Lauda Integral T 1200 User manual

Operating instructions
Read the operating manual before starting all work.
The right temperature worldwide
Integral T
T 1200 (W), T 2200 (W), T 4600 (W), T 7000 (W), T 10000 (W)
Process thermostats

Translation of the original operating instructions
release 01/2019 i
replaces release 05/2017 h, 09/2016 g7, 04/2016 g6,
04/2015 g5, 03/2015 g4, 07/2012 f2, 08/2006
LAUDA DR. R. WOBSER GMBH & CO. KG
Pfarrstraße 41/43
97922 Lauda-Königshofen
Germany
Read the operating instructions before starting all work.
YAWE 0026
Phone [phone]
Fax [phone]
e-mail [email protected]
Internet http://www.lauda.de
Operating instructions
INTEGRAL T
Process thermostats
T 1200 (W), T 2200 (W),
T 4600 (W), T 7000 (W), T 10000 (W)

Integral T process thermostats
YAWE 0026 / 21.01.201921/01/2019 Prefixed safety notes 5
Prefixed safety notes
Before you operate the equipment please read carefully all the instructions and
safety notes. If you have any questions please phone us!
Follow the instructions on setting up, operation etc. This is the only way to exclude
incorrect operation of the equipment and to ensure full warranty protection.
Transport the equipment with care!
Careful transportation of the equipment requested!
The unit may NEVER be overturned nor put upside down!
Equipment and its internal parts can be damaged:
by dropping,
by shock.
Equipment must only be operated by properly instructed personnel!
Never operate the equipment without heat transfer liquid!
Do not start up the equipment if
it is damaged or leaking
the supply cable is damaged.
Switch off the equipment and pull out the mains plug for:
servicing or repair,
before moving the equipment!
Drain the bath before moving the equipment!
Have the equipment serviced or repaired only by properly qualified personnel!
The Operating Instructions include additional safety notes which are identified by a triangle with
an exclamation mark. Carefully read the instructions and follow them accurately!
Disregarding the instructions can have serious consequences, such as damage to the equipment,
damage to property or injury to personnel.
We reserve the right to make technical alterations!

Integral T process thermostats
6Contents YAWE 0026 /21/01/2019
Contents
1SAFETY NOTES........................................................................................................................................9
1.1 GENERAL SAFETY NOTES .........................................................................................................................9
1.2 OTHER SAFETY NOTES.............................................................................................................................9
1.3 EU CONFORMITY ...................................................................................................................................11
2BRIEF INSTRUCTIONS...........................................................................................................................12
3CONTROL AND FUNCTIONAL ELEMENTS..........................................................................................14
4EQUIPMENT DESCRIPTION ..................................................................................................................15
4.1 ENVIRONMENTAL CONDITIONS ................................................................................................................15
4.2 EQUIPMENT TYPES.................................................................................................................................15
4.3 BASIC PRINCIPLE ...................................................................................................................................15
4.4 BATH,PUMP ..........................................................................................................................................16
4.5 MATERIALS............................................................................................................................................16
4.6 REFRIGERATION UNIT.............................................................................................................................16
4.7 CONTROL UNIT,CONTROL AND SAFETY CIRCUIT.......................................................................................17
4.8 INTERFACES..........................................................................................................................................18
4.9 OPTIONS...............................................................................................................................................19
4.9.1 Option enlarged temperature range to 150 °C.............................................................................19
4.9.2 Option high-power pump..............................................................................................................19
4.9.3 Option flow control instrument .....................................................................................................19
4.9.4 Option low-pressure pump...........................................................................................................19
5UNPACKING............................................................................................................................................20
6PREPARATIONS.....................................................................................................................................21
6.1 ASSEMBLY AND SETTING UP ...................................................................................................................21
6.2 FILLING AND CONNECTION OF EXTERNAL CIRCUIT ....................................................................................23
6.3 EMPTYING.............................................................................................................................................24
6.4 HEAT TRANSFER LIQUIDS,COOLING WATER AND HOSES ...........................................................................25
7STARTING UP .........................................................................................................................................29
7.1 CONNECTION TO THE SUPPLY.................................................................................................................29
7.2 SWITCHING ON ......................................................................................................................................29
7.3 KEY FUNCTIONS.....................................................................................................................................31
7.3.1 General.........................................................................................................................................31
7.3.2 Key inhibit (KEY)..........................................................................................................................32
7.4 LC-DISPLAY..........................................................................................................................................33
7.5 LEVEL 0(BASE MENU)AND LEVEL 1 ........................................................................................................34
7.5.1 Setpoint selection (Level 0)..........................................................................................................35
7.5.2 External actual temperature display.............................................................................................35
7.5.3 Pressure indication.......................................................................................................................36
7.5.4 Menu . . .......................................................................................................................................36
7.6 LEVEL 1 ................................................................................................................................................37
7.6.1 Standby (ON) ...............................................................................................................................37
7.6.2 External control (CON).................................................................................................................37

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YAWE 0026 / 21/01/2019 Contents 7
7.6.3 Programmer level (PGM).............................................................................................................38
7.6.3.1 Example of programme.............................................................................................................39
7.6.3.2 Menu structure..........................................................................................................................39
7.6.3.3 Programme selection and start.................................................................................................40
7.6.3.4 Terminate, pause, continue the programme.............................................................................41
7.6.3.5 INFO submenu..........................................................................................................................42
7.6.3.6 Edit submenu............................................................................................................................44
7.6.4 Parameter level (PARA)...............................................................................................................52
7.6.4.1 Serial interface parameters / Remote control ...........................................................................53
7.6.4.2 Manual Start - Autostart............................................................................................................54
7.6.4.3 Outflow temperature limit..........................................................................................................55
7.6.4.4 Neutral contact function ............................................................................................................56
7.6.4.5 Tolerance range contact ...........................................................................................................56
7.6.4.6 Sensor calibration (CAL)...........................................................................................................56
7.6.4.7 Base settings (DEFAULT).........................................................................................................57
7.6.4.8 Menu end “Parameter“..............................................................................................................58
7.6.5 Analogue interface level (ANA)....................................................................................................59
7.6.5.1 Submenu Analogue inputs........................................................................................................63
7.6.5.2 Submenu Analogue outputs......................................................................................................66
7.6.5.3 Submenu Calibration (ANA)......................................................................................................69
7.6.6 Control parameter level................................................................................................................73
7.7 SERIAL INTERFACES RS 232, RS 485....................................................................................................76
7.7.1 RS 232 Interface ..........................................................................................................................76
7.7.2 RS 485 Interface ..........................................................................................................................77
7.7.3 Write commands (data commands to the thermostat).................................................................79
7.7.4 Read commands (data requested from the thermostat)..............................................................80
7.7.5 Error messages............................................................................................................................82
7.7.6 Driver software for LABVIEW®.....................................................................................................82
7.8 WARNING AND SAFETY FUNCTIONS.........................................................................................................83
7.8.1 Overtemperature protection and testing ......................................................................................83
7.8.2 Low-level protection and testing ..................................................................................................84
7.8.3 Pump motor monitoring................................................................................................................85
7.8.4 Refrigerant pressure ....................................................................................................................85
7.8.5 Floating contact connection "Combination fault" 12N (Alarm out)...............................................86
7.8.6 Other error messages ..................................................................................................................86
8MAINTENANCE.......................................................................................................................................88
8.1 CLEANING .............................................................................................................................................88
8.2 MAINTENANCE AND REPAIR ....................................................................................................................88
8.3 SERVICING INTERVALS ...........................................................................................................................89
8.4 INSPECTING THE HEAT TRANSFER LIQUID.................................................................................................89
8.5 PROTECTIVE CUT-OUTS AND FUSES ........................................................................................................89
8.5.1 Dismantling the control unit..........................................................................................................91
8.6 MAINTENANCE OF THE REFRIGERATION UNIT ...........................................................................................92
8.6.1 Air-cooled condenser...................................................................................................................92
8.6.2 Water-cooled condenser..............................................................................................................92

Integral T process thermostats
8Contents YAWE 0026 /21/01/2019
8.6.3 Decalcifying the cooling water circuit...........................................................................................92
8.7 DISPOSAL INFORMATION ........................................................................................................................94
8.8 SERVICE AND ORDERING REPLACEMENT PARTS.......................................................................................94
9TECHNICAL DATA..................................................................................................................................95
10 ACCESSORIES .....................................................................................................................................101
Special symbols:
Danger:
This symbol is used where there may be injury to
personnel through incorrect handling.

Note:
Here special attention is drawn to some aspect. May
include reference to danger.

Reference
Refers to additional information in other sections.

Integral T process thermostats
21/01/2019 / YAWE 0026 Safety notes 9
1 Safety notes
1.1 General safety notes
A LAUDA process thermostat is intended for heating or cooling and circulating liquids. This leads to
hazards through high or low temperatures, excess pressures, fire and the general hazards through the
use of electrical energy.
The user is largely protected through the application of the appropriate standard specifications.
Additional hazards may arise from the type of material being thermostated, e.g. when going above or
below certain temperature levels or through breaking of the container and reaction with the heat
transfer liquid.
It is not possible to cover all possibilities; they remain largely within the responsibility and the
judgement of the user.

The equipment must only be used as intended and as described in these Operating
Instructions. This includes operation by suitably instructed qualified personnel.
The units are not designed for use under medical conditions according to DIN EN 60601-1 or
IEC 601-1!
1.2 Other safety notes
Operation with water as heat transfer liquid (6.4).
Connect the equipment only to an earthed supply socket.
Parts of the hose connectors and of the external circuit may reach surface temperatures above 70 °C
when operating at higher temperatures. Take care when touching them!
Use suitable hoses (Section 6.4).
Protect tubing with hose clips against slipping off. Prevent kinking of tubing!
Check tubing from time to time for possible material fatigue!
Heat transfer tubing and other hot parts must not come into contact with the supply cable!!
Failure of tubing may cause leaking of hot liquid, a danger to personnel and objects.
Allow for expansion of the bath oil at elevated temperatures!
Depending on the heat transfer liquid used and the method of operation it is possible for toxic
vapours to be produced. Ensure appropriate ventilation!!
When changing the heat transfer liquid from water to oil for temperatures above 100 °C carefully
remove all traces of water, also from tubing and from the external circuit, otherwise danger of
burns through delayed boiling!
Always pull out the mains plug before cleaning, maintenance or moving the thermostat!
Repairs must only be carried out by properly qualified personnel!
The relevant prescriptions regarding the operation of installations in need of observation must be
taken into consideration as well as the maintenance of industrial health and safety standards. For
Germany this includes also the prescriptions for operational safety (Betriebssicherheitsverordnung -
BetrSichV), the rules for prevention of accidents “Refrigerating Plants, Heating Pumps and Cooling
Systems” (Unfallverhütungsvorschriften BGV D4) as well as “Electrical Installations and Operating
Material (BGV A2).
Values for temperature control and indicating accuracy apply under normal conditions according to
DIN 12876. High-frequency electromagnetic fields may under special conditions lead to unfavourable
values. This does not affect safety!

Integral T process thermostats
10 Safety notes YAWE 0026 / 21/01/2019
Classification in accordance with EMC requirements of DIN EN 61326-1
Device
Immunity
Emissions class
Customer power supply
Process thermostat
Integral T
single-phase and
triple-phase
devices
Type 2 in
accordance with
DIN EN 61326-1
Emissions Class B
in accordance with
CISPR 11
Only for EU
Domestic connection value
≥100 A
Process thermostat
Integral T
single-phase and
triple-phase
devices
Type 2 in
accordance with
DIN EN 61326-1
Emissions Class B
in accordance with
CISPR 11
Worldwide (outside EU)
No limitation
Instructions for Class A digital device, USA:
“Note: This equipment has been tested and found to comply with the limits for Class A digital device,
pursuant to Part 15 of the FCC (Federal Communication Commission) Rules. These limits are
designed to provide reasonable protection against harmful interference when the equipment is
operated in a commercial environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the instruction manual, may cause
harmful interference to radio communications. Operation of this equipment in a residential area is likely
to cause harmful interference in which case the user will be required to correct the interference at his
own expense”.
Instructions for Class A digital device, Canada:
“This Class A digital apparatus complies with Canadian ICES-003” (ICES = Interference Causing
Equipment Standards).
« Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada ».
Applicable only to water-cooled devices:
Danger of corrosion of the cooling water circuit due to water of unsuitable quality (6.4).
Secure the return hose of the water cooling in the discharge area in order to prevent the hose
sliding off uncontrollably, also during pressure surges.
Secure the return hose of the water cooling in the discharge area so that it is not possible of hot
cooling water to splash out.
Avoid kinking or crushing the return hose of the water cooling. Excessive pressure can cause the
cooling water hoses to tear and hot water to escape.
To avoid damage due to a leak in the cooling water system we recommend the use of a water leak-
age sensor with water cut-off.

Integral T process thermostats
21/01/2019 / YAWE 0026 Safety notes 11
1.3 EU conformity
EU conformity
The device complies with the basic health and safety requirements outline
in the Directives listed below.
Machinery Directive 2006/42/EC
EMC Directive 2014/30/EU
LAUDA DR. R. WOBSER GMBH & CO. KG –Pfarrstraße 41/43 -
97922 Lauda-Königshofen - Germany

The device does not fall under Pressure Equipment Directive
2014/68/EU because the device is only classified as high as
Category 1 and is covered by the Machinery Directive.

Integral T process thermostats
12 Brief instructions YAWE 0026 / 21.01.2019
2 Brief instructions
These brief instructions are intended to provide you with a quick introduction to
operating the equipment. For reliable operation of the thermostats it is however
absolutely essential that you read carefully the full Operating Instructions and observe
the safety notes!
1. Set up the equipment and add further items as appropriate (Section 6.1).
The unit may NEVER be overturned nor put upside down!
Note the details on the hose connections (Section 6.2 and 6.4).
2. Fill the equipment with the appropriate heat transfer liquid (Section 6.4). The equipment is
designed for operation with non-flammable and flammable liquids to DIN EN 61010-2-010. Note
liquid level! (Section 6.2)
The T 4600 (W), T 7000 (W) and T 10000 (W) should not be filled with pure water, but
only with a water-glycol mixture (minimum 70 % : 30 %) or Kryo 30!
3. Connect the equipment only to a supply socket with protective earth contact. Check the details on
the rating label against the supply voltage.
4.
Set the overtemperature switch-off point to a value clearly above ambient
temperature (Section 7.8.1).
5. Switch on the equipment or
6. The function “Manual Start”(display STArt) is activated. To start the unit and enter the basic menu,
press the key .

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21/01/2019/ YAWE 0026 Brief instructions 13
7. Equipment setup
The Parameter menu includes a default function (Section 7.6.4.7) which produces a basic
adjustment of nearly all functions and permits basic operation with internal control.
Section 7.6.3
Section 7.6.4
Section 7.6.5
Section 7.6.6

Integral T process thermostats
14 Unpacking YAWE 0026 / 21/01/2019
3 Control and functional elements
1. Rating label
2. Bypass adjustment
3. Pump connections
4. Mains cable
5. Drain cock
6. Overflow
7. Exit and entrance cooling water connections R3/4”
(only water cooled devices W).
8. Level indication (6.2)
9. Filler opening for heat transfer liquid
10. Mains supply switch
11. Menu functions
12. Control unit tilted (4.7 and 4.8)
2
5
9
3
8
4
1
6
10
11
7
12

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21/01/2019 / YAWE 0026 Equipment description 15
4 Equipment description
4.1 Environmental conditions
The operation of the thermostats is only allowed under the following conditions as specified in
DIN EN 61010-2-010:2003 and DIN EN 61010-1:2001:
Indoor use.
Altitude up to 2000 m above sea level.
Foundation must be dense, even, non-slippery and non-flammable.
Keep clear distance (Section 6.1).
Ambient temperature range (Section 9).
Use only within this range for an undisturbed operation.
Mains supply voltage fluctuations (Section 9).
Maximum relative humidity 80 % for temperatures up to 31 °C, decreasing linearly to 50 %
relative humidity at 40 °C.
Transient over voltage according to Installation Categories (Over voltage Categories) II.
Pollution degree: 2.
4.2 Equipment types
Integral process thermostats are identified by the letter T in the type designation. The number which
follows refers to the cooling capacity at 20 °C outflow temperature. Types with the letter W at the
end operate with a water-cooled condenser.
4.3 Basic principle
Integral T process thermostats are powerful heating/cooling circulation thermostats with a very
small active bath volume. A largely thermally inactive bath volume serves as additional expansion
space.
The heating and cooling capacities are suitably matched in order to achieve rapid temperature
change both in the heating and in the cooling range.
Bypass valve
Pump
Level sensor
Heater
Outflow to
Consumer
Consumer return
Cooling
(Evaporator)

Integral T process thermostats
16 Equipment description YAWE 0026 / 21/01/2019
4.4 Bath, pump
The relatively small bath contains the functional elements such as tubular heater, pump for external
circulation, evaporator or pump for internal circulation on units from T 4600, temperature probe and
low-level sensor.
In addition there is a larger expansion volume which is only partially thermally active. The front of
the equipment carries a level indicator.
The connections and sizes for the external thermostating circuit are selected to be suitable for the
pump output.
All pumps are immersion pumps. An adjustable bypass between liquid outlet and bath allows the
pressure to be reduced (pump characteristics, Section 9).
A pressure sensor at the pump outlet measures the actual discharge pressure which can be
indicated on the display for monitoring purposes.
4.5 Materials
All components in contact with the heat transfer liquid are made from materials suitable for the
recommended liquids (Section 6.3) and temperature. The materials used are rust free stainless
steel, copper, brass, NBR, plastics.
4.6 Refrigeration unit
The refrigeration unit consists essentially of a fully sealed compressor. The heat transfer liquid is
cooled through a heat exchanger located inside the bath, or on the more powerful units (from
T 4600) via a separate circuit with its own pump using a plate heat exchanger. Heat of
condensation and motor heat are dissipated on air-cooled units through a fan-cooled ribbed
condenser on water-cooled units through a counter-flow heat exchanger with the water flow
controlled by the condenser pressure.
The refrigerant used throughout is HFKW R-404A. The refrigeration unit is protected against
overpressure and compressor overload. With insufficient ventilation of the condenser (e.g. dirt
deposits) or in the absence of cooling water (e.g. water tap not opened) the equipment is switched
off.

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21/01/2019 / YAWE 0026 Equipment description 17
4.7 Control unit, control and safety circuit
Tilting the control unit with display
Better readability of the display
The control unit can be tilted to two positions. This increases
the readability of the display. Carefully pull the bracket on the
control unit forwards and upwards. The control unit engages
in two positions.
The equipment is provided with a 2-line LC display to indicate the measurements and settings as
well as the operational status. The setpoint and other settings are selected under menu guidance
using two or three keys.
A Pt100 temperature probe senses the outflow temperature inside the bath. The measurement is
processed by a high-resolution AD converter. Further processing involves a special control
algorithm to operate the heating triac (with reduced reaction on the mains supply), the automatic
compressor control, and the cooling control which operates with low-noise solenoid valves. The
LAUDA proportional cooling principle permits control in the cooling range without any energy-
wasting counter-heat.
On single-phase units (T 1200 –T 2200 W) the maximum heater power is reduced to 1500 W while
the compressor is running in order to limit the current uptake.
An external Pt100 for sensing an external temperature can be connected to a socket (10S). This
value can be indicated and used (if required) as controlling variable when the external controller
(cascade control) is activated. The system is then controlled from the external measurement and
not from the outflow temperature
The safety system corresponds to that for laboratory liquid thermostats and conforms to
DIN EN 61010-2-010. A double-channel system is employed with the two micro controllers checking
each other. There is a low-level sensor and a second bath temperature probe (Pt100) used in the
safety circuit to switch off in case of over temperature and for checking the measuring/ control probe
The over temperature switch-off point is adjusted with a screwdriver (tool) on the control unit. The
setting is also automatically indicated on the display.
With low liquid level, over temperature and certain system faults the heating is switched off on all
poles. The pump and refrigeration unit are also switched off. This fault shut-down is permanent, i.e.
the blockage is stored in the memory and has to be reset by operating the key after the fault has
been rectified. The fault blockage is retained after the mains supply is switched off.
Other equipment functions are described in the appropriate Sections and in Section 7.

Integral T process thermostats
18 Equipment description YAWE 0026 / 21/01/2019
4.8 Interfaces
Connectors for standby contact input, fault (alarm) contact output, analogue inputs and outputs,
external Pt100 and serial RS 232/RS 485 interfaces are accessible from below after swinging out the
control unit. The control unit can be folded out to Position 2 in order to connect the sockets and then
be folded back to Position 1.
Position 1
Position 2
Standby
16N
Alarm OUT
12N
RS 232/485
65S
Pt100
10S
Standard signal
66S
Plug
Socket
Plug
Plug
Plug
EQS 048
EQD 047
EQM 042
EQS 022
EQS 057
Plug housing
EQG 026
For additional description of the interfaces see under Section 7.7 and Section 7.

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21/01/2019 / YAWE 0026 Equipment description 19
4.9 Options
The options installed in the device are to be recognized by a label next to the type designation
plate.
4.9.1 Option enlarged temperature range to 150 °C
Only at T 7000 (W) and T 10000 (W)!
The device is modified so that the upper limit of the working temperature range is expanded from
120 °C to 150 °C.
An additional fan is built in at the back side. Do not close the aspirating hole!
In particular it is to be noted that with temperatures exceeding 120 °C metal tubing
is used!
4.9.2 Option high-power pump
For devices T 1200 (W) –T 4600 (W)!
A high-power 2-stage pump with maximum values 5.5 bar/40 L/min is installed. Pump
characteristics (Section 9 Technical Data).
The units T 1200 –T 2200 W have a larger overall height (Section 9 Technical Data). The
cooling capacity is reduced by approx. 200 W.
4.9.3 Option flow control instrument
In the return line for the heat transfer a paddle flow control instrument is installed. The contact is
connected to the flanged 3 pole plug.
The contact closes at Q > 5 L/min with T 1200 –T 4600 W and
Q > approx.10 L/min with T 7000 –T 10000 W.
View on flange plug (Front) or solder side coupler
socket.
Maximum contact load 30 V; 1 A.

Use shielded lines.
Connect shielding with connector housing.
Cover unused plug connections with protecting caps!
Coupler socket Cat. No. EQD 047
4.9.4 Option low-pressure pump
Only for devices T 1200 (W) and T 2200 (W)!
This is a 2-stage radial disc pump with a maximum pressure of 1 bar and a maximum pump output/
flow rate of 30 L/min. This pump has a smaller noise level and in most cases can be used to
temper glass instruments. Pump characteristics (Section 9 Technical Data).

Integral T process thermostats
20 Preparations YAWE 0026 / 21/01/2019
5 Unpacking
Keep your original packing of your thermostat for later transport.
After unpacking, check first the equipment and accessories for possible transport damage. If
unexpectedly any damage can be noticed on the equipment it is essential to notify the forwarding agent or
the postal authorities so that an inspection can take place.
Please also inform the LAUDA Service Constant Temperature Equipment (Contact 8.8).
Do not start operations with damaged instruments!
The unit may NEVER be overturned nor put upside down!
Standard accessories
Quantity
Article
for device
Cat. No.
1
Operating Instructions
for all devices
YAWE 0026
1
Plug for filler opening
for all devices
EZV 086
2
Nipples 3/4" with thread
T 1200 (W), T 2200 (W), T 4600 (W)
EOA 004
2
Nipples 1" with thread
T 7000 (W), T 10000 (W)
EOA 036
2
Water hoses, 4 m each, with
quick-release coupling and
hose clips
for water-cooled devices (W)
½“ T 1200 W, T 2200 W, T 4600 W, T 7000 W
¾“ T 10000 W
LWZ 025
LWZ 026
For further accessories please contact us (8.8).