Ethernet interface
6.1.1 Write commands
Data specifications to the flow meter:
Command
Meaning
PO_4_25_0_E6
Switch on the flow rate control.
PO_4_25_1_E7
Switch off the flow rate control.
PO_4_24_XX.XX_CS
Specify the target value for the flow rate control.
Setup of the write command PO_4_24_XX.XX_CS
The value CS is a checksum.
The value XX.XX is within the range of 00.00 to 20.00 in the unit L/min
CS depends on the value XX.XX and can be calculated as follows:
All digits before the checksum are shown in decimal and added up. The calculated value is converted
to hexadecimal and the last two digits are added to the command as a checksum.
Example:
Target flow rate value: PO_4_24_XX.XX_CS
With a target flow rate of 12.34 L/min, the calculation is as follows:
‘P’ = 80D
‘O’ = 79D
‘_’ = 95D
.4 = 52D
‘_’ = 95D
‘2’ = 50D
‘4’ = 34D
‘_’ = 95D
‘1’ = 49D
‘2’ = 50D
‘.’ = 46D
‘3’ = 51D
‘4’ = 52D
‘_’ = 95D
The sum of “PO_4_24_12.34_”is 923D= 39BH.
The CS is then the last two digits of the hexadecimal checksum, i.e. 9BH.
The following character string must thus be transferred:
PO_4_24_12.34_9B<CR>