Lauda RP 4050 C User manual

Operation manual
PROLINE Kryomats
Low-temperature thermostats
with SmartCool System
RP 4050 C, RP 4050 CW
RP 3090 C, RP 3090 CW
RP 4090 C, RP 4090 CW
Release 03/2022 j Read the instructions before starting work!

2 / 137 Proline Kryomats 03/2022
Manufacturer
LAUDA DR. R. WOBSER GMBH & CO. KG
Laudaplatz 1
97922 Lauda-Königshofen
Germany
Phone: [phone]
Fax: [phone]
E-Mail [e-mail]
Internet https://www.lauda.de
Translation of the original operating instructions Q4DA-E_13-010-EN;
replaces release 08/2020 i, 11/2018 e, 10/2018 d, 05/2016 b2, 03/13, 01/09, 06/08
Valid from:
software control system (Master) version 2.13
software safety system (Master) version 2.07
software operating system (Command) version 3.45
software chilling system version 2.13
software analog IO module version 3.14
software serial IO module version 3.22
software digital IO module version 3.14
software solenoid valve version 3.06
software Ethernet module version 1.23
software EtherCAT module version 1.06

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Prefixed safety notes

Before operating the equipment, please read carefully all the instructions and safety notes in
Section 1.
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.
The master head is supplied with power via the lower section of the unit. After switching off the
head using the switch at the front of the head and/or using the switch at the back of the head,
mains voltage is still present on the master head.
Switch off the unit by using the rotary switch on the front panel.
Switch off the equipment and pull out the mains plug:
for servicing or repair,
moving the equipment!
Transport the equipment with care!
The unit may NEVER be overturned nor put upside down!
Equipment and its internal parts can be damaged:
by dropping,
by shock.
Technically qualified personnel must only operate the equipment!
Never operate the equipment without the heat transfer liquid!
Do not start up the equipment if ...
it is damaged or leaking,
cable (not only supply cable) is damaged.
Drain the bath before moving the equipment!
Do not carry out any technical changes on the device!
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!

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Contents
Prefixed safety notes.....................................................................................................................................................................3
1SAFETY INFORMATION ............................................................................................................................................8
1.1 SAFETY INFORMATION......................................................................................................................................................8
1.2 GENERAL SAFETY INFORMATION.....................................................................................................................................9
1.3 OTHER SAFETY INFORMATION...................................................................................................................................... 10
2BRIEF OPERATING INSTRUCTIONS .................................................................................................................. 11
2.1 MENU STRUCTURE:MASTER......................................................................................................................................... 12
2.2 MENU STRUCTURE:COMMAND REMOTE CONTROL.................................................................................................. 13
3CONTROLS AND FUNCTIONAL ELEMENTS................................................................................................... 14
4UNIT DESCRIPTION................................................................................................................................................. 18
4.1 ENVIRONMENTAL CONDITIONS.................................................................................................................................... 18
4.2 TYPES OF UNIT................................................................................................................................................................ 18
4.3 VARIOFLEX PUMP .......................................................................................................................................................... 18
4.4 MATERIALS..................................................................................................................................................................... 19
4.5 TEMPERATURE DISPLAY,CONTROL AND SAFETY CIRCUIT............................................................................................ 19
4.6 PROGRAMMER AND RAMP FUNCTION ......................................................................................................................... 20
4.7 INTERFACES ................................................................................................................................................................... 20
4.8 INTERFACE MODULES (ACCESSORIES)......................................................................................................................... 20
4.9 REFRIGERATING UNIT .................................................................................................................................................... 21
4.10 AVOIDANCE OF DEWING .............................................................................................................................................. 21
4.11 HEATER RATING AND POWER CONSUMPTION FROM THE MAINS............................................................................... 21
5UNPACKING .............................................................................................................................................................. 22
5.1 AFTER UNPACKING........................................................................................................................................................ 22
5.2 STANDARD ACCESSORIES............................................................................................................................................. 23
5.3 PACKING AND UNPACKING WITH ORIGINAL PACKAGING MATERIAL........................................................................... 23
5.3.1 Background.................................................................................................................................................................... 23
5.3.2 Requirements ................................................................................................................................................................ 23
5.3.3 Unpacking the device.................................................................................................................................................... 24
5.3.3.1 Outer cardboard box............................................................................................................................................ 24
5.3.3.2 Lift device from the pallet .................................................................................................................................... 25
5.3.4 Repacking with original packing material..................................................................................................................... 26
5.4 IN-PLANT TRANSPORT WITH HAND PELLET TRUCK OR FORK LIFTER............................................................................ 26
5.5 BEFORE PREPARATION ................................................................................................................................................. 27
6PREPARATION .......................................................................................................................................................... 28
6.1 ASSEMBLY AND SITING................................................................................................................................................... 28
6.2 FILLING AND DRAINING................................................................................................................................................. 29
6.3 CONNECTION OF THE COOLING WATER...................................................................................................................... 31
6.4 HEAT TRANSFER LIQUIDS,COOLING WATER AND HOSES ........................................................................................... 32
6.5 CONNECTING EXTERNAL LOADS .................................................................................................................................. 35
7STARTING UP............................................................................................................................................................. 37

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7.1 MAINS CONNECTION.................................................................................................................................................... 39
7.2 SWITCHING ON.............................................................................................................................................................. 39
7.3 SWITCHING OFF /STANDBY .......................................................................................................................................... 41
7.4 KEY FUNCTIONS............................................................................................................................................................. 41
7.4.1 General key functions and pilot lamps......................................................................................................................... 41
7.4.2 Changing window information...................................................................................................................................... 45
7.4.3 Locking the keyboard.................................................................................................................................................... 46
7.5 IMPORTANT SETTINGS.................................................................................................................................................... 48
7.5.1 Temperature setpoint setting....................................................................................................................................... 48
7.5.2 Displaying the actual external temperature ................................................................................................................ 50
7.5.3 Setting pump power or standby ................................................................................................................................... 51
7.5.4 Activate external pump................................................................................................................................................. 53
7.5.5 Activating external control ........................................................................................................................................... 53
7.5.6 Current consumption from the mains......................................................................................................................... 55
7.5.7 Setting the date and time ............................................................................................................................................. 56
7.5.8 Display resolution setting ............................................................................................................................................. 57
7.6 SPECIAL SETTINGS.......................................................................................................................................................... 58
7.6.1 Defining the type of start mode................................................................................................................................... 58
7.6.2 Defining temperature limits ......................................................................................................................................... 59
7.6.3 Setpoint offset operating mode................................................................................................................................... 60
7.6.4 Restoring works settings............................................................................................................................................... 61
7.6.5 Setting the volume of the acoustic signals.................................................................................................................. 62
7.6.6 Entering the offset of the internal temperature probe.............................................................................................. 62
7.6.7 Restoring the works setting of the internal temperature-probe offset.................................................................... 63
7.6.8 Entering the offset of the external temperature probe ............................................................................................. 64
7.6.9 Restoring the works setting of the external temperature-probe offset................................................................... 64
7.7 GRAPHICAL DISPLAY OF TEMPERATURE MEASUREMENTS........................................................................................... 65
7.8 PROGRAMMER .............................................................................................................................................................. 67
7.8.1 Program example .......................................................................................................................................................... 67
7.8.2 Selecting and starting the program (Start, Hold, Stop)............................................................................................. 69
7.8.3 Interrupting, continuing or terminating the program (Hold, Continue, Stop) ........................................................ 70
7.8.4 Creating or modifying a program (Edit)...................................................................................................................... 71
7.8.5 Defining the number of program loops (Loops)......................................................................................................... 76
7.8.6 Viewing the program sequence as a graph (Graph) ................................................................................................... 76
7.8.7 Obtaining information on a program (Info) ................................................................................................................ 77
7.9 RAMP FUNCTION........................................................................................................................................................... 78
7.10 TIMER FUNCTION........................................................................................................................................................... 79
7.11 CONTROL PARAMETERS................................................................................................................................................ 80
7.11.1 Internal control variable (integral measurement probe) ............................................................................................ 81
7.11.1.1 Proven settings for control parameters and pump (integral measurement probe) ........................................ 81
7.11.2 External control variable (External measurement probe).......................................................................................... 81
7.11.2.1 Steps for setting the control parameters for external control.......................................................................... 82
7.11.3 Internal and external control parameter sets.............................................................................................................. 84
7.11.4 Self Adaption ................................................................................................................................................................. 85
7.12 ALARMS,WARNINGS AND ERRORS ............................................................................................................................. 88
7.12.1 Overtemperature protection and checking ................................................................................................................ 88
7.12.2 Low-level alarm and low-level checking...................................................................................................................... 90
7.12.3 High-level settings ........................................................................................................................................................ 91

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7.12.4 High-level warning or alarm ......................................................................................................................................... 92
7.12.5 Pump-motor supervision: Overload or blockage ....................................................................................................... 93
7.12.6 Pump-motor supervision: Dry running ....................................................................................................................... 93
7.12.7 Compressor Overtemp................................................................................................................................................. 94
7.12.8 Three-phase current ..................................................................................................................................................... 94
7.12.9 Fault list „Alarms and Warnings“ ................................................................................................................................. 95
8INTERFACE MODULES........................................................................................................................................... 98
8.1 INSTALLING OF MODULES ............................................................................................................................................. 98
8.2 MENU STRUCTURE FOR ALL MODULES......................................................................................................................... 99
8.3 SERIAL INTERFACE RS 232/485...............................................................................................................................100
8.3.1 Connecting cables and interface test RS 232.........................................................................................................100
8.3.2 Protocol RS 232.........................................................................................................................................................101
8.3.3 Connecting cable RS 485 .........................................................................................................................................101
8.3.4 Protocol RS 485.........................................................................................................................................................102
8.3.5 Write commands (Data commands to the thermostat) ..........................................................................................102
8.3.6 Read commands (Data requested from the thermostat)........................................................................................104
8.3.7 Error messages ............................................................................................................................................................106
8.3.8 Driver software for LABVIEW® ...............................................................................................................................106
8.4 ANALOGUE MODULE...................................................................................................................................................107
8.5 CONTACT MODULE .....................................................................................................................................................108
8.5.1 Contact module LRZ 915 with three inputs and three outputs.............................................................................108
8.5.2 Namur-Contact module LRZ 914 with only one input and one output ...............................................................109
9MAINTENANCE.......................................................................................................................................................110
9.1 DEVICE STATUS ............................................................................................................................................................110
9.1.1 Interrogating the device type .....................................................................................................................................110
9.1.2 Software version ..........................................................................................................................................................110
9.1.3 Serial numbers .............................................................................................................................................................110
9.1.4 Device data ..................................................................................................................................................................110
9.1.5 Fault memory ..............................................................................................................................................................111
9.2 CLEANING....................................................................................................................................................................111
9.2.1 Cleaning the surface of the device ............................................................................................................................111
9.2.2 Draining the water-cooled condenser.......................................................................................................................112
9.3 SERVICING,CLEANING,REPAIR AND DISPOSAL INFORMATION................................................................................112
9.3.1 Servicing.......................................................................................................................................................................113
9.3.2 Service intervals...........................................................................................................................................................114
9.3.3 Testing the heat transfer liquid...................................................................................................................................114
9.3.4 Cleaning the condenser ..............................................................................................................................................115
9.3.4.1 Air-cooled condenser ........................................................................................................................................115
9.3.4.2 Water-cooled condenser...................................................................................................................................115
9.3.4.2.1 Cleaning the dirt trap.....................................................................................................................................115
9.3.4.2.2 Decalcifying the water cooling circuit ..........................................................................................................116
9.3.5 Repair information.......................................................................................................................................................116
9.3.6 Remedying faults.........................................................................................................................................................117
9.4 DISPOSAL INFORMATION............................................................................................................................................118
9.4.1 Disposal of the refrigerant..........................................................................................................................................118
9.4.2 Disposal of the packaging ...........................................................................................................................................119

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9.5 HELP DESK AND ORDERING REPLACEMENT PARTS ...................................................................................................119
10 ACCESSORIES.........................................................................................................................................................120
11 TECHNICAL DATA AND DIAGRAMS................................................................................................................121
12 DECLARATION OF CONFORMITY AND PRODUCT RETURNS DECLARATION ...............................130
13 INDEX.........................................................................................................................................................................132

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1Safety information
1.1 Safety information
Danger!
Type and source
Consequences of non-compliance
Action 1
Action ...
"DANGER" indicates an immediate dangerous situation which –if the safety requirements
are ignored –may result in fatal or severe, irreversible injuries.
Warning!
Type and source
Consequences of non-compliance
Action 1
Action ...
"WARNING" indicates a possible dangerous situation which –if the safety requirements are
ignored –may result in fatal or severe, irreversible injuries.
Caution!
Type and source
Consequences of non-compliance
Action 1
Action ...
"CAUTION" indicates a possible dangerous situation which –if the safety requirements are
ignored –may result in slight, reversible injuries.
Notice
Type and source
Consequences of non-compliance
Action 1
Action ...
"NOTICE" warns of possible property or environmental damage.

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
Reference
Refers to further information in other sections.

Note
Here special attention is drawn to some aspect.
1.2 General safety information
A heating and cooling thermostat heats or cools and circulates heat transfer liquids according to specified parameters.
This involves hazards due to high or low temperatures, fire and general hazards due to the application of electrical
energy.
The user is largely protected by the application of relevant standards.
Further hazard sources may arise due to the type of tempering medium, e.g. by exceeding or undercutting certain
temperature thresholds or by the breakage of the container and reaction with the heat transfer liquid.
It is not possible to consider all eventualities. They remain largely subject to the judgment and responsibility of the
operator.
The equipment must only be used as prescribed and as described in these operating instructions. This includes
operation by instructed specialist personnel.
The equipment is not rated for use under medical conditions according to DIN EN 60601-1 or IEC 601-1.
Classification in accordance with EMC requirements of DIN EN 61326-1
Device
Immunity
requirements
Emissions class
Customer power supply
Proline Kryomat
Table 2 (Industrial) in
accordance with
DIN EN 61326-1
Emissions Class B
in accordance with
CISPR 11
Only for EU
Domestic connection value
≥100 A
Proline Kryomat
Table 2 (Industrial) in
accordance with
DIN EN 61326-1
Emissions Class B
in accordance with
CISPR 11
Worldwide
No limitation
Only for the USA:
Instructions for Class A digital devices
“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.”
“This device complies with Part 15 of the FCC (Federal Communication Commission) Rules. Operation is subject to
the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any
interference received, including interference that may cause undesired operation.”
Only for Canada:
“This Class A digital apparatus complies with Canadian ICES-003” (ICES = Interference Causing Equipment

10 / 137 Proline Kryomats 03/2022
Standards).
« Cet appareil numérique de la Classe A est conforme à la norme NMB-003 du Canada ».
1.3 Other safety information
Only connect equipment to PE grounded mains sockets.
At higher operating temperatures, parts of the bath cover can reach surface temperatures exceeding 70 °C. Be
careful when touching it! Danger of burning!
Use suitable hoses (6.3).
Secure hose against slippage with the aid of hose clips. Avoid kinks in the hoses.
Check hoses from time to time for any possible material fatigue.
Thermal medium hoses and other hot parts must not come into contact with the mains cable.
With the use of thermostats as circulating thermostats hot or cold liquid can be emitted when the hose breaks,
presenting a hazard to persons and material.
If no external load is connected, the pump outflow must be closed (use screw plugs) and the bypass valve must be
set to "internal" (4.3).
Take into account the thermal expansion of the heat transfer oils with increasing bath temperature.
Irritant vapors may develop, depending on the heat transfer liquid and operating mode used. Always ensure that the
vapors are adequately extracted. Use the bath cover.
By changing the heat transfer liquid from aqueous heat transfer liquid to a thermal transfer liquid for temperatures
above 100 °C, carefully remove all water residues, including from the hoses and loads. When doing this, also open
the blanking caps of the pump outputs and inputs and blow compressed air through all the pump outputs and
inputs. Danger of scald due to delay in boiling!
Withdraw the mains plug before cleaning, maintenance or moving the thermostat.
Specialist personnel must only carry out repairs in the control section.
Figures of temperature constancy and display accuracy apply under normal conditions according to DIN 12876.
Electromagnetic high frequency fields may in special cases lead to unfavorable values. Safety is not impaired.
The following action may start the thermostat unintentionally from the standby mode: Previously activated timer
mode (7.10), "Start" command via interfaces (8).
Only water-cooled devices:
The return hose of the water-cooling must be securely fixed on the outlet port in order to prevent the hose sliding
off uncontrollably, also during pressure surges.
The return hose of the water-cooling must be fixed on the outlet port that hot cooling water cannot splash out.
It is essential to prevent kinking or squashing of the return hose for the water cooling. Excessive pressure can cause
the cooling water hoses to tear and hot water to escape.
To prevent damages by a leakage of the cooling water system its recommended to use a leak-water detector with
shut-off valve (Aqua Stop).