JULABO FCW1600, FCW1600S User Manual

English

Operating

manual

Recirculating coolers

FC600 FC600S FCW600 FCW600S FC1200 FC1200S FCW1200 FCW1200S FC1600 FC1600S FCW1600 FCW1600S

air-cooled water cooled

JULABO GmbH 77960 Seelbach / Germany Tel. +49 (0) 7823 / 51-0 Fax +49 (0) 7823 / 24 91

1.951.4802-V2 06/13

19514802-V2.doc 26.07.13

info@julabo.de www.julabo.de

Congratulations!

You have made an excellent choice. JULABO thanks you for the trust you have placed in us. This operating manual has been designed to help you gain an understanding of the operation and possible applications of our circulators. For optimal utilization of all functions, we recommend that you thoroughly study this manual prior to beginning operation.

The JULABO Quality Management System

Temperature control devices for research and industry are developed, produced, and distributed according to the requirements of ISO 9001 and ISO 14001. Certificate Registration No. 01 100044846

Unpacking and inspecting

Printed in Germany Changes without prior notification reserved

Unpack the recirculating cooler and accessories and check for damages incurred during transit. These should be reported to the responsible carrier, railway, or postal authority, and a request for a damage report should be made. These instructions must be followed fully for us to guarantee our full support of your claim for protecting against loss from concealed damage. The form required for filing such a claim will be provided by the carrier.

Important: keep operating manual for future use

Recirculating coolers

Table of Contents

1. Intended use ............................................................................................... 4

1.1. Description ......................................................................................... 4

2. Operator responsibility – Safety instructions .............................................. 4

2.1. Disposal .............................................................................................. 6

2.2. EC Conformity .................................................................................... 7

2.3. Warranty conditions ............................................................................ 7

2.4. Technical specifications ..................................................................... 8

2.5. Cooling water connection ................................................................. 11

3. Safety notes for the user .......................................................................... 12

3.1. Explanation of safety notes .............................................................. 12

3.2. Explanation of other notes ................................................................ 12

3.3. Safety instructions ............................................................................ 12

4. Operating controls and functional elements ............................................. 14

5. Operation .................................................................................................. 17

5.1. Preparations ..................................................................................... 17

5.2. Return flow safety device ................................................................. 18

5.3. Bath fluids ......................................................................................... 19

5.4. Tubing ............................................................................................... 19

5.5. Power connection ............................................................................. 20

5.6. Filling ................................................................................................ 20

5.7. Draining ............................................................................................ 21

6. Manual operation ..................................................................................... 22

6.1. Switching on ..................................................................................... 22

6.2. Start .................................................................................................. 22

6.2.1. Automatic / non-automatic start mode.......................................... 23

6.3. Setting the setpoint temperatures .................................................... 24

6.3.1. Setting the temperature ................................................................ 24

6.3.2. Setting the control ratio for feed/return flow temperature ............. 25

6.3.3. Setting the safety temperatures ................................................... 26

6.3.4. Low liquid level protection ............................................................ 26

6.4. PID control parameters .................................................................... 27

7. Trouble shooting guide ............................................................................. 29

7.1. Other error messages ...................................................................... 30

8. Electrical connections .............................................................................. 30

9. Remote control ......................................................................................... 32

9.1. Communication with a PC or data system ....................................... 32

9.2. List of commands ............................................................................. 33

9.3. Status messages .............................................................................. 34

9.4. Error messages ................................................................................ 34

10. Menu functions ......................................................................................... 35

10.1. Selecting/exiting the configuration level ........................................... 35

10.2. Setting the parameters ..................................................................... 35

10.3. Adjustable parameters ..................................................................... 36

11. Cleaning / repairing the unit ..................................................................... 37

Intended use

1. Intended use

JULABO recirculating coolers have been designed for temperature application to specific fluids. The pump connections can be used for cooling applications in an external circuit at a constant temperature.

JULABO recirculating coolers are not suitable for direct temperature control of foods, semi-luxury foods and tobacco, or pharmaceutical and medical products. Direct temperature control means unprotected contact of the object with the bath medium (bath fluid).

1.1. Description

The recirculating cooler consists of

 control unit with splash-proof keypad (microprocessor technology)  cooling compressor  heater  heating/cooling bath and recirculating pump

The electronics comprises two microprocessors that provide reciprocal monitoring via sensors for the working and safety circuit. The actual and setpoint temperatures are permanently visible on the MULTI-DISPLAY (LED 1 + LED 2) and thus may be easily compared. The bath tank is located in the lower part of the unit. The cooling machine draws heat from the bath liquid via the cooling coil (evaporator). If the setpoint lies above the ambient temperature, the integrated heater produces more heat. The integrated circulating pump ensures constant conditions for the external cooling loop and provides a good circulation of the liquid in the bath tank. The unit provides analog electrical connections and a serial interface.

Safety installations: High temperature and low temperature limits, both adjustable via the MULTI-DISPLAY, as well as low liquid level protection.

2. Operator responsibility – Safety instructions

The products of JULABO ensure safe operation when installed, operated, and maintained according to common safety regulations. This section explains the potential dangers that may arise when operating the recirculating coolers and also specifies the most important safety precautions to preclude these dangers as far as possible.

Recirculating coolers

The operator is responsible for the qualification of the personnel operating the units.

 The personnel operating the units should be regularly instructed about the dangers

involved with their job activities as well as measures to avert these dangers.

 Make sure all persons tasked with operating, installing, and maintaining the unit have read

and understand the safety information and operating instructions.

 When using hazardous materials or materials that could become hazardous, the unit may

be operated only by persons who are absolutely familiar with these materials and the unit. These persons must be fully aware of possible risks.

If you have any questions concerning the operation of your unit or the information in this manual, please contact us!

Contact:

Safety recommendations for the operator

 You received a product conceived for industrial use. Nevertheless, avoid strikes to the

housing, vibrations, damages to the keypad foil (keys, display) or contamination.

 Make sure the product is regularly checked for proper condition. Regularly check (at least

every 2 years) the proper condition of the mandatory, warning, prohibition and safety labels.

 Take care that the mains supply features a low impedance to avoid any negative affects

on the instrument being operated in the same mains.

 This unit is designed for operation in a controlled electromagnetic environment. This

means that transmitting devices (e.g. cellular phones) should not be used in the immediate vicinity. Magnetic radiation may influence other units with components susceptible to magnetic fields (e.g. a monitor). We recommend to keep a minimum distance of 1 m.

 Permissible ambient temperature: max. 40 °C, min. 5 °C.  Permissible relative air humidity: 50 % (40 °C).  Do not store in an aggressive atmosphere. Protect from contaminations.  Do not expose to sunlight.

JULABO GmbH Eisenbahnstraße 45 77960 Seelbach / Germany

Tel. +49 (0) 7823 / 51-0 info@julabo.de Fax +49 (0) 7823 / 24 91 www.julabo.de

Appropriate Operation

Only qualified personnel is authorized to perform configuration, installation, maintenance and repairs of the water bath. Routine operation can also be carried out by untrained personnel who should however be instructed by trained personnel.

Operator responsibility – Safety instructions

Use

For the use according to the intended purpose, special material requirements have to be respected (bath fluids). Only use non-acid and non corroding materials. Observe all warnings for the used materials (bath fluids) and the respective instructions (safety data sheets). Only use the unit in well ventilated areas. The recirculating coolers are not for use in explosive atmosphere

When using hazardous materials or materials that could become hazardous, the operator

must affix the enclosed safety labels (1 + 2) to the front of the unit so they are highly visible: 1

or 2

Observe the instructions in the manuals for instruments of a different make that you connect to the recirculating cooler, particularly the corresponding safety instructions. Also observe the pin assignment of plugs and technical specifications of the products.

Warning label W00: Colors: yellow, black Danger area. Attention! Observe instructions. (operating manual, safety data sheet)

Mandatory label M018: Colors: blue, white Carefully read the user information prior to beginning operation. Scope: EU

Semi S1-0701 Table A1-2 #9 Carefully read the user information prior to beginning operation.

Scope: USA, NAFTA

2.1. Disposal

This unit contains the refrigerants R134a or R404A, which at this time are not considered harmful to the ozone layer. However, over the long operating period of the unit, disposal rules may change. Therefore, only qualified personnel should handle the disposal.

Valid in EU countries See the current official journal of the European Union – WEEE directive. Directive of the European Parliament and of the Council on waste electrical and electronic equipment (WEEE). This directive requires electrical and electronic equipment marked with a crossed-out trash can to be disposed of separately in an environmentally friendly manner. Contact an authorized waste management company in your country. Disposal with household waste (unsorted waste) or similar collections of municipal waste is not permitted!

2.2. EC Conformity

Recirculating coolers

Low voltage regulations with respect to legal harmonization of the member countries

EMC guideline with respect to legal harmonization of the member countries concerning

2.3. Warranty conditions

The products described in the operating instructions conform to the requirements of the following European guidelines:

concerning electric devices for use within certain voltage limits.

electromagnetic compatibility.

JULABO GmbH Eisenbahnstr. 45 77960 Seelbach / Germany

JULABO GmbH warrants its products against defects in material or in workmanship, when used under appropriate conditions and in accordance with appropriate operating instructions

for a period of ONE YEAR.

Extension of the warranty period – free of charge

With the ‘1PLUS warranty’ the user receives a free of charge extension to the warranty of up to 24 months, limited to a maximum of 10 000 working hours.

To apply for this extended warranty the user must register the unit on the JULABO web site

www.julabo.de

JULABO GmbH’s original invoice. JULABO GmbH reserves the right to decide the validity of any warranty claim. In case of

faults arising either due to faulty materials or workmanship, parts will be repaired or replaced free of charge, or a new replacement unit will be supplied.

Any other compensation claims are excluded from this guarantee.

, indicating the serial no. The extended warranty will apply from the date of

Operator responsibility – Safety instructions

2.4. Technical specifications

FC(W)600 FC(W)600S Working temperature range °C -20 ... 80 -10 ... 80

Cooling capacity °C 20 5 -10 20 5 -10 (water-glycol) kW 0.6 0.4 0.21 0.5 0.3 0.1 Refrigerant R134a Heater capacity kW 1.2 Pump capacity:

Pressure max. psi 7.25 17.4

Flow rate max. Lpm 20 / 14 22 / 15 with tubing connections mm dia 13,5/9,5 13,5/9,5 Pump connections M16x1 M16x1 Noise level, 1 m distance dBA 51 54 Filling volume l 6 ... 8 Dimensions (WxLxH) mm 350 x 540 x 490 Ambient temperature °C 5 ... 40 Shipping weight kg 48 52 Mains power connection V/Hz 230/50 or 208 - 230 / 60 Total power consumption W 2000 2300

FC(W)1200 FC(W)1200S Working temperature range °C -20 ... 80 -15 ... 80

Cooling capacity °C 20 5 -10 20 5 -10 (water-glycol) kW 1.3 0.75 0.37 1.2 0.65 0.26 Refrigerant R134a Heater capacity kW 1.2 Pump capacity:

Pressure max. bar 0.5 1.2

Flow rate max. l/min 20 / 14 22 / 15 with tubing connections mm  13,5/9,5 13,5/9,5 Pump connections M16x1 M16x1 Noise level, 1 m distance dBA 53 57 Filling volume l 8 ... 11 Dimensions (WxLxH) mm 460 x 610 x 490 Ambient temperature °C 5 ... 40 Shipping weight kg 60 66 Mains power connection V/Hz 230/50 or 208 - 230 / 60 Total power consumption W 2300 2800

All data have been determined at mains voltage: 230 V / 50 Hz ambient temperature: 20 °C bath liquid: water-glycol

Recirculating coolers

FCW1600 FCW1600S Working temperature range °C -20 ... 80 -15 ... 80

Cooling capacity °C 20 5 -10 20 5 -10 (water-glycol) kW 1.65 1.0 0.47 1.55 0.9 0.36 Refrigerant R134a Heater capacity kW 1.2 Pump capacity:

Pressure max. bar 0.5 1.2

Flow rate max. l/min 20 / 14 22 / 15 with tubing connections mm  13,5/9,5 13,5/9,5 Pump connections M16x1 M16x1 Noise level, 1 m distance dBA 53 57 Filling volume Liters 8 ... 11 Dimensions (WxLxH) mm 460 x 610 x 490 Ambient temperature °C 5 ... 40 Shipping weight kg 65 66 Mains power connection V/Hz 230/50 or 230 / 60 Total power consumption W 2400 2900

All data have been determined at mains voltage: 230 V / 50 Hz ambient temperature: 20 °C bath liquid: water-glycol

Temperature selection digital (keypad) Resolution °C 0.1 MULTI-DISPLAY indications LED + LED Resolution °C 0.1 Display accuracy % 0.5 Temperature stability °C ±0.2 Temperature control on/off Control ratio for feed/return flow temperature, adjustable % 0 ... 100 Temperature sensor (number) PTC (3) Level indication spy-glass Error message indication LED

Electrical connections: Computer interface RS 232 Stand-by input conforming to Namur recommendations Alarm output potential-free Return flow safety device V 230

Operator responsibility – Safety instructions

Safety installations (adjustable via LED): High temperature protection °C -25 ... 85 Low temperature protection °C -25 ... 85 Low liquid level protection float switch Classification according to DIN 12876-1 III Overload protection for pump motor contactor Overload protection for cooling compressorcontactor Alarm signal optical + audible

Environmental conditions according to IEC 61 010-1: Use only indoor. Altitude up to 2000 m - normal zero. Ambient temperature: +5 ... +40 °C Air humidity: Max. rel. humidity 80 % for temperatures up to +31 °C, linear decrease down to 50 % relative humidity at a temperature of +40 °C Max. mains fluctuations of ±10 % are permissible.

The unit corresponds to Class I Overvoltage category II Pollution degree 2

Caution:

The unit is not for use in explosive environment.

Standards for interference resistance according to EN 61326-1 This unit is an ISM device classified in Group 1 (using high frequency for internal purposes) Class A (industrial and commercial range).

2.5. Cooling water connection

Only for water cooled models - FCW: Cooling water pressure (IN / OUT ) max. 6 bar Difference pressure (IN - OUT ) 3.5 to 6 bar Cooling water temperature <20 °C

Recommended quality of cooling water:

Recirculating coolers

pH – value Sulfate [SO4 2- ] Hydrocarbonate [HCO3- ] / Sulphate [SO4 2-] Hardness [Ca2+, Mg2+] / [HCO3-] Alkalinity Conductivity Chloride (CL-) Phosphate (PO43-) Ammonia (NH3) Free Chlorine Ferri Ions (Fe3+ ) Mangano Ions (Mn2+) Carbon dioxide (CO2) Hydrosulfide (H2S) Content of oxygen Algae growth

Suspended solids impermissible

Notice:

7,5 to 9,0 < 100 ppm > 1 ppm > 0,5 dH 60 ppm < [HCO3-] < 300 ppm < 500 μs / cm < 50 ppm < 2 ppm < 0,5 ppm < 0,5 ppm < 0,5 ppm < 0,05 ppm < 10 ppm < 50 ppm < 0,1 ppm impermissible

Danger of corrosion of heat exchanger due to unsuitable quality of cooling water.

 Due to its high content of lime hart water is not suitable for cooling and

causes calcination of the heat exchanger.

 Ferrous water or water containing ferrous particles will cause formation of

rust even in heat exchangers made of stainless steel.

 Chlorous water will cause pitting corrosion in heat exchangers made of

stainless steel.

 Due to its corrosive characteristics distilled and deionized water is

unsuitable and will cause corrosion of the bath. .

 Due to its corrosive characteristics sea water is not suitable.  Due to its microbiological (bacteria) components which settle in the heat

exchanger untreated and unpurified river water and water from cooling towers is unsuitable.

 Avoid particulate matter in cooling water.  Avoid putrid water.

Safety notes for the user

3. Safety notes for the user

3.1. Explanation of safety notes

In addition to the safety warnings listed above, warnings are posted throughout the manual. These warnings are designated by an exclamation mark inside an equilateral triangle. “Warning of a dangerous situation (Attention! Please follow the documentation).” The danger is classified using a signal word. Read and follow these important instructions.

Warning:

Describes a possibly highly dangerous situation. If these instructions are not followed, serious injury and danger to life could result.

Caution:

Describes a possibly dangerous situation. If this is not avoided, slight or minor injuries could result. A warning of possible property damage may also be contained in the text.

Notice:

Describes a possibly harmful situation. If this is not avoided, the product or anything in its surroundings can be damaged.

3.2. Explanation of other notes Note!

Draws attention to something special.

3.3. Safety instructions

Follow the safety recommendations to prevent damage to persons or

Important!

Indicates usage tips and other useful information.

property. Further, the valid safety instructions for working places must be followed.

 Only connect the unit to a power socket with earthing contact (PE –

protective earth)!

 The power supply plug serves as a safe disconnecting device from the

line and must always be easily accessible.

 Place the instrument on an even surface on a pad made of non-

inflammable material.

 Never operate the unit without bath fluid in the bath.  The instrument is not suited for unsupervised continuous operation.  Do not stay in the area below the unit.

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