Lauda RE 104 User manual

LAUDA DR. R. WOBSER
GMBH & CO. KG
P.O. Box 1251
97912 Lauda-Königshofen
Germany
From Series Z 01
Software version 2.0
01/01
YACE0059
Phone: (+49) (0) 9343/ 503-0
Fax: (+49) (0) 9343/ 503-222
e-mail [email protected]
Internet http://www.lauda.de
Operating Instructions
Ecoline
Low-temperature thermostats
RE 104, RE 106, RE 107, RE 112, RE 120

I
Safety notes
Before operating 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 avoid
incorrect operation of the equipment and to ensure full warranty protection.
• Transport the equipment with care!
• Equipment and its internal parts can be damaged:
− by dropping
− by shock.
• Equipment should only be operated by technically qualified personnel!
• Never operate the equipment without the bath 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
− the supply cable is damaged!
• Drain the bath before moving the equipment!
• Have the equipment serviced or repaired by properly qualified personnel only!
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 may have serious consequences, such as
damage to the equipment, damage to property or injury to personnel
We reserve the right to make technical alterations!

II
1 BRIEF OPERATING INSTRUCTIONS...........................................................................................1
2 CONTROL AND FUNCTIONAL ELEMENTS.................................................................................2
3 UNIT DESCRIPTION .....................................................................................................................3
3.1 Unit types ...............................................................................................................................3
3.2 Pumps.....................................................................................................................................3
3.3 Temperature indication, control, and safety circuit ............................................................4
3.4 Materials.................................................................................................................................4
3.5 Refrigeration system .............................................................................................................4
4 UNPACKING .................................................................................................................................5
5 PREPARATIONS...........................................................................................................................6
5.1 Assembly and setting up.......................................................................................................6
5.2 Filling and emptying..............................................................................................................7
5.3 Bath liquids and hose connections......................................................................................9
5.4 Connection of external circuits...........................................................................................11
6 STARTING UP.............................................................................................................................12
6.1 Connection to the supply....................................................................................................12
6.2 Switching on ........................................................................................................................12
6.3 Setpoint selection................................................................................................................13
6.4 Menu functions ....................................................................................................................14
6.4.1 Refrigeration system (level 1)..........................................................................................................14
6.4.2 Pump output......................................................................................................................................15
6.4.3 User calibration.................................................................................................................................16
6.5 Warning and safety functions.............................................................................................17
6.5.1 Overtemperature protection and testing........................................................................................17
6.5.2 Low-level protection and testing ....................................................................................................19
6.5.3 Pump motor monitoring...................................................................................................................19
6.5.4 Other error messages ......................................................................................................................20
7 SAFETY NOTES..........................................................................................................................21
7.1 General safety notes............................................................................................................21
7.2 Other safety notes ...............................................................................................................21
8 MAINTENANCE...........................................................................................................................23

III
8.1 Cleaning................................................................................................................................23
8.2 Maintenance and repair.......................................................................................................23
8.2.1 Maintenance of the refrigeration unit.............................................................................................24
8.2.2 Note on repair and disposal ............................................................................................................24
8.3 Ordering spares ...................................................................................................................24
9 TECHNICAL DATA (TO DIN 58966)............................................................................................25
10 ACCESSORIES .........................................................................................................................28
11 CIRCUIT DIAGRAM...................................................................................................................29
12 PIPE PLAN ................................................................................................................................33

IV
Explanation of signs
Danger: This sign is used where there may be injury to
personnel if a recommendation is not followed
accurately or is disregarded.
☞Note Here special attention is drawn to some aspect. May
include reference to danger.
➾Reference: Refers to other information in different Sections.

Brief operating instructions
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1 Brief operating instructions
This brief instruction shall give you the possibility to operate the unit quickly. For safe operation
of the unit it is absolutely necessary to read carefully all the instructions and safety notes!
1. Assemble unit and add items as appropriate (➾Section 5).
Take care of the hose tubing connections (➾Section 5.1. and 5.4.).
2. Fill the unit with corresponding liquid. (➾Section 5.3.).
The units are designed for operation with non-flammable and flammable liquids to
EN 61010-2-010. !Take care of the level of the bath liquid! (➾Section 5.2.)
3. Connect the unit only to a socket with a protective earth (PE) connection.
Compare the information on the rating label with the supply details.
4. Using a screwdriver, set the overtemperature cut-out point to a value clearly
above ambient temperature (➾Section 6.5.1.).
5. Switch on at the mains switch
6. Setting of the functions

Control and functional elements
2
2 Control and functional elements
Cooling
LED green, Supply ON
Menu functions
Mains switch
Setting of the
overtemperature switch-off
point
Pump connections
− return
Pump connections
− outflow
Bath bridge
Bath cover

Unit description
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3 Unit description
3.1 Unit types
The type designation of the Ecoline low-temperature thermostats consists of the letter R
(identification as low-temperature unit), the control unit E 100 and the type of bath and refrigeration
system.
Example: Refrigeration unit R, Control unit E 100 and bath and refrigeration system 004 produces
Thermostat Type RE 104.
Type RE 120 is supplied without bath cover. A bath cover is available as accessory. (➾Section 10.
Accessories).
3.2 Pumps
All units are equipped with a pressure pump with vario drive. The pump has an outflow with a rotatable
bend which is connected to the pump nipple for external thermostating units. An additional outflow
provides circulation inside the bath.
By turning the setting knob it is possible to choose between both outlets or to divide the flows.
The pump ca n be used up to viscosities of 150 mm²/s. However, to get an optimum accuracy of control
a viscosity of 30 mm²/s is recommended.
One of five pump output steps can be selected using the operating menu.
On small low-temperature thermostats (e.g. RE 104 or RE 106) and with operation as bath thermostat it
is advisable to use output step 2. The advantage is a low heat generation while having a uniform
circulation.
When operating as circulation thermostat with an external circuit it is preferable to use a larger flow rate
in order to ensure a small temperature difference, especially at higher temperatures and in conjunction
with oil as the bath liquid.
The pump outflow connection can be closed without causing any damage to the pump.
Pump characteristics (➾Section 9. Technical data)

Unit descri
p
tion
4
3.3 Temperature indication, control, and safety circuit
The equipment is provided with a 7 segment LCD-Display (3 ½ places) with additional symbols for
indicating bath temperature and settings as well as operating states. The setpoint can be input and
additional adjustments can be made using either two or three keys.
A Pt 100 temperature probe is used for measuring the actual temperature and for control. A second Pt
100 serves as independent temperature probe for the safety circuit (overtemperature protection) which is
independent of the control function
A low-level cut-out switches off the heating on both poles in order to prevent dry operation of the heater.
The pump is switched off through the electronics. The setting of the overtemperature cut-out is adjusted
with a tool on a potentiometer and is always limited to 5°C above the operating temperature range.
All settings and fault messages are stored in the memory in case of a supply failure or when the mains
switch is set to OFF.
The tubular heater is controlled from a modified PID controller through a triac circuit specially designed
to be unaffected by supply variations and interference.
3.4 Materials
All parts which come into contact with the bath liquid are made from high-grade materials appropriate to
the operating temperature. These are rust-free stainless steel, PPS plastics and fluoride rubber.
3.5 Refrigeration system
The refrigeration system consists essentially of a hermetically sealed compressor. Heat of
condensation and motor heat are dissipated by a fan-cooled finned condenser. Fresh air is drawn in
at the front of the unit, warmed air is discharged at the back and to the sides. The ventilation
openings must not be restricted in order to ensure proper air circulation.
At working temperatures below approx. 30 °C the refrigeration system operates continuously to
remove a certain amount of heat, with the heater acting in opposition to provide automatically
controlled heating power.
The compressors are fitted with a temperature monitor which responds both to the compressor
temperature and to the motor current. In addition the cooling system is protected against excessive
pressure by a pressure monitor. The refrigeration unit is switched on either automatically or
manually through the operating menu .(➾Section 6.4.1.).
When the fault circuit is activated the refrigeration system is also switched off.
Cooling curves (➾Section 9. Technical data)

Unpacking
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4 Unpacking
After the unit and accessories have been unpacked they have to be examined for possible transport
damage. If there is any damage visible on the unit, the forwarding agent or the post office has to be
notified so that the shipment can be examined.
Standard accessories:
Bath cover on all low-temperature thermostats except for RE 120
Closing plugs on all low-temperature thermostats
Warning label on all low-temperature thermostats
Operating Instructions on all low-temperature thermostats

Pre
p
arations
6
5 Preparations
5.1 Assembly and setting up
☞− Place the unit on a flat surface
− After transport and before starting up, store
it standing in upright position for two hours
if possible
− Do not cover the ventilation openings at the
back of the unit and its lower part.
Keep clear distance of at least 40 cm.
− Adjust the pump setting knob so that when
using the unit as bath thermostat (no
external circulation) the flow emerges at
the opening for the bath circulation, or link
together the pump connections. (See
ill. 3).
Operation with external consumer (circulation
thermostat) (➾Section 5.4.)
Adjustments of the pump outflows
Ill 1
Pump setting knob turned
anticlockwise
Ill 1
Pump setting knob medium
position
Ill 3.
Pump setting knob turned
clockwise
− When operating as bath thermostat without external consumer the pump outflow
connection has to be closed (use closing plugs) or linked to the return.
− At bath temperature above 70°C the label supplied must be affixed on
the bath in a clearly visible position!

Preparations
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☞− The unit can be operated safely up to an ambient temperature of 40°C
− Depending on the loading of the refrigeration system, a temporary shut-off can
occur, especially in case of an ambient temperature of over 35°C.
Additionally a higher ambient temperature results in less refrigerating capacity.
− When starting up the refrigeration system after a longer time, it can take up to 30
min, depending on the ambient temperature and the unit type, until the nominal
refrigerating capacity is reached.
5.2 Filling and emptying
Filling
− Close the drain cock.
− Fill baths up to a maximum level of 20 mm below the bath
bridge.
− Optimum operation at 20-40 mm below the bath bridge.
− Operation is possible down to 60 mm below the bath bridge.
− The low-level cut-out operates approx. 90 mm below the
bath bridge!
☞− When using thermal oils it is necessary to allow for an expansion of approx.
8 %/100 °C.
− When operating with an external consumer the total expansion takes place in the
bath!

Pre
p
arations
8
Emptying
− Switch off the thermostat, pull out the mains plug!
− Drain the bath liquid through the drain cock
!using tubing.
☞− The units are designed for operation with non-flammable and flammable liquids to
EN 61010-2-010! Flammable liquids can be operated up to no more than 25°C
below the firepoint (➾Section 5.3.).
− Observe the appropriate regulation when disposing used thermostating liquid.
− When connecting an external consumer take care of the bath liquid level for it
must not decrease too much !fill in bath liquid if necessary.
Do not drain the thermostating liquid when it is hot or very cold (below 0°C)!

Preparations
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5.3 Bath liquids and hose connections
Bath liquids
LAUDA
Designation Working tem-
perature
range
Chemical
Designation Visco- sity
(kin)
Viscosity
(kin) at
Temperature
Fire-
point Ref.No. Quantity
Former
designation from °C to °C at 20°C mm²/s mm²/s 5 l 10 l 20 l
water +5...+90 deionised
water ➀-- -- --
Kryo 30 ➁G 100 ➁-30...+90 Mono-
ethylene-
glycol/water
4 50 at -25°C -- LZB 109 LZB 209 LZB 309
Kryo 50 SK Super
Frigor -50...+95 Silicone oil 6 35 at -50°C > 139 LZB 103 LZB 203 LZB 303
Kryo 20 160 MS -20...+180 Silicone oil 11 28 at -20°C > 230 LZB 116 LZB 216 LZB 316
Ultra 350 330 SCB +30...+200 synthetic
thermal oil 47 28 at +30°C > 240 LZB 107 LZB 207 LZB 307
Therm 230 RDS 50 +60...+230 Silicone oil 44 28 ... +60°C > 362 LZB 117 LZB 217 LZB 317
☞①At higher temperatures !Evaporation losses !Use bath covers (➾Section 10. Accessories).
Distilled water or fully deionised water must only be used with the addition of 0,1g sodium
carbonate/l water, otherwise
!danger of corrosion!
➁Water content falls after prolonged operation at higher temperatures
!mixture becomes flammable (flash point 128 °C).
!Check the mixture ratio with a densiometer.
−When selecting bath liquids it should be noted that performance must be expected to worsen
at the lower limit of the operating temperature range due to increasing viscosity. The full
operating range should only be utilised if really necessary.
−The operating ranges of the bath liquids and tubing represent general data which may be
limited by the operating temperature range of the unit.
Silicone oil causes pronounced swelling of Silicone rubber !never use Silicone oil with
Silicone tubing!
DIN Safety data sheets are available on request

Pre
p
arations
10
Hose connections
Tubing type Int. dia.
Ø mm Temperature range °C Application Ref. No.
Perbunan tubing,
uninsulated 90 to 120 for all bath liquids RKJ 011
Perbunan tubing,
uninsulated 12 -0 to 120 for all bath liquids RKJ 012
Perbunan tubing
insulated 12 ext. dia.
35mm approx.
-60 to 120 for all bath
liquids LZS 008
Silicone tubing,
uninsulated 11 -30 to 100 water, water/glycol
mixture
RKJ 059
Silicone tubing
insulated 11 ext. dia.
35mm approx.
-60 to 100 water,
water/glycol
mixture
LZS 007
Viton 11 -60 to 200 for all bath
liquids RKJ 091
− Silicone oil causes pronounced swelling of Silicone rubber !never use Silicone
oil with Silicone tubing!
− Protect tubing with hose clips against slipping off.

Preparations
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5.4 Connection of external circuits
Operation as circulation thermostat
− Connect 11-12 mm int. dia. tubing (➾Section 5.3.) to
the pump connector
− Pump outflow connection always in front, return
connection always at the back.
☞− If the cross-section of the tubing is too small !temperature drop between bath
and external system due to low flow rate. Increase the bath temperature
appropriately.
− Always ensure the maximum possible flow cross-section in the external circuit!
− When the external consumer is placed at a higher level than the thermostat the
pump is stopped and air penetrates into the thermostating circuit the external
liquid may drain down into the bath even with a closed system !danger of
flooding the thermostat
− Protect tubing with hose clips against slipping off!
− When no external consumer is connected to the thermostat, the pump outflow
connection must be closed (use closing plugs) or linked to the return!
− Using the setting knob at the pump outflows, divide up
the pump flow in accordance to the thermostating
task.(➾Section 5.1)
− Position ➀
➀➀
➀!maximum flow in the external circuit, the
setting knob is turned anticlockwise.
− Position ➁
➁➁
➁!flow passes through pump outflow and
outlet for bath circulation, the setting knob is in medium
position.
− Position ➂
➂➂
➂!external circuit is closed and the outlet for
bath circulation fully open, the setting knob is turned
clockwise.
− Operate the setting knob only when the bath contents are near the ambient
temperature.
− When no tubing is connected, close the pump outflow with closing plugs even in
position ➂.

Starting up
12
6 Starting up
6.1 Connection to the supply
Compare the supply voltage against the data on the rating label.
Model according to EMC directive EN 61326-1 class B.*
−Connect the unit only to a grounded mains power socket (PE).
−No warranty when the thermostat is connected to a wrong supply!
−Without external circuit ensure that the pump pressure outflow is closed or linked to the
pump return.
−Ensure that the unit is filled in accordance with Section 5.2.!
6.2 Switching on
−Using a screwdriver. Set the overtemperature switch-off
point to a value clearly above ambient temperature.
−Switch on at the mains switch.
The green LED for "Supply ON" lights up.
!
!!
!0,25s −A tone sounds for approx. 0,25 s.
−The unit self-test starts up. All display segments and
symbols light up for approx. 1 s. Then the software version
is indicated for approx. 1 s.
−Display shows the actual bath temperature. The pump
starts up. The values which were active before switching off
are used.
☞−If necessary add more bath liquid to replace the amount pumped out to the external
circuit.
−If the pump does not purge the system immediately. The unit may switch off again
although it is filled sufficiently (only when starting up for the first time).
!
!!
! −A double signal tone sounds.
* Notice only valid for EU countries

Starting up
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−The display for LLL (low-level) appears.
−The fault triangle is flashing
−Press the key. If necessary repeat several times.
−Also press the key if the unit had switched off under a fault
condition.
6.3 Setpoint selection
or
−Shortly press one of the keys !adjusted setpoint appears
for approx. 4 s.
−°C is flashing, in contrast to the actual value.
or
−During the 4 s. start to set the required setpoint using the
keys.
−Speeding the setting process by:
a) continuous pressing the keys or
b) pressing one key (holding it down) and shortly pressing
the other key.
−Briefly releasing (1 s) the key (s) and again pressing one of
the keys moves the cursor one place to the right.
−Display flashes 4 s !the new value is accepted
automatically, or
−Value is entered immediately with this key.
☞−For safety reasons the setpoint can only be adjusted up to 2 °C above the upper limit of
the operating temperature range of the particular unit type.

Startin
g
u
p
14
6.4 Menu functions
− Switching from setpoint selection (level 0) to level 1 using
the key
or − Within one level it is possible to scroll using the keys.
− In principle, after each setting has been made it is entered
automatically after approx. 4 s or
− Settings are entered immediately on operating this key
6.4.1 Refrigeration system
(level 1)
− The display shows C and the actual operating mode of the
refrigeration system
0 = OFF, 1 = ON, A = automatic operation
− Press the key !display flashes for approx. 4 s.
or − During this time start to set the required operating mode
with one of the keys. After 4 s the value is entered
automatically.
− It is only then that the selected status is activated.
− Forward with key to "pump output" or
− back with key to the actual value display.
☞− The refrigeration system can normally work with automatic operation = A.
The refrigeration system switches on or off depending on the temperature and
operation status.
− In special cases the cooling machine can be switched off !”0” or adjusted at
permanent running !”I”.