Julabo FL2503, FLW2503, FL2506, FLW2506, FL4003 Operating manual

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Operating manual

Recirculating Coolers

FL2503 FLW2503 FL2506 FLW2506

FL4003 FLW4003 FL4006 FLW4006

RS23

FL2506

°C

LARM

JULABO USA, Inc. 884 Marcon Boulevard Allentown, PA 18109 Phone: +1(610) 231-0250 Fax: +1(610) 231-0260 info @ julabo.com

19534829-V1.doc Print date: 02.01.2013

www.julabo.com

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 9001:2008. Certificate Registration No. 01 100044846

Unpacking and inspecting

1.953.4829-V1 01/13 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.

 Lifting device for transportation by crane see page 18

Important: keep operating manual for future use

TABLE OF CONTENTS

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

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

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

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

3. Technical specifications ................................................................................................................ 7

3.1. Cooling water connection ................................................................................................ 12

4. Safety notes for the user ............................................................................................................ 13

4.1. Explanation of safety notes ............................................................................................. 13

4.2. Explanation of other notes .............................................................................................. 13

4.3. Safety instructions ........................................................................................................... 13

5. Installation .................................................................................................................................. 15

5.1. Tubing ............................................................................................................................. 17

6. Operating controls and functional elements ............................................................................... 18

7. Operating procedures ................................................................................................................. 20

7.1. Bath fluids ....................................................................................................................... 20

7.2. Power connection ........................................................................................................... 20

7.3. Filling ............................................................................................................................... 21

7.4. Switching on / Start - Stop .............................................................................................. 21

7.5. Setting the feed pressure ................................................................................................ 22

7.6. Setting the temperatures ................................................................................................. 22

7.7.

7.8. Remote control: activate – deactivate ............................................................................. 23

8. Safety installations...................................................................................................................... 23

8.1. Excess temperature protection ....................................................................................... 23

8.2. Low level protection ........................................................................................................ 23

9. Troubleshooting guide / Error messages .................................................................................... 24

10. Electrical connections ....................................................................................................... 26

11. Remote control .................................................................................................................. 27

11.1. Setup for remote control ................................................................................................. 27

11.2. Communication with a PC or a superordinated data system .......................................... 27

11.3. List of commands ............................................................................................................ 28

11.4. Status messages ............................................................................................................ 28

11.5. Error messages ............................................................................................................... 29

12. Cleaning / repairing the unit .............................................................................................. 30

12.1. JULABO Service – Online remote diagnosis .................................................................. 32

12.2. Draining ........................................................................................................................... 33

13. Adequate storing of operating manual .............................................................................. 33

14. WARRANTY PROVISIONS .............................................................................................. 34

AUTOSTART ON / OFF .................................................................................................. 22

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 water baths are not suitable for direct temperature control of foods, semiluxury 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 coolers are operated via the splash-proof keypad. The

implemented microprocessor technology allows to set and to store the setpoint that

PID1

RS232

can be indicated on the LED temperature display.

 The PID temperature regulation is used to withdraw heat from the bath fluid by

means of the cooling machine and to automatically regulate the required need.

 Electrical connections:

1. The serial interface RS232 allows modern process technology without additional interface.

2. Alarm output for external alarm message.

 Manually adjustable by-pass (handwheel) to reduce the pump capacity

(e. g. for glass equipment).

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 circulator and also specifies the most important safety precautions to preclude these dangers as far as possible.

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 USA, Inc. 884 Marcon Boulevard Allentown, PA 18109

Phone: +1(610) 231-0250 Fax: +1(610) 231-0260 info @ julabo.com www.julabo.com

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.

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. (see page 14). 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 to the front of the unit so they are highly visible:

If this unit is intended for use within the United States of America, all 3 warning labels must be affixed

to the housing of the unit prior to use. Directions for the positioning of the individual warning labels are enclosed with the warning labels included in the delivery. Warning labels must be easily visible to users.

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

or 2

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

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

Warning label Proposition 65

2.1. Disposal

This unit contains the refrigerant R404A, which at this time is 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.

3. Technical specifications

Recirculating Cooler

Cooling Working temperature range °C -20 ... +40 -20 ... +40 Temperature stability °C ±0.5 Temperature selection: digital via key pad indication on LED-DISPLAY remote control via personal computer indication on monitor Temperature indication: LED-DISPLAY Resolution °C 0.1 Temperature control PID 1 Temperature sensor Pt 100 Excess temperature protection 85 °C - fixed value Low liquid level protection float switch Cooling capacity Medium: Mixture water-glycol Cooling compressor 1-stage Refrigerant R404A

Electrical connections: Computer interface RS232 Alarm output for external alarm signal

Circulating pump: discharge, max. at 0 bar l/min 40 40 pressure, adjustable at 0 Liter bar 0.5 ... 3.0 0.5 ... 3.0 Feed pressure indication bar Manometer Manometer Filling level indicator sight glass Filling volume from ... to liters 24 … 30 Dimensions (WxLxH) cm 60x76x115 Weight kg 146 143 Ambient temperature range °C 5 ... 40 Return flow temperature °C 80 max. Cooling water Flow rate at 20 °C inlet temperature IP class according to IEC 60 529 IP 21

Mains power connection 230 V/50 Hz V/ Hz 207-253 / 50 207-253 / 50

Current input at 230 V A 11 12

Mains power connection 208 - 220 V/60 Hz V/ Hz 197 - 242 / 60 197 - 242 / 60 Current input at 208V / 220 V A 13 ----

All measurements have been carried out at: rated voltage and frequency, ambient temperature: 20 °C

°C kW

l/min

FL2503 FLW2503

air cooled water cooled

+20 0 -10 +20 0 -10

2.5 1.5 1.2 2.7 1.7 1.0

----- 4.1

Recirculating Cooler

Electrical connections: Computer interface RS232 Alarm output for external alarm signal

Circulating pump: discharge, max. at 0 bar l/min 60 60 pressure, adjustable at 0 Liter bar 0.5 ... 6.0 0.5 ... 6.0 Feed pressure indication bar Manometer Manometer Filling level indicator sight glass Filling volume from ... to liters 24 … 30 Dimensions (WxLxH) cm 60x76x115 Weight kg 158 160 Ambient temperature range °C 5 ... 40 Return flow temperature °C 80 max. Cooling water Flow rate at 20 °C inlet temperature IP class according to IEC 60 529 IP 21

Mains power connection 230 V/50 Hz V/ Hz 207-253 / 50 207-253 / 50 Current input at 230 V A 14 15 Mains power connection 208 - 220 V/60 Hz V/ Hz 197 - 242 / 60 197 - 242 / 60 Current input at 208V / 220 V A 16 ------

All measurements have been carried out at: rated voltage and frequency, ambient temperature: 20 °C

°C kW

l/min

FL2506 FLW2506

air cooled water cooled

+20 0 -10 +20 0 -10

2.5 1.0 0.3 2.5 1.0 0.3

----- 4.1

Recirculating Cooler

Cooling

FL4003 FLW4003

air cooled water cooled Working temperature range °C -20 ... +40 -20 ... +40 Temperature stability °C ±0.5 Temperature selection: digital via key pad indication on LED-DISPLAY remote control via personal computer indication on monitor Temperature indication: LED-DISPLAY Resolution °C 0.1 Temperature control PID 1 Temperature sensor Pt 100 Excess temperature protection 85 °C - fixed value Low liquid level protection float switch Cooling capacity Medium: Mixture water-glycol

°C kW

+20 0 -10 +20 0 -10

4.0 2.4 1.5 4.3 2.2 1.3 Cooling compressor 1- stage Refrigerant R404A

Electrical connections: Computer interface RS232 Alarm output for external alarm signal

Circulating pump: discharge, max. at 0 bar l/min 40 40 pressure, adjustable at 0 Liter bar 0.5 ... 3.0 0.5 ... 3.0 Feed pressure indication bar Manometer Manometer Filling level indicator sight glass Filling volume from ... to liters 24 ... 30 Dimensions (WxLxH) cm 60x76x115 Weight kg 148 143 Ambient temperature range °C 5 ... 40 Return flow temperature °C 80 max. Cooling water Flow rate at 20 °C inlet temperature

l/min ----- 6.6

IP class according to IEC 60 529 IP 21

Mains power connection 400 V/3PNPE/50 Hz

V/ Hz 360-440/3PNPE/50 360-440/3PNPE/50

Current input at 230 V A 8 8 Mains power connection 230 V/3PPE/60 Hz

V/ Hz 197-242/3PPE/60 207-253/3PPE/60

Current input at 208V / 220 V A 11 ------

All measurements have been carried out at: rated voltage and frequency, ambient temperature: 20 °C

Recirculating Cooler

Cooling

FL4006 FLW4006

°C kW

+20 0 -10 +20 0 -10

4.0 1.9 0.9 4.0 1.7 0.7 Cooling compressor 1- stage Refrigerant R404A

Electrical connections: Computer interface RS232 Alarm output for external alarm signal

Circulating pump: discharge, max. at 0 bar l/min 60 60 pressure, max. at 0 liter bar 0.5 ... 6.0 0.5 ... 6.0 pressure, adjustable at 0 Liter Feed pressure indication bar Manometer Manometer Filling level indicator sight glass Filling volume from ... to liters 24 ... 30 Dimensions (WxLxH) cm 60x76x115 Weight kg 157 160 Ambient temperature range °C 5 ... 40 Return flow temperature °C 80 max. Cooling water Flow rate at 20 °C inlet temperature

l/min ----- 6.6

IP class according to IEC 60 529 IP 21

Mains power connection 400 V/3PNPE/50 Hz

V/ Hz 360-440/3PNPE/50 360-440/3PNPE/50

Current input at 230 V A 12 13 Mains power connection 230 V/3PPE/60 Hz

V/ Hz 197-242/3PPE/60 207-253/3PPE/60

Current input at 208V / 220 V A 16 ------

All measurements have been carried out at: rated voltage and frequency, ambient temperature: 20 °C

Warning functions and safety installations

Excess temperature protection 85 °C - fixed value Low liquid level protection float switch Alarm message optical + audible (permanent) Excess temperature - Warning function 75 °C Overload protection for compressor and pump motor Classification according to DIN 12876-1 class I

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 atmosphere

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).

3.1. Cooling water connection

Only for water cooled models - FLW: Cooling water pressure (IN / OUT ) max. 6 bar Difference pressure (IN - OUT ) 2 bar to 6 bar Flow rate on FLW250x typical 4,1 l/min Flow rate on FLW400x typical 6,6 l/min Cooling water temperature <20 °C

Recommended quality of cooling water:

pH – value 7,5 to 9,0 Sulfate [SO4 2- ] < 100 ppm Hydrocarbonate [HCO3- ] / Sulphate [SO4 2-] > 1 ppm Hardness [Ca2+, Mg2+] / [HCO3-] > 0,5 dH Alkalinity 60 ppm < [HCO3-] < 300 ppm Conductivity < 500 μs / cm Chloride (CL-) < 50 ppm Phosphate (PO43-) < 2 ppm Ammonia (NH3) < 0,5 ppm Free Chlorine < 0,5 ppm Ferri Ions (Fe3+ ) < 0,5 ppm Mangano Ions (Mn2+) < 0,05 ppm Carbon dioxide (CO2) < 10 ppm Hydrosulfide (H2S) < 50 ppm Content of oxygen < 0,1 ppm Algae growth impermissible Suspended solids impermissible

Notice:

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.

4. Safety notes for the user

4.1. 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.

4.2. Explanation of other notes

Note!

Draws attention to something special.

Important!

Indicates usage tips and other useful information.

4.3. Safety instructions

Follow the safety recommendations to prevent damage to persons or 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.

 Do not stay in the area below the unit.

 Make sure you read and understand all instructions and safety precautions listed

in this manual before installing or operating your unit.

 Never operate the unit without bath fluid in the bath.

 Do not drain the bath fluid while it is hot or cold!

Check the temperature of the bath fluid prior to draining (by switching the unit on for a short moment for example).

 Use suitable connecting tubing.

 Avoid sharp bends in the tubing, and maintain a sufficient distance from

surrounding walls.

 Make sure that the tubing is securely attached.

 Regularly check the tubing for material defects (e.g., for cracks).

 Never operate damaged or leaking equipment.

 Always turn off the unit and disconnect the mains cable from the power source

before performing any service or maintenance procedures, or before moving the unit.

 Always turn off the unit and disconnect the mains cable from the power source

before cleaning the unit.

 Always empty the bath before moving the unit.

 Transport the unit with care.

 Sudden jolts or drops may cause damage in the interior of the unit.

 Observe all warning labels.

 Never remove warning labels.

 Never operate equipment with damaged mains power cables.

 Repairs are to be carried out only by qualified service personnel.

 Risk of injury for hands. Close cover carefully.

Notice:

Recommendation in case of single-phase current supply (e.g. FL250x): The safety cutouts of the house wiring should have the trait „C“ (C16A).

WARNING

This product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

5. Installation

 Place the unit on an even surface on a base made of nonflammable

material. Using the castors (10a, 10b) move the unit to the intended location. For better stability, apply the holding breaks on the front casters (10a).

 Cooling machine, pump motor and electronics produce intrinsic heat that is

dissipated via the venting openings.! Never cover these openings!

 Keep at least 20 cm of open space on the front and rear venting grids.

 The place of installation should be large enough and provide sufficient air

ventilation to ensure the room does not warm up excessively because of the heat the instrument rejects to the environment. (Max. permissible ambient temperature: 35 °C). For a fault (leakage) in the refrigeration system, the standard EN 378 prescribes a certain room space to be available for each kg of refrigerant. > For 0.52 kg of refrigerant R-404A, 1 m

Rear view Example: FL2503

min

of space is required.

 Connect the tubings for cooling the external system to

the pump connectors M16x1 for feed and return (14) on the rear of the recirculating cooler.

– Return - Feed

 Connect a piece of tubing to the overflow connector

IN OUT

(15) and drain into a suitable vessel, which always has to be placed lower thant the exit „Overflow“.

 Turn the adjusting valve (13) counter-clockwise to set

the lowest manometric pressure.

 Do not set up the unit in the immediate vicinity of heat

sources and do not expose to sun light.

 Before operating the unit after transport, wait about

one hour after setting it up. This will allow any oil that has accumulated laterally during transport to flow back down thus ensuring maximum cooling performance of the compressor.

OUT

Example: PVC-tubing

 Only water cooled models - FLW:

Ensure circulation of cooling water by connecting the tubing to cooling water inlet (IN)and outlet (OUT) on the rear (18) of the recirculating cooler.

Cooling water see page 12.

12 mm inner dia.

Cooling water connectors G3/4" external thread Tubing 12 mm inner dia. tubing IN Cooling water inlet OUT Cooling water outlet

Even high quality heat exchangers as they are installed in our equipment can be

damaged by unsuitable cooling water. The quality of the cooling water depends on the local conditions. The heat exchanger may become leaky due to corrosion or it may become clogged due to particulate matter

Notice: Cooling water circuit

Risk of oil leaking from the cooling circuit (compressor) of the recirculating cooler into the cooling water in case of a fault in the circuit! Observe the laws and regulations of the water distribution company valid in the location where the unit is operated.

Caution: Pump pressure

 Determine and check the max. admissible pressure for the external circuit before

Return flow safety device

Order No. Description

8 970 454 Shut-off valve G ¾“ FL(W) 2503/4003 8 970 458 Shut-off valve G 1¼“ FL(W) 2506/4006

The following questions shall help to recognize possible dangers and to reduce the

putting the unit into operation. The max. pressure is determined by the weakest element in the circuit (e. g. glass equipment).

 Securely attach all tubing to prevent slipping.

Notice: Flood hazard!.

In case the system to be cooled is located at a higher level than the recirculating cooler, take note of bath liquid flowing back when the unit is switched off.

Should the filling volume of the bath tank not be sufficient, prevent the liquid from flowing back by using shut-off valves..

Suitable for

risks to a minimum.  Are all tubes and electrical cables connected and installed?

Note: sharp edges, hot surfaces in operation, moving machine parts, etc.

 What to do when a dangerous substance was spilled on or in the unit?

Before starting to work, obtain information concerning the substance and determine the method of decontamination.

5.1. Tubing

Caution:

 Employ suitable connecting tubing.  Make sure that the tubing is securely attached.

Recommended tubing:

Order No. Description

8930319 1 m Reinforced tubing ¾“ inner dia. 8930325 1 m Reinforced tubing 1“ inner dia. (-40 ... +120°C) FL(W) 2506/4006

Tubing insulation

8930419 1 m Insulation, 29 mm inner dia. Reinforced tubing ¾“ inner dia. 8930425 1 m Insulation, 35 mm inner dia. Reinforced tubing 1“ inner dia.

Tube clamps

8970483 2 Tube clamps, size 4 Reinforced tubing ¾“ inner dia. 8970484 2 Tube clamps, size 5 Reinforced tubing 1“ inner dia.

 Avoid sharp bends in the tubing, and maintain a sufficient distance from

surrounding walls.

 Regularly check the tubing for material defects (e.g. for cracks).  Preventive maintenance: Replace the tubing from time to time.

Suitable for

(-40 ... +120°C) FL(W) 2503/4003

6. Operating controls and functional elements

Example: FL25xx Front view Rear view

°C

RS23

LARM

FL2506

IN OUT

OUT

13 14

15 16 17

10a

Top view

Push

°C

10b

4 Protection lid for fill in opening

12 Protection lid for storing place of operating manual

Lifting device for transportation by crane

Mains power switch

2.0

°C

2.1

2.2

3.0

3.1

Keypad, spash-water protected

Edit keys (set point increase or decrease)

Enter key Store set point value / parameter

Indication

LED temperature display

3.2

3.3

Control indicator – Cooling

Control indicator – Alarm

4 Protection lid for fill in opening

5 Feed pressure indication: Manometer

Interface RS232: remote control via personal computer

RS232

Alarm output (for external alarm signal)

8 Filling level indication

9 Drain tap with drain port

10a

10b

Castor with brake (at the front)

Castor without brake (at the back)

11 Venting grid, removable

12 Protection lid for storing place of operating manual

13 Feed pressure adjusting valve

Pump connector OUT – pressure pump Pump connector IN– Return

FL/FLW2503 G ¾“ außen FL/FLW4003 G ¾“ außen FL/FLW2506 G 1¼“ FL/FLW4006 G 1¼“

Overflow connector

Mains circuit breakers (resettable) FL250x

2 Mains circuit breakers (resettable) 4 A (for Electronics) 2 Mains circuit breakers (resettable) 10 A (for Pump motor)

F1, F2, F3, F4

Mains circuit breakers (resettable) FL400x

1 Motor protection switch for compressor motor

2 Mains circuit breakers (resettable) 4 A (for Electronics) 2 Mains circuit breakers (resettable) 10 A (for Pump motor)

17 Mains power cable with plug

OUT

Only water cooled models

IN Cooling water inlet

OUT Cooling water outlet G3/4" external thread 12 mm inner dia. tubing

7. Operating procedures

7.1. Bath fluids

Caution:

No liability for use of other bath liquids! Please contact JULABO before using other than recommended bath fluids. JULABO takes no responsibility for damages caused by the selection of an unsuitable bath fluid

Do not use alcohols.

Water:

The quality of water depends on local conditions.  Due to the high concentration of lime, hard water is not suitable for temperature

control because it leads to calcification in the bath.

 Ferrous water can cause corrosion - even on stainless steel.  Chloric water can cause pitting corrosion.

 Distilled and deionized water is unsuitable. Their special properties cause corrosion

in the bath, even in stainless steel.

No liablity for use with water. Danger of freezing at working temperatures <5 °C.

Recommended bath fluids:

Bath fluids Temperature range

soft/decalcified water 5 °C to 80 °C

See website for list of recommended bath fluids.

Contact: see page 5

7.2. Power connection

Caution:

 Only connect the unit to a power socket with earthing contact (PE – protective earth)!

 The power supply plug serves as safe disconnecting device from the line and must

be always easily accessible.

 Never operate equipment with damaged mains power cables.  Regularly check the mains power cables for material defects (e.g. for cracks).

We disclaim all liability for damage caused by incorrect line voltages!

Recommendation in case of single-phase current supply (e.g. FL250x): The safety cutouts of the house wiring should have the trait „C“ (C16A).

Make sure that the line voltage and frequency match the supply voltage specified on the

type plate.

7.3. Filling

Top view

Notice:

Risk of injury for hands. Close cover carefully.

Take care that no liquid enters the interior of the circulating cooler.

 Connect the tubing from the external system to the pump

connectors and check for leaks

Push

°C

 Turn the mains switch (1) on (Switching on - see page 21)

 Switch on unit. To do so press button

 Tempering fluid is pumped into the externally connected system.

Refill fluid up to marking „H“.

 The recirculating cooler is ready for operation.

7.4. Switching on / Start - Stop



Switching on: The recirculating cooler is turned on and off with the mains switch. The unit performs a self-test. All segments of the 4-digit LED temperature DISPLAY and all indicator lights will illuminate (as illustrated on the left). Then the software version and the type of unit is indicated. Examples: (v 1.02) (FL2506)

The display "OFF" indicates the unit is ready to operate (standby

mode).

Start: Press enter

Respect instructions from page 14 to page 17!

 Check to make sure that the drain tap (9) is closed.

 Unlock and open lid of fill in opening (4) by slightly

pushing.

 Fill in tempering fluid up to marking „H“ of the filling level

indicator.

for approx. 4 seconds.

for about 4 seconds.

The LED temperature DISPLAY indicates the actual bath temperature.

2. Wait until the LED display stops blinking!

3. Turn the unit off with the mains power switch.

Stop: 1. Press enter

for about 4 seconds.

7.5. Setting the feed pressure

Set the max. permissible feed pressure (example: 2 bar) by slowly closing the adjusting valve (13) on the rear and looking at the

max.

manometer (5).

 The max. pressure is determined by the weakest element in the

circuit (e. g. glass equipment).

7.6. Setting the temperatures

Factory setting: 25 °C

 Setting can be carried out in the start/stop condition.

1. Press one of the keys for a short moment.

The setpoint value instead of the actual value is indicated on the display for about 8 seconds. The value can now be changed.

2. Change value:

Press Press

Keep the keys depressed for the value to change fast.

to set a higher value. to set a lower value.

3. Press enter to store the value.

7.7. AUTOSTART ON / OFF

The recirculating cooler has been configured and supplied by JULABO

according to N.A.M.U.R. recommendations. This means for the start mode, that the unit must enter a safe operating state after a power failure (non-automatic start mode). This safe operating state is indicated by „OFF“ on the LED temperature display. A complete shutdown of the main functional elements such as compressor and circulating pump is effected simultaneously. Should such a safety standard not be required, the AUTOSTART function (automatic start mode) may be activated, thus allowing the start of the circulator directly by pressing the mains power switch.

Warning:

For supervised or unsupervised operation with the AUTOSTART function, avoid any hazardous situation to persons or property. The circulator does no longer conform to N.A.M.U.R. recommendations.

Keep depressed enter turn on the unit with the mains power switch. For a short while the LED DISPLAY indicates the effective start mode:

and

AUTOSTART on. AUTOSTART off.

7.8. Remote control: activate – deactivate

The recirculating cooler is to be prepared for remote control by a personal computer via the serial interface RS232. Set the interface item from >IOFF< to >ION<.

Remote control: activate – deactivate:

(Interface OFF)

(Interface On)



 Switch off recirculating cooler by pressing the mains switch and

wait approx. 5 seconds.

 Keep depressed the keys

turn on the unit with the mains power switch.

>I OFF< No remote control via RS232 (Factory setting) >I On< Remote control via RS232

 The software version and the type of unit is indicated

(see example on the left).

The display "rOFF" indicates the unit is ready to be operated via

remote control.

8. Safety installations

8.1. Excess temperature protection

This safety installation is independent of the control circuit.

+

When the temperature of the bath fluid has reached the safety temperature (85 °C), a complete shutdown of the compressor and pump is effected. The alarm is indicated by optical and audible signals (continuous tone) and on

the LED-DISPLAY appears the error message "Error 14".

and enter simultaneously and

8.2. Low level protection

+

Caution:

For refill always use the same bath fluid type that is already in the bath.

This safety installation is independent of the control circuit. If the low liquid level protection device is triggered, a complete shutdown of the compressor and circulating pump is effected. The alarm is indicated by optical and audible signals (continuous tone) and on the LED-DISPLAY appears the error message

"Error 01".

 Turn off the unit with the mains switch, refill bath fluid and turn the unit on

again!

Notice:

Check the low liquid level protection device at least twice a year!



To execute a functional test, drain the liquid until the alarm for low liquid level is triggered. Refill liquid afterwards.

9. Troubleshooting guide / Error messages

+

Whenever the microprocessor electronics registers a failure, a complete shutdown of the compressor and circulating pump is performed. The alarm

light " The LED temperature display indicates the cause for the alarm in form of a code.

Press enter

The recirculating cooler is operated without bath fluid, or the liquid level is insufficient. Replenish the bath tank with the bath fluid.

Tube breakage has occured (insufficient filling level due to excessive bath fluid pumped out). Replace the tubing and replenish the bath tank with the bath fluid.

Cable of the working temperature sensor interrupted or short-circuited.

Error in A/D converter

The return temperature is above the switch-off value of the high temperature protection (85°C). Check dimensioning of application. Use a stronger recirculating cooler if necessary.

" illuminates and a continuous signal tone sounds.

to quit the audible signal.

 The motor protection switch for the compressor motor is off. Set motor

protection switch to >1< . Check the fuses.

 The pressure sensor of low pressure side (evaporation pressure) is faulty,

short-circuited or has a line interruption. Have the repair done by a specialist.

 The motor protection switch for the compressor motor is off. Set motor

protection switch to >1< . Check the fuses.

 The pressure sensor of high pressure side is faulty, short-circuited or has a

line interruption. Have the repair done by a specialist.

The suction gas temperature sensor is faulty, short-circuited or has a line interruption. Have the repair done by a specialist.

After eliminating the malfunction, press the mains power switch off and on again to cancel the alarm state.

If the unit cannot be returned to operation, contact an authorized service station.

Warning without a complete shutdown of the unit

Excess temperature warning starting at 75 °C The return temperature soon reaches the swith-off value of the high temperature protection (85 °C).

Cooling of the condenser is affected. (see page 30)

Clean air-cooled condenser. Check the flow rate and cooling water temperature on water-cooled

condenser.

If the unit cannot be returned to operation, contact an authorized JULABO service station.

Disturbances that are not indicated.

Overload protection::

a) for cooling machine b) for pump motor

After a short cooling interval, the unit will automatically start running.

Mains circuit breakers (resettable) FL250x

2 Mains circuit breakers (resettable) 4 A (for Electronics)

2 Mains circuit breakers (resettable) 10 A (for Pump motor)

F1, F2, F3, F4

Mains circuit breakers (resettable) FL400x

1 Motor protection switch for compressor motor

2 Mains circuit breakers (resettable) 4 A (for Electronics) 2 Mains circuit breakers (resettable) 10 A (for Pump motor)

10. Electrical connections

Notice: Use shielded cables only.

The shield of the connecting cable is electrically connected to the plug housing. The unit ensures safe operation if connecting cables with a maximum length of 3 m are

used. The use of longer cables does not affect proper performance of the unit, however

external interferences may have a negative impact on safe operation.

RS232C

Accessories:

RS232 serial interface

This port can be used to connect a computer with an RS232 cable for remote control of the recirculating cooler.

Pin assignments RS232:

Pin 2 RxD Receive Data Pin 3 TxD Transmit Data Pin 5 0 V Signal GND Pin 7 RTS Request to send Pin 8 CTS Clear to send

Pin 1; 4; 6, 9 Reserved - do not use!

Order No. Description

8 980 073 RS232 interface cable 9-pol./9-pol. , 2,5 m

8 900 110 USB interface adapter cable

Alarm output

Potential-free change-over contact for external alarm signal.

Pin 2 and 3 are connected in case of an alarm. Pin 2 and 1 are connected in normal condition or mains switch "Off".

Switching capacity max. 30 W / 30 VA Switching voltage max. 30 V/ Switching current max. 1 A

11. Remote control

11.1. Setup for remote control

RS232

Check the interface parameters for both interfaces (on recirculating cooler and PC) and make sure they match.

Interface parameters are pre-determined. Type RS232

Baudrate 4800 bauds Parity even Handshake hardware handshake

11.2. Communication wit h a PC or a superordinated data system



A transfer sequence consists of:



If the recirculating cooler is put into remote control mode the MULTI-DISPLAY (LED) will read „R -OFF-„ = REMOTE STOP. The recirculating cooler is now operated via the computer. In general, the computer (master) sends commands to the recirculating cooler (slave). The recirculating cooler sends data (including error messages) only when the computer sends a query.

In remote control mode: After a power interruption the order to start and all values which have to be adjusted must be resent from the personal computer via the interface. AUTOSTART is not possible.

command out/in command space (; Hex: 20) out/in command parameter (the character separating decimals in a group is the period) out command end of file (; Hex: 0D) out/in command

The response (data string) after an in command is always followed by a line feed (LF, Hex: 0A).

Important times for a command transmission:

To ensure a safe data transfer, the time gap between two commands should be at least 250 ms.

The recirculating cooler automatically responds to an in command with a data

string followed by a LF (Line Feed). The next command should only be sent after 10 ms.

The commands are divided into in or out commands.

in commands: asking for parameters to be displayed out commands: setting parameters

The out commands are valid only in remote control mode.



Examples: Command to set the working temperature to15,5 °C:

out_sp_00

Command to ask for the working temperature

in_sp_00

Response from the recirculating cooler:

15.5 LF

15.5



11.3. List of commands

out commands: Setting parameters or temperature values.

Command Parameter Response of recirculating cooler

out_mode_05 0 Stop the unit = R –OFF-.

out_mode_05 1

out_sp_00 xxx.xx

Start the unit.

Set working temperature

in commands: Asking for parameters or temperature values to be displayed.

Command Parameter Response of recirculating cooler

version none Number of software version (V X.xx)

status none

in_pv_00 none Actual bath temperature.

in_sp_00 none Working temperature

in_mode_05 none

Status message, error message (see page 28 )

Recirculating cooler in Stop/Start condition: 0 = Stop 1 = Start

11.4. Status messages

Status messages Description

00 MANUAL STOP

01 MANUAL START

02 REMOTE STOP

03 REMOTE START

Recirculating cooler in „OFF“ state.

Recirculating cooler in keypad control mode.

Recirculating cooler in „r OFF“ state.

Recirculating cooler in remote control mode.

11.5. Error messages

Error messages

-01 LOW LEVEL ALARM

-05 WORKING SENSOR ALARM

-03 EXCESS TEMPERATURE WARNING

-07 I2C-BUS ERROR

-08 INVALID COMMAND

-09 COMMAND NOT ALLOWED IN CURRENT OPERATING MODE

-10 VALUE TOO SMALL

-11 VALUE TOO LARGE

-12 TEMPERATURE MEASUREMENT ALARM

-14 EXCESS TEMPERATURE PROTECTOR ALARM

-20 WARNING: CLEAN CONDENSOR OR

CHECK COOLING WATER CIRCUIT OF REFRIGERATOR

-51 PRESSURE SENSOR ALARM LOW

PRESSURE SIDE

-52 PRESSURE SENSOR ALARM HIGH

PRESSURE SIDE

-53 SUCTION GAS TEMPERATURE

SENSOR ALARM

Description

Low liquid level alarm.

Working temperature sensor short-circuited or interrupted.

High temperature warning. Starting at 75 °C (no deactivation) The return temperature soon reaches the switch-off value of the high temperature warning function (85 °C)

Internal error when reading or writing the I

C bus.

Invalid command.

Invalid command in current operating mode.

Entered value too small.

Entered value too large.

Error in A/D converter.

The return temperature is above the switch-off value of the high temperature warning function of 85 °C. Check dimensioning of application. Use a stronger recirculating cooler if necessary.

Cooling of the condenser is affected. Clean air-cooled condenser. Check the flow rate and cooling water temperature on water-cooled condenser.

 The motor protection switch for the compressor

motor is off. Set motor protection switch to >1< . Check the fuses.

 The pressure sensor of low pressure side

(evaporation pressure) is faulty, short-circuited or has a line interruption. Have the repair done by a specialist.

 The motor protection switch for the compressor

motor is off. Set motor protection switch to >1< . Check the fuses.

 The pressure sensor of high pressure side is

faulty, short-circuited or has a line interruption. Have the repair done by a specialist.

The suction gas temperature sensor is faulty, shortcircuited or has a line interruption. Have the repair done by a specialist.

12. Cleaning / repairing the unit

Caution:

Always turn off the unit and disconnect the mains cable from the power source before cleaning the unit. Prevent humidity from entering into the circulator. Service and repair work may be performed only by authorized electricians.

Notice:

Risk of injury for hands when mounting the venting grid.

Maintaining the cooling performance

°C

RS232ALARM

Air cooled models = FL

To maintain the full cooling performance, clean the condenser from time to time.

 Switch off the unit, disconnect mains power cable.

 Hold the venting grid, pull out and remove.

 Clean the ribbed condenser with a vacuum cleaner.

 Replace the venting grid.

 Switch on the unit.

OUT

Water cooled models = FLW In order to maintain a good condition of the cooling compressor,

the sieve in the cooling water input should be cleaned in regular intervals.

 Switch the unit off, disconnect the power plug.

 Interrupt the cooling water input.

 Disconnect the tubing from the nozzle „IN“ and take out the

dirty sieve.

 Clean the sieve.

 Put in the sieve and reconnect the tubing.

 Open the cooling water input.

 Take care the tubing connection is not leaking.

 The unit is ready to operate again.

Cleaning:

Clean the outside of the unit using a wet cloth and low surface tension water. The recirculating cooler is designed for continuous operation under normal conditions. Periodic maintenance is not required. The tank should be filled only with a bath fluid recommended by JULABO. To avoid contamination, it is essential to change the bath fluid from time to time.

Repairs:

Before asking for a service technician or returning a JULABO instrument for repair, please contact an authorized JULABO service station.

When returning the unit:  Clean the unit in order to avoid any harm to the service

personnel

 Attach a short fault description.

 When returning a unit, take care of careful and adequate

packing.

 During transport the unit has to stand upright. Mark the

packing correspondingly.

 JULABO is not responsible for damages that might occur from

insufficient packing.

JULABO reserves the right to carry out technical modifications with repairs for providing improved performance of a unit.

12.1. JULABO Service – Online remote diagnosis

JULABO circulators of the HighTech series are equipped with a black box. This box is implemented in the controller and records all significant data for the last 30 minutes. In case of a failure, this data can be read out from the unit by

using special software. This software is available as a free

download from www.julabo.com

 Installation is easy and is performed step by step.

Please observe the instructions.

 Data read-out is possible in the conditions

“OFF”, “R OFF” or “ALARM”.

 Connect the circulator to the computer using an interface

cable.

 Start the EasyBlackBox program.

The program asks for the port used (COM1, ......) and the baud

rate of the unit. You do not have this information on hand? Simply try it out! The program continues to send the request until the correct settings are made.

 Data is read out and shown on the monitor

divided in the sections >Einstellungen/Settings<, >Alarmspeicher/Alarms stored<, >Blackbox<

 see example

 After pressing >Speichern/Save< a text file is

compiled. The program proposes a filename >C:\model description and barcode no.<. Modifications are possible.

 E-mail this file to ServiceUSA@Julabo.com,

JULABO's service department. JULABO is thus able to provide rapid support.

\ EasyBlackBox.

RS232

ALARM

RS232

ALARM

°C

12.2. Draining

Notice:

Store and dispose the used bath fluid according to the laws for environmental protection.

Risk of injury for hands when mounting the venting grid.

 Turn off the unit and disconnect the

mains cable from the power source.

 Hold the venting grid, pull out and

remove.

 Slide a short piece of tube onto the

drain port and hold it into a pail.

 Open the drain tap and empty the

unit completely.

 Close the drain tap and replace the

venting grid.

13. Adequate storing of operating manual

Store the operating manual at the foreseen place at the unit and

lock it by means of the protection lid (18).

14. WARRANTY PROVISIONS

The following Warranty Provisions shall apply to products sold in North America by Julabo (“Seller”) to the entity shown as buyer (“Buyer”) on Seller’s invoice.

1. Initial Warranty. Upon Seller’s receipt of payment in full for the products and subject to Buyer’s compliance with the terms of sale and any other agreement with Seller relating to the products, Seller warrants to the Buyer that the products manufactured by the Seller are free from defects in material and workmanship for a period not to exceed two (2) years or ten thousand (10,000) hours of operation, whichever comes first, from the date the product is shipped by Seller to Buyer (the “Initial Warranty”).

2. EXCLUSION OF ALL OTHER EXPRESS WARRANTIES; EXCLUSION OF ALL IMPLIED

WARRANTIES. OTHER THAN THE INITIAL WARRANTY, NO OTHER EXPRESS WARRANTIES ARE MADE. ALL IMPLIED WARRANTIES OF EVERY TYPE AND KIND, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE, ARE EXCLUDED IN ALL RESPECTS AND FOR ALL PURPOSES. SELLER DISCLAIMS AND MAKES NO IMPLIED WARRANTIES WHATSOEVER.

3. Exclusions. The Initial Warranty does not include damage to the product resulting from accident, misuse, improper installation or operation, unauthorized or improper repair, replacement or alteration (including but not limited to repairs, replacements, or alterations made or performed by persons other than Seller’s employees or authorized representatives), failure to provide or use of improper maintenance, unreasonable use or abuse of the product, or failure to follow written installation or operating instructions. Buyer must return the product’s record of purchase to the Seller or one of Seller’s authorized representatives within thirty (30) days of the date the product is shipped by Seller to Buyer in order to make a claim under the Initial Warranty. Notwithstanding anything contained herein to the contrary, all glassware, including but not limited to reference thermometers, are expressly excluded from the Initial Warranty.

4. Buyer’s sole remedies; Limitations on Seller’s Liability. Buyer’s sole and exclusive remedy under the Initial Warranty is strictly limited, in Seller’s sole discretion, to either: (i) repairing defective parts; or (ii) replacing defective parts. In either case, the warranty period for the product receiving a repaired or replaced part pursuant to the terms of the Initial Warranty shall not be extended. All repairs or replacements performed by Seller pursuant to these Warranty Provisions shall be performed at Seller’s facility in Allentown, Pennsylvania, U.S.A. or Vista, California, U.S.A or at the facility of an authorized representative of Seller, which location shall be determined by Seller in its sole discretion; provided, however, that Seller may, in its sole discretion perform such repairs or replacements at Buyer’s facility in which case Buyer shall pay Seller’s travel, living and related expenses incurred by Seller in performing the repairs or replacements at Buyer’s facility. As a condition precedent to Seller’s obligation to repair or replace a product part under the Initial Warranty, Buyer shall (i) promptly notify Seller in writing of any such defect; (ii) shall have returned the product’s record of purchase to Seller or to one of Seller’s authorized representatives within thirty (30) days of the date the product is delivered to Buyer; and (iii) assist Seller in all respects in its attempts to determine the legitimacy and basis of any claims made by or on behalf of Buyer including but not limited to providing Seller with access to the product to check operating conditions. If Buyer does not provide such written notice to Seller within the Initial Warranty period or fails to return the product’s record of purchase as set forth above, Seller shall have no further liability or obligation to Buyer therefore. In no event shall Seller’s liability under the Initial Warranty exceed the original purchase price of the product which is the subject of the alleged defect.

5. THE REMEDIES PROVIDED IN THE INITIAL WARRANTY ARE THE SOLE AND EXCLUSIVE REMEDIES AVAILABLE TO THE BUYER. NOTWITHSTANDING ANYTHING TO THE CONTRARY CONTAINED HEREIN, AND EVEN IF THE SOLE AND EXCLUSIVE REMEDIES FAIL OF THEIR ESSENTIAL PURPOSE FOR ANY REASON WHATSOEVER, IN NO EVENT SHALL SELLER BE LIABLE FOR BUYER’S MANUFACTURING COSTS, LOST PROFITS, GOODWILL, OR ANY OTHER SPECIAL, INDIRECT, PUNITIVE,

INCIDENTAL OR CONSEQUENTIAL DAMAGES TO BUYER OR ANY THIRD PARTY AND ALL SUCH DAMAGES ARE HEREBY DISCLAIMED.

6. Assignment. Buyer shall not assign any of its rights or obligations hereunder without the prior written approval of Seller; provided, however, that if Bu yer is a distributor of Seller, the rights and obligations of Buyer under these Warranty Provisions shall inure to the benefit of and be binding upon Buyer’s cust omers who provide the product’s proof of purchase to Seller pursuant to the terms set forth herein. Seller may assign any or all of its rights or obligations hereunder without Buyer’s prior consent.

7. Governing Law. The Warranty Provisions and all questions relating to their validity, interpretation, performance, and enforcement shall be construed in accordance with, and shall be gov erned by, t he subst antive laws of the Commonwealth of Pennsylvania without regard to its principles of conflicts of law.

8. Waiver. Any failure of the part of Seller to insist on strict compliance with the Warranty Provisions shall no way constitute a waiver of such right. No claim or rights arising out of a breach of the Warranty Provisions by Buyer may be discharged in whole or in part by a waiver of the claim or right, unless the waiver is in writing signed by an authorized representative of Seller. Seller’s waiver or acceptanc e of any breach by Buyer of any prov isions of the Warranty Provisions shall not constitute a waiver of or an excuse for nonperformance as to any other provision of the Warranty Provisions nor as to any prior or subsequent breach of the same provision.

9. Freight. Buyer will arrange and pay for shipping and handling charges for the unit to be returned to the Seller.Seller will arrange and pay for shipping and handling for the return of the unit to the Buyer.

Julabo FL2503, FLW2503, FL2506, FLW2506, FL4003 Operating manual

Specifications and Main Features

Frequently Asked Questions

User Manual