Professional Documents
Culture Documents
Operating Manual
for
Water Chiller
Typ BR 058-31
ERL 3000 TA
Notice 3
1 User Information 4
2 List of Danger Notices 5
2.1 Material-related dangers 6
2.2 Process-related dangers and process documentation 6
2.3 Analysis of process dangers 7
3 Designated/Intended usage 8
4 Unpacking and handling 8
5 Transport 9
6 Storage 9
7 Assembly and Installation 10
7.1 Hydraulic connection 10
7.2 Electrical connection 10
7.3 Setting up 10
7.4 General Information 11
8 Application, Function and Description 12
8.1 Description - refrigeration unit 13
8.2 Safety facilities 14
8.3 Monitoring facilities 14-15
9 Putting into operation and operating 15
9.1 Safety checks before putting into operation 15
9.2 Safety checks during operation 15
9.3 Training and performance 16
9.4 Accident analyses 16
9.5 Management of changes in personnel 16
9.6 Preparation for putting into operation 16
9.7 Switching on when putting into operation 16
10 Maintenance 17
10.1 Maintenance for the operator 17
10.2 Notes on the replacement of components 18
11 Warranty provisions 18
12 Taking out of operation 18
13 Breakdown: What is to be done if ...? 19
14 Information about Spare Parts 19
15 Details about Disposal and Recycling 19
16 Rules for the Owner/Operator 19
16.1 Rules referring to the refrigeration unit 19
16.2 Planning for emergencies and assignment 20
16.3 Operational regulations and safety practices 20
Appendices
02-2010 2
Notice
02-2010 3
1 User Information
The contents of these operating instructions are targeted on a number of groups of persons.
At least the relevant chapters are to be read and understood for the particular group of
persons.
Safety Instructions
Safety instructions indicated in the Operating Instructions
documentation are to be strictly adhered to at all times.
Safety instructions are labelled with a danger symbol:
EC-EMC-Directive 2004/108/EC
EN ISO 13857
BGR 500 Accident Prevention Regulation Refrigerating Systems and Heat Pumps
02-2010 4
2 List of Danger Notices
The following list is not guaranteed to be fully complete. It is only an indication of the collectively
most important dangers.
Cooling tank, cooling ⇐ Wait till parts cool down to under 40°C
system with pump, Danger through burns
⇐ Use protective gloves:
refrigeration unit with e.g. during maintenance, cleaning or
cooling medium fault corrections
piping
Complete aggregate
Danger of tripping-over through ⇐ Lay-out all conduit so that no-one can trip-over
cables and leads it and/or thereby damage it or themselves
02-2010 5
2.1 Material-related dangers
The customer´s-own cooling medium should be documented on the side of the customer.
All information about dangers should be handed out and/or at least made easily available to those
persons who are either involved in the system, or the potential dangers thereby through the
individual materials.
The cooling agent circuit is enclosed in a closed system. A systematic cooling agent leakage is not
possible.
The refrigeration unit is constructed so that it protects itself from straying above the designated
max. value and below the min. value, via
- a high-pressure cut-out
- a low-pressure cut-out
- a circuit-breaker (motor safety switch) and fuses
- a fluid level indicator
If the high-pressure cut-out fails, then the circuit will burst at its weakest point. As the cooling circuit
is enclosed in a housing, in the case of a burst, plant and persons in the surrounding area are
sufficiently protected. Cooling agent and cooling oil will however leak out In this case the safety
datasheets for the corresponding medium are to be consulted. And in addition, the deployment
regulations are to be adhered to.
If the low-pressure cut-out fails, there is a possibility of the customer-sided cooling medium
freezing. Generally the plate heat exchanger bursts internally. There is a possibility of cooling
agent and cooling oil penetrating into the customer-side cooling medium, i.e. customer-sided
medium gets into the cooling agent circuit. In this case the safety datasheets for the
corresponding medium are to be consulted. Also consult the chapter “Analysis of process
dangers“. The unit will most likely suffer the fate of a write-off.
In some models, instead of the plate heat exchanger there is a specially coiled heat transfer pipe
deployed as evaporator, which is submersed in the tank. In this case the danger of freezing is
eliminated. The need for a low-pressure cut-out is likewise relinquished.
If the fluid level indicator fails,then the customer-sided cooling medium in the tank can sink so low
that the pump(s) run dry. This can lead to overheating and the pumps catch fire.
02-2010 6
If the fluid tank is overfilled with customer-sided cooling medium, then this overflows. The tank
volume capacity is given in the operating instructions.
As protection against a customer-sided closed slide valve, the units have a continuous bypass,
between forward & return flows that insures that the pumps never work against a closed slide
valve. In some applications, a pressure-controlled bypass is installed, depending on customer
requirements. This only opens above a preset pressure and ensures that the system is never
exposed to to a pressure higher than that preset.
If the refrigeration system is lockable, then the circuit which is lockable is secured with an
additional high pressure switch. This means that cooling agent can never be locked in a non-
secured sub-circuit.
Electrical data for mains connection is likewise to be found in the operating instructions.
Technical classification, as well as electrical circuit diagrams are similarly to be found in the
operating instructions.
Before leaving the factory, the unit is tested thoroughly for safety, performance and function.
Special attention here at operational location: a series of analyses in connection with the listed
material-related and process-related dangers is to be recommended.
Special attention here at operational location: regular analysis in relation to potential for fire &
explosion danegrs, as well as aggressive media in the air and cooling medium is recommended,
e.g. via local gases or fluids, especially the danger of fire through the presence of oil mist in and
around the aggregate.
Special attention here in connection with the user on-site, a follow-up analysis in relation to the
listed material-related and process-related dangers is recommendable, e.g. max. pump pressure
(pump performance characteristics are to be found in the operating manual) in relation to the
permitted pressures of the customer-side plant components, etc.
02-2010 7
3. Designated/Intended Usage
This cooling medium device serves the cooling and transporting of cooling medium.
In certain cases heating has been installed. This is for heating the medium.
All inappropriate uses (normally foreseeable misuse), with incorrect cooling media is not
permitted and can:
02-2010 8
5 Transport
6. Storage
02-2010 9
7. Assembly and Installation
7.3 Setting up
Set up the cooling equipment at its intended place in such a way that the connection ends
are readily accessible.
The equipment must be set up so that it is absolutely horizontal and stable.
Setting up sheet- see Appendix.
Indoor-Setting up
The cooling aggregate is to be erected in a frost-free room on a flat, level floor with
sufficient load-carrying capacity.
Outdoor-Setting up
Installation of the unit outside requires various options: Winter pressure control,
compressor crankcase heating.
Outside mounting location must be protected by a roof with appropriate
distance to the chiller (min. 1m above fan).
02-2010 10
A foundation-based anchorage as well as cross-ply or vibrations damper are not
neccessary.
Cooling aggregate and consumer are generally to be based at the same level.
In the case of units fitted with rollers, then these rollers are to be secured in position to
protect them from rolling out of position. Many units are actually fitted with 2 rollers with
interlocks to stop them from moving once in position. Press the brake lever downwards to
lock in position.
02-2010 11
8. Application, Function and Description
Refrigeration of the user cooling medium generally takes place in an insulated open vessel
via plate heat exchanger or a special heat transfer pipe as evaporator. The heat taken up in
the cooling agent evaporator is released from the air-cooled condenser into the
surroundings or depending on model, into a local water supply über via water heat-
exchanger. Alternatively, the refrigeration unit can also be built as thru-flow cooler without
tank and pump or as a closed system or as immersion cooler.
Regulation of the medium temperature takes place via electronic temperaturre regulator or
through a customer-sided software program.
Through the installation of a time relay, there is a standstill time of 4 minutes when the
refrigeration unit is switched on(to protect the compressor from “chopping”). The
refrigeration unit does no cooling during this time! There is a possibility of a malfunction
message in this time!
Function and setting of the temperature regulator can be taken from the description.
An oil sump heating (with selector switch above a certain size) has the task of evaporating
the cooling agent from the refrigeration machine oil in case of low surroundings
temperatures and during long standstill times of the refrigeration unit. If this does not
happen, then the compressor primes with liquid, which renders the compressor a write-off.
This immediately relinquishes the warranty.
Points to be observed after long periods of standsstill and low storage or surrounding
temperature:
- Machines without selector switch are to be connected to the mains supply 24 hours before
being putting into operation. During this time the oil sump heating runs and evaporates the
cooling agent away. Then after 24 hours have passed, the unit can be put into operation.
- Units with selector switch are to be connected to the mains supply 24 hours before being
putting into operation. As soon as the selector switch is switched on, the oil sump heating
runs and evaporates the cooling agent out. The refrigeration unit can still be prepared
further for putting into operation. It can only start run-up when the selector switch is
switched off again. The selector switch can be switched off after 24 hours.
02-2010 12
In the case of pure water outlets without heat exchanger, for each cooling circuit a
dedicated consumer pump is required in addition to the main water pump. In this case the
secondary consumer pumps must be protected against dry-run. This protection is ensured
through complete opening of the mixer valves for 2 minutes and operating the main water
pump after starting-up the chiller. After 2 minutes the secondary consumer pumps are
switched on. This ensures sufficient water supply for the secondary consumper pump after
chiller start-up.
Option: Heating
The heating has the function of heating-up the medium to a certain temperature. Switching
over from cooling to heating and reverse takes place manually or automatically at the
regulator. The temperature is controlled by the regulator. For further details see Operating
Instructions- “Regulator”.
Option: User height
A solenoid valve in the return flow to the refrigeration unit and a non-return valve in the
refrigeration unit prevent discharges, that cooling medium runs back into the tank, when a
user stands higher than the refrigeration unit and when the pump does not run, i.e. when
the refrigeration unit is switched off.
Option: Winter pressure regulation
A pressure switch in the cooling agent circuit compulsively switches the ventilator off in
case of low surrounding temperatures under 8°C, until the system has enough higher
pressure, so that a circulation of cooling agent in the system is safeguarded.
Any other or excessive/outside the intended limits use thereof is regarded as non-designed
usage.
02-2010 13
A dirt trap or medium filter is installed in the medium circuit which is to be cleaned regularly,
or exchanged depending on the degree of contamination of the medium.
The high pressure switch protects the refrigeration unit against unnecessary high operating
pressure in the cooling agent circuit. In case of malfunction the HP switch switches the
refrigeration unit off for a minimum of 4 minutes.
The mains isolation device serves the manual switching off of the unit in case of
emergency. In some cases the refrigeration unit has to be switched off by the
user/operator.
Thelow pressure switch protects the refrigeration unit against unnecessary low operating
pressure in the cooling agent circuit. In case of malfunction the LP switch switches the
refrigeration unit off for a minimum of 4 minutes.
The winter pressure regulator prevents low pressure malfunctions in case of low
surrounding temperatures in the unit´s run-up phase until normal operating conditions have
been established.
The overheating protection at the compressor ensures that the refrigeration unit is switched
off in cases of increased motor current. The refrigeration unit switches on again after the
compressor has cooled down.
The overheating protection at the ventilator ensures that die refrigeration unit is switched off
in cases of increased motor current. The unit switches on again after cooling down.
02-2010 14
Circuit-breakers interrupt the current supply to the corresponding current consumer in
cases of increased motor current and short-circuits. Circuit-breakers can be waived,
depending on the plant & components and requirements of the standards.
A level indicator monitors the level of the user medium in the tank. In cases of insufficient
medium, the refrigeration unit is switched off until the level of medium has been restored.
In own-refrigeration units there is a current flow monitor to monitor the medium flow. If the
amount of flow falls below a certain value then the refrigeration unit is switched off.
The instrumentation unit monitors certain medium temperatures. Depending on the setting,
the refrigeration unit is switched off in cases of too-high or too-low values. For further
details see the circuit diagram.
A documented function, performance & safety acceptance procedure is carried out during
the course of manufacture.
The refrigeration unit is thoroughly inspected and tested in all its certified operative
elements.
A complete safety inspection is carried out on the unit before leaving the factory for
delivery.
Due to a change in the operational location, a safety, health and environment check on
location at the customer is recommended before putting into operation.
The room chosen for the aggregate has to have sufficient emergency exits. If this is not the
case, then a corresponding amount of room space according to DIN EN 378 has to be
available, so that in case of a cooling agent leakage there is no danger to health caused by
the leakage of cooling agent. This is best solved through consultation with the
manufacturer.
In accordance with EN 378, regular inspections by suitable capable persons are prescribed
in order to maintain the minimum regulations regarding health & safety for the refrigeration
aggregate, the carrying out thereof being in the hands of the owner/operator. These can be
entered into the operating manual available from the manufacturer. The operating manual is
compiled in accordance with legal requirements.
02-2010 15
In order to ensure safe operation of the refrigeration unit and user, personnel are to be
retrained at regular intervals and on the basis of the operating manual. Included here are
the consequences for the user when the unit is switched off. A clearly readable & concise
notice is to be positioned near to the refrigeration unit. This is contained in the operating
manual available from the manufacturer.
Here it is recommended to ensure that there is always a minimum amount of experience &
knowledge in the persons operating the machine. This is especially important in times of
vacations and illness, as well as for deputisatzions and outsourcings.
The cooling medium appliance is a compact unit which only needs to be connected to
electrical and hydraulic supplies, and can be in operation immediately after filling with
cooling medium. Take note of oil sump heating regulations.
The recommended medium level can be taken from the technical data.
Medium connections for the external circuit are to be laid out in accordance with the
available pump pressure and the amount of pressure loss to be expected. Take care to
observe nominal diameters. Take care to observe corrosion behaviour.
Make use of the circuit diagram to observe the prescribed electrical, as well as the signal-
technical connections.
Make sure that the unit cannot fall over.
Always adhere to the safety-related points.
ATTENTION. Once the tanks have been filled, the pumps immediately start running when
switched on. Take note of oil sump heating regulations (10.1).
Pumps must never be allowed to run dry. Danger of fire.
After a brief period of operation, it should be checked whether the medium has to be topped
up. Once the operating temperature has been reached, all of the screw connections should
be checked again to ensure their tightness. The cooling cuts-in itself after 4 minutes. The
heating starts-up immediately upon being selected at the regulator.
10 Maintenance
02-2010 16
Place Symbol Description How can I avoid the danger?
All maintenance work, especially electrical work,
may only be carried out by suitably trained and
Danger through electric current qualified persons
Elektric As with all electrical work, there is the Isolate the refrigeration aggregate from the
danger of electric shocks, short- mains supply before staring maintenance work
circuits etc.
The main switch is to be fitted with a suitable
padlock
All information about dangers has to be made
Danger through materials and easily accessible to the operators and made
Complete aggregate other substances (or the other available nearby
components thereof)
Only suitable trained personnel
Observance of the danger datasheets
Danger through internal/external
Complete aggregate
contact with liquids Customer-sided filling of cooling medium is to be
documented
No technical changes to the refrigeration unit on the side of the customer are to be carried
out without agreement with the manufacturer.
Technical documentation for the machine is kept with the manufacturer for at least 10
years.
All changes to the documented technology are to be agreed upon with the manufacturer.
A change is only a change when it is not concerned with a homologous replacement within
the documented technology.
At regular intervals, the status of the cooling medium is to be checked and the medium is to
be topped up if so required.
It is recommended to check the tightness of all screw-connections in the circulations of
medium and cold water, resp. the oil circulation regularly 2 times a year.
The air intake of the pump is to be checked at regular weekly intervals for contamination i.e.
for free intake of the cooling air and cleaned if so required.
At certain prescribed time intervals, regular legally-binding leakage tests on the cooling
agent circuit have to be carried out by certified personnel. These persons have to present
their qualifications to the satisafction of the owner/operator. Test intervals are directly
dependant on the cooling agent amount and vary between yearly ( above 3kg i.e. 6kg in the
case of Hermetic systems), half-yearly (above 30kg) and quarter-yearly (above 300kg).
Tests are to be documented in one of the special manuals prepared for the unit. A suitable
operating manual is available from the manufacturer.
02-2010 17
Maintenance intervals for the air filter mats are dependant on the on-site condition of the
surroundings. These can be cleaned and are re-usable.
Only original spare parts may be used, or only those expressly recommended by the
manufacturer.
Replacement of components is only permitted through the manufacturer or a specialist
company acting in the name of the manufacturer i.e. specialist persons known and
recommended by the manufacturer.
11 Warranty Provisions
Within the statutory warranty period, functional faults that are attributable to faulty
workmanship and/or material faults shall be rectified free of charge in the domestic market.
Abroad only the cost of material shall be borne.
All further claims, especially for consequential damage, shall be excluded
Damage and malfunctions brought about by improper handling and/or non-observance of
the operating instructions shall not fall under the warranty provisions.
The warranty shall expire if there has been any interference in the system structure or the
serial number on the item of equipment has been changed or has been rendered
unrecognisable.
The cooling equipment has been carefully checked and adjusted in the works. Should you
nevertheless have a complaint at any time, please confidently contact your contractual
partner. Please do not forget to let us have, for any possible queries, the name of the clerk
or technician responsible for the matter in hand.
To maintain your entitlement to any possible claims under the warranty please note the
following:
• Enclose with the letter an exact description of the defect.
• Enclose the evidence of purchase in the form of a copy of a delivery note or of an
invoice. Note on it the type and serial number of the item of equipment.
02-2010 18
In case of emergency the Emergency telephone number 0049 (0) 170 582 64 84 is
available at all times.
It is recommended to include the equipment into the emergency measures & control plan in
order to minimize potential consequences.
02-2010 19
16.3 Operational regulations and safety practices
Here there is a recommendation to include the operational regulations into the local
regulations.
02-2010 20
APPENDICES
1 Technical datasheet
2 Dimensional drawing(Setup)
3 System scheme
4 Pump performance characteristics
5 Electric circuit diagram
6 Troubleshooting table
7 Functional description regulator
8 Chemical requirements for circuit water
9 Conformity
10 Spare Parts recommended
Anlage 1: Technisches Datenblatt
Typ BR 058-31
Artikel-Nr. 1000000305831
Nenn-Kälteleistung kW 6,6
Wasser-Temperatur von °C 18
Nenn-Volumenstrom Mediumkreis dm³/min 1)
Luftvolumenstrom am Verflüssiger m³/h 3240
Umgebungstemp. bei Nennbetrieb °C 32
Umgebungstemperatur min/max °C/°C 10 / 42
Regel-Thermostat, EIN/AUS °C/°C 18,05/17,95
Elektrische Kenndaten
Nennspannung V 400/3/PE
Nennfrequenz Hz 50
Nenn-Leistungsaufnahme kW 4,60
Nenn-Stromaufnahme A 8,75
Schutzart IP54
A A
Medium Austritt 1" Medium Eintritt 1"
medium outlet 1" medium inlet 1"
Lamellenverflüssiger
plate fin condenser
extern
Kugelhahn Kugelhahn
ball valve ball valve
B B
Hochdruckschalter
Filtertrockner high pressure switch
filter drier 18 bar Diff.5
Filtermatte
air filter PSH PC
Flüssigkeitssammler
liquid receiver
PWT Verdampfer
PWT evaporator
E E
Wassertank isoliert
watertank isolated
Tankentleerung
tank drain
F Datum 27.07.09 - F
Version 1.0 Bearb. Gemmer Anlage/annex +
Geprüft: Gemmer Blatt :
Änderung Datum Name Norm DIN EN 1861 Urspr. Ersatz für : Erstell - Datum: 27.07.09
BR 058-31 Folge :
1 2 3 4 5 6 7 8
Anlage 4 / annex 4
50
45
40
35
Förderhöhe / lift of pump [m]
30
25
20
15
10
0 8 16 24 32 40 48 56
Förderstrom / delivery volume [dm³/min]
neutral_LTN_DT_F26_003
Kunde Bruker
Anlagenbezeichnung 1 BR 058-31
Anlagenbezeichnung 2 Anlage/Annex 5
Anlagenbezeichnung 3
Anlagenbezeichnung 4
Kommission
Elektrische Daten:
Netzanschluß 400 V AC
Frequenz 50 Hz
Stromaufnahme 8,75 A
Leistungsaufnahme 4,60 kW
Steuerspannung 230 V/24 V AC
2
Datum 2009-07-13 Titel- / Deckblatt =
Version Bearb. L.Gemmer +
Gepr BR 058-31 Blatt 1
Änderung Datum Name Urspr Ersatz von Ersetzt durch Blatt 11
0 1 2 3 4 5 6 7 8 9
Inhaltsverzeichnis Spalte X: eine automatisch erzeugte Seite wurde manuell nachbearbeitet Inhalt_LTN_DT_F06_001
1 3
Datum 2009-07-13 Inhaltsverzeichnis : 1 - 16 =
Version Bearb. L.Gemmer +
Gepr BR 058-31 Blatt 2
Änderung Datum Name Urspr Ersatz von Ersetzt durch Blatt 11
0 1 2 3 4 5 6 7 8 9
BK BK
1,5 1,5 230 V
LT2 / 4.0
BK BK
1,5 1,5
BK
1,5
BK BK rt
1,5 1,5 1,0
BK BK BK BK BK BK
1,5 1,5 1,5 1,5 1,5 1,5
1 3 5 13
-F4
0,3 A 14
1 3 5 1 3 5 I> I> I>
4.6
-Q1 -Q2 2 4 6
BK
1,5
BK
1,5
BK
1,5
4.6 2 4 6 4.7 2 4 6 LT02 / 4.0
sw sw PE
1,5 1,5 X01
PE
rt rt
1,0 1,0
rt/ws
1,0 24V
LT1 / 5.2
-W6 BK BK BK BK BK BK BK BK BK
7x1,5 4 5 6 1,5 1,5 1,5 1,5 1,5 1,5 1,5 1,5 1,5
-PE
1 3 5 13 1 3 5 13 1 3 5 13
-X01
PE
1 3 5 -F1 -F2 -F3
-Q01 5,5-8,0 A 14 0,7-1 A 14 1,8-2,5 A 14
5,76 A 0,74 A 1,9 A
I> I> I> I> I> I> I> I> I>
4.6
4.6
4.6
2 4 6
2 4 6 2 4 6 2 4 6
A1/D-Control A1
BK BK BK 0
1,5 1,5 1,5
TK -PE
L1 L2 L3
GND
PE
BK BK BK 24V BK BK BK
1,5 1,5 1,5 U V W 1,5 1,5 1,5 230V 0 24 V 0
E TK
x1
-B2 T1
x2
-400V -0
L1 L2 L3 N PE
2 4
Datum 2009-07-13 Hauptstromkreis =
Version 1.0 Bearb. L.Gemmer +
Gepr BR 058-31 Blatt 3
Änderung Datum Name Urspr Ersatz von Ersetzt durch Blatt 11
0 1 2 3 4 5 6 7 8 9
rt rt rt
230V 50Hz 1,0 1,0 1,0
3.9 / LT2
13 15
-Q2 1 K4
4.7 14
+0,05K
4.1 18 -X2 13
rt 4min
1,0 20 °C -W12
-W11 2x0,75
-W7 7x1 1 -0,05K 13 bn rt
2x0,75 0 1,0
K1.1
L1/2 -F1 -F10
-X2 1 3.2 14 Niveauwächter wh
L1/1 L1/3 -W11
1
3 7x1
-W11 13
-W12
P
F11 Hochdruckschalter 7x1 2 2x0,75
2 18-12 bar -F2
-W7
3.4 14 -X2 14
2x0,75 -W11
-X2 2 rt
1,0 7x1 4
rt rt
1,0 1,0
13
25,0°C
-F3 L3/4
3.6 14 K1.3
-X2 3 L3/5
-W8 -K5 1 -K6 1
4x1 1 -W11
A3 A3 7x1 5
1
P Niederdruckschalter
13
1,6-3,4 bar A4 A4
F12
4 2 -F4
-X2 6 3.8 14
-W8
4x1 3 2
rt
1,0
3x1 1 3x1 1
R R
Magnetventil Bybass Magnetventil Flüssigkeitsleitung
x2 x1
M4 R
-R1 M5 -R2 R R
A1 -X2 9 x1
C
x2
C
A1
K4 -W9 -X2 12
-W10
A1 A1 K7 -R4
4 min A2
3x1 2 3x1 2
-Q1 -R3 Q2 -R5 Temperaturalarm A2
C
rot Kühlung A2 Pumpen A2
1,0 C C
-X2 8 -X2 11
rot rt
1,0 1,0
3.9 / LT02 0V
15 18 4.6 1 2 3.2 14
3 4 3.2 11 5.7
12
5 6 3.2
1 2 3.6
3 4 3.6
5 6 3.6
13 14 4.1
3 5
Datum 2009-07-13 Steuerstromkreis =
Version 1.0 Bearb. L.Gemmer +
Gepr BR 058-31 Blatt 4
Änderung Datum Name Urspr Ersatz von Ersetzt durch Blatt 11
0 1 2 3 4 5 6 7 8 9
24 V
3.9 / LT1
rt/ws
1,0
1
F5
2A 2
W13
5.3
3x1,0qmm
Spannungsversorgung 1
11
-K7
4.9 14 12
-K1
-A1:L3/1
00,0°C OG OG OG
-A2:L3/2 -111:L2/3 -112:L2/4 -113:L2/2 1,5 1,5 1,5
W13 X3 1 2 3
5.3
3x1,0qmm -W2
x1
Spannungsversorgung 2 Θ 10 m
B1 4x1 1 2 3
x2
Temperaturalarm
rt/ws
1,0
3.9 / LT01 0V
4 10
Datum 2009-07-13 Steuerstromkreis =
Version 1.0 Bearb. L.Gemmer +
Gepr BR 058-31 Blatt 5
Änderung Datum Name Urspr Ersatz von Ersetzt durch Blatt 11
0 1 2 3 4 5 6 7 8 9
Klemmenplan Klemme_LTN_DT_F13_003
Leiste
Externe Ziele
X1 Interne Ziele
M2 1mm² 8 Ventilator PE
N =
PE = 1mm² PE 3.1
5 11
Datum 2009-07-13 Klemmenplan : X1 =
Version Bearb. L.Gemmer +
Gepr BR 058-31 Blatt 10
Änderung Datum Name Urspr Ersatz von Ersetzt durch Blatt 11
0 1 2 3 4 5 6 7 8 9
Klemmenplan Klemme_LTN_DT_F13_003
Leiste
Externe Ziele
X2 Interne Ziele
2 1mm² 5 =
1mm² 9 PE
X2 1mm² 12 PE
PE =
PE
10 12
Datum 2009-07-13 Klemmenplan : X2 =
Version Bearb. L.Gemmer +
Gepr BR 058-31 Blatt 11
Änderung Datum Name Urspr Ersatz von Ersetzt durch Blatt 11
0 1 2 3 4 5 6 7 8 9
Klemmenplan Klemme_LTN_DT_F13_003
Leiste
Externe Ziele
X3 Interne Ziele
11 15
Datum 2009-07-13 Klemmenplan : X3 =
Version Bearb. L.Gemmer +
Gepr BR 058-31 Blatt 12
Änderung Datum Name Urspr Ersatz von Ersetzt durch Blatt 11
Apprendix 6: Troubleshooting Table
Low pressure switches off a) Not enough cooling agent a) Inform refrigeration specialist
b) Cold dispersion: occasionally a blue b) Inform refrigeration specialist
greasy liquid can be seen
c) Expansion valve defective
c) Inform refrigeration specialist
d) Bubble formation in the inspection
d) Inform refrigeration specialist
glass
e) - Check tank on cleanliness
e) Medium flow impeded by - Check system on cleanliness
- pipework - Check slide valve
- control valves
- contamination
- contaminated plate exchanger f) Check medium level, refill if so
reqd.
- Closed slide valves
g) Check pump
f) Shortage of medium
g) Pump defective
h) Increase ambient temperature
Type 703041/42/43/44
Compact Controller
with program function Type 703041/ ...
Brief description
The series of controllers includes four freely programmable devices in different DIN formats for
controlling temperature, pressure and other process variables. As a temperature controller (TR)
according to EN 14597 the devices are used in heat-generating plants to control the
temperature of liquids or gases (mode of action: 1B).
The high-contrast, multicolor LC display for process value, setpoint and operator prompting
contains two four-digit 7-segment displays, two single-character 16-segment displays, display
of the active setpoints, six switch position indicators, and displays for the dimensional unit,
ramp function and manual operation.
Type 703042/ ...
Simple operation through 4 keys. The instruments can be used as 2-state, 3-state, modulating
or continuous controllers. The controller software includes a program or ramp function,
parameter set changeover, two autotuning (self-optimization) procedures, a math and logic
module, as well as 4 limit comparators.
Linearizations for the usual transducers are stored, and a customer-specific linearization table
can be programmed.
A setup program is available for user-friendly configuration from a PC.
A serial interface for RS422/485 or Profibus-DP can be used to integrate the instruments into a
data network. Type 703043/ ...
The electrical connection is made at the back, via screw terminals.
The possible input and output configurations are shown in the following block diagram. The
option boards are universally applicable for all instruments in the series.
Block structure
Analog input 2 relays (changeover)
(make contact at type 703041)
Supply voltage
17V / 20mA
for 2-wire transmitter
only at type 703042/43/44 Key features
Option 1
+ Max. two programmable analog inputs
+ Four programmable setpoints,
Option 2 two parameter sets
+ Program function with 8 segments,
or ramp function
Option 3
only for type 703042/43/44
+ Math and logic module
+ 4 limit comparators
Option boards: + Two timer functions
– Analog input – 1 solid-state relay + Two self-optimization procedures
– 2 logic inputs – Analog output (voltage/current) + Fast, user-friendly configuration through
– 1 relay 230V/8A (changeover) – RS422/485 interface the setup program with program editor
– 2 relays 230V/3A (make contact)
with common pole
– PROFIBUS-DP interface
+ RS422/485 interface
+ PROFIBUS-DP interface
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Data Sheet 70.3041 Page 2/10
2009-09-30
Data Sheet 70.3041 Page 3/10
PROFIBUS-DP
The Profibus-DP interface can be used to
integrate the controller into a fieldbus system
operating according to the Profibus-DP
standard. This Profibus version is especially
designed for communication between
automation systems and decentralized
peripheral devices at the field level, and
A setpoint profile can be implemented with a maximum of 8 program segments. The settings optimized for speed.
for the segment setpoints (SPP1 — SPP8) and segment times (tP1 — tP8) are carried out at the Data transmission is made serially, using the
user level. The time scale can be configured as mm:ss or hh:mm (s = seconds, h = hours). RS485 standard.
A program-end signal can be generated, and the program can be halted or canceled. GSD generator, the project-planning tool that
Further functions can be defined through the setup program (start at process value, cyclical is supplied with the package (GSD =
program handling, segment-by-segment assignment of parameter sets and four control Gerätestammdaten, i.e. device data), is used
contacts). The program profile can also be visualized. to make a selection of device characteristics
for the controller to create a standardized
Warm-up ramp for hot-channel controller GSD file that is used to integrate the controller
The warm-up ramp for hot-channel equipment is used, for example, for the gentle operation of into the fieldbus system.
ceramic heater elements. Damage can be avoided by allowing moisture to evaporate slowly
from the hygroscopic heater elements during the warm-up phase.
Parameter level
All the parameters and their meanings are included in the table. Some parameters may be missing or meaningless for a particular type
of controller. Two parameter sets can be stored, to handle special applications.
Parameter Value range Factory Meaning
setting
Proportional band 0 to 9999 digits 0 digits Size of the proportional band
0 means that the controller structure is out of action!
Derivative time 0 to 9999 sec 80 sec Influences the differential component
of the controller output signal
Reset time 0 to 9999 sec 350 sec Influences the integral component of the controller output
signal
Cycle time 0 to 999.9 sec 20.0 sec When using a switched output, the cycle time should
be chosen so that the energy flow to the process is as
continuous as is practicable without overloading the switching
elements.
Contact spacing 0 to 999.9 digits 0.0 digits The spacing between the two control contacts for 3-state or
modulating controllers
Switching differential 0 to 999.9 digits 1.0 digits Hysteresis for switching controllers
with proportional band = 0
Actuator time 5 to 3000 sec 60 sec Actuator time range used by the control valve for modulating
controllers
Working point -100 to +100% 0% The output level for P and PD controllers (if x = w then y = Y0)
Output level limiting 0 to 100% 100% The maximum limit for the output level
-100 to +100 % -100% The minimum limit for the output level
2009-09-30
Data Sheet 70.3041 Page 4/10
Technical data
Thermocouple input
Designation Measuring range Measuring accuracy Ambient
temperature error
Fe-Con L -200 to + 900°C ≤0.25% 100 ppm /°C
Fe-Con J EN 60584 -200 to +1200°C ≤0.25% 100 ppm /°C
Fe-Con U -200 to + 600°C ≤0.25% 100 ppm /°C
Cu-Con T EN 60584 -200 to + 400°C ≤0.25% 100 ppm /°C
NiCr-Ni K EN 60584 -200 to +1372°C ≤0.25% 100 ppm /°C
NiCr-Con E EN 60584 -200 to +1000°C ≤0.25% 100 ppm /°C
NiCrSi-NiSi N EN 60584 -100 to +1300°C ≤0.25% 100 ppm /°C
Pt10Rh-Pt S EN 60584 0 to 1768°C ≤0.25% 100 ppm /°C
Pt13Rh-Pt R EN 60584 0 to 1768°C ≤0.25% 100 ppm /°C
Pt30Rh-Pt6Rh B EN 60584 0 to 1820°C ≤0.25% in the range 300 to 1820°C 100 ppm /°C
W5Re-W26Re C 0 to 2320 °C ≤0.25% 100 ppm /°C
W3Re-W25Re D 0 to 2495 °C ≤0.25% 100 ppm /°C
W3Re-W26Re 0 to 2400 °C ≤0.25% 100 ppm /°C
Cold junction Pt100, internal
Logic inputs
Floating contacts
2009-09-30
Data Sheet 70.3041 Page 5/10
Outputs
Relay (changeover)
for type 703042/43/44
contact rating 5A at 230VAC resistive load 1
contact life 350,000 operations at rated load / 750,000 operations at 1A
Relay (changeover) (option)
contact rating 8A at 230V AC resistive load 1
contact life 100,000 operations at rated load / 350,000 operations at 3A
Relay (make)
for type 703041
contact rating 3A at 230VAC resistive load
contact life 150,000 operations at rated load / 350,000 at 1A
Relay (changeover) (option)
contact rating 3A at 230VAC resistive load
contact life 350,000 operations at rated load / 900,000 operations at 1A
Logic output 0/12V / 30mA max. (sum of all output currents) or
0/18V / 25mA max. (sum of all output currents)
Solid-state relay (option) The holding current of the triac is at least 50mA.
contact rating 1A at 230V
protection circuitry varistor
Voltage (option)
output signals 0 — 10V / 2 — 10V
load resistance Rload ≥ 500Ω
accuracy ≤ 0.5%
Current (option)
output signals 0 — 20mA / 4 — 20mA
load resistance Rload ≤500Ω
accuracy ≤ 0.5%
Supply voltage for electrically isolated, not stabilized
2-wire transmitter
for type 703042/43/44
voltage 17V DC at 20mA load, 25V DC with no load
1. 3A with devices certified to DIN EN 14597
Controller
Controller type 2-state controller (factory setting),
3-state controller, modulating controller, continuous controller
Controller structures P, PD, PI, PID
A/D converter dynamic resolution up to 16-bit
Sampling time 50msec, 90msec, 150msec, 250msec (factory setting: 250msec)
Electrical data
Supply voltage (switchmode PSU) 110—240V AC -15/+10%, 48 — 63Hz
20—30V AC/DC, 48—63Hz
Electrical safety Type 703041: to EN 61010, Part 1
Type 703042/43/44: to EN 60730
overvoltage category III, pollution degree 2
Power consumption Type 703041: max. 8VA; type 703042/43/44: max. 13VA
Data backup EEPROM
Electrical connection at the back, via screw terminals,
conductor cross-section up to 2.5mm2
with core ferrules (length: 10mm)
Electromagnetic compatibility EN 61326-1
Interference emission Class B
Interference immunity to industrial requirements
Housing
Housing type plastic housing for panel mounting to IEC 61554
Depth behind panel 90 mm
Ambient/storage temperature range 0 to 55°C / -30 to +70°C
Climatic conditions rel. humidity ≤90% annual mean, no condensation
Operating position horizontal
Protection to EN 60529, front IP65 / back IP20
Weight (fully fitted) Type 703041: approx. 220g
Type 703042/43: approx. 380g
Type 703044: approx. 490g
2009-09-30
Data Sheet 70.3041 Page 6/10
Interface
Modbus
Interface type RS422/485
Protocol Modbus, Modbus Integer
Baud rate 9600, 19200, 38400
Device address 0 — 255
Max. number of nodes 32
PROFIBUS
Device address 0 — 255
Approvals/marks of conformity
Mark of Testing laboratory Certificates/certification Test basis valid for
conformity numbers
DIN DIN CERTCO Register No. TR118707 DIN EN 14597 all types
GL - Hardware Germanischer Lloyd Type Approval Certificate GL-Approval 703044/191-320-23/214, 062
GL - Software No. 45 059-07 HH Category C, EMC1
c UL us Underwriters Laboratories E 201387 UL 61010-1 all types
CAN/CSA-C22.2 No. 61010-1
2009-09-30
Data Sheet 70.3041 Page 7/10
1 2 3 Terminal strip 3
L1
Supply
L1(L+) L1 L+
1 1 L+
110 — 240V AC 20 — 30V AC/DC
N(L-) N
2 N L-
2 L-
3 3 3 3
4 4 4 4 P
230V/3A (logic output 1)
5 5 5 S
Outputs
6 6 6 6
7 7 7 7 P
230V/3A (logic output 2)
8 8 8 8 S
Terminal strip 2
Resistance Resistance Resistance Resistance Thermo- Current Voltage Voltage Terminal assignment of strip 1
thermometer thermometer thermometer transmitter couple 0(2)—10V 0 —1V for analog input 2
1 + 1 5
? E Ux
Option 1
Option 2
input 1
2 + - + 2 6
? ? S Ux
3 -
Ix - / Ix~
+ - 3 7
A
4 - 4 8
6 bin1 Logic input 1 Out3 (+) Logic output 3 Logic output level 12V or 18V
Logic
Terminal strip 1
Analog 2 logic Analog Relay 2 relays Solid-state PROFIBUS RS422 RS485
input inputs output (changeover) (make) relay
1 3 Ö 5 VP (+5 V) RxD +
Option 1
2 Analog input 2
connection as for
4
U x / Ix
+ P RxD/TxD-P (B) RxD -
analog input 1
3 GND - S 8 RxD/TxD-N (A) TxD + RxD/TxD +
4 Logic input 3+4 Analog output 5 Logic output 5 Logic output 5+8 Logic output 5 DGND TxD - RxD/TxD -
5 5 VP (+5 V) RxD +
Option 2
6 Analog input 2
connection as for
6
U x / Ix
+ (not possible) (not possible) RxD/TxD-P (B) RxD -
analog input 1
7 GND - RxD/TxD-N (A) TxD + RxD/TxD +
8 Logic input 5+6 Analog output 6 Logic output 6 DGND TxD - RxD/TxD -
2009-09-30
Data Sheet 70.3041 Page 8/10
1 2 3 Terminal strip 3
Supply
L1 L1
L1(L+) L+
L+
1 1 N
N
110 — 240V AC 20 — 30V AC/DC
N(L+) L- L-
2 2
3 3
4 4
4 4
5 5
6 6
5 6 +
8 8 Supply voltage for 2-wire transmitter
U=
6 7 U= 17V/20mA
(off-load voltage approx. 25V)
7 8 9 9 -
8 9
10
11 11 Ö
9
10 15 15 Ö
Terminal strip 2
RTD RTD RTD Resistance Thermo- Current Voltage Voltage Terminal assignment of strip 1
transmitter couple 0(2)—10V 0—1V for analog input 2
1 + 1 5 9
? E Ux
Option 3
Option 1
Option 2
Input 1
2 + - + 2 6 10
? ? S Ux
3 -
Ix - / Ix~
+ - 3 7 11
A
4 - 4 8 12
Terminal strip 1
Analog 2 logic Analog Relay 2 relays Solid-state PROFIBUS RS422 RS485
input inputs output (changeover) (make) relay
1 3 Ö 5 VP (+5 V) RxD +
Option 1
2 Analog input 2
connection as for
4
Ux
+ P RxD/TxD-P (B) RxD -
analog input 1
3 GND - S 8 RxD/TxD-N (A) TxD + RxD/TxD +
4 Logic input 3+4 Analog output 5 Logic output 5 Logic output 5+8 Logic output 5 DGND TxD - RxD/TxD -
5 5 Ö 6 VP (+5 V) RxD +
Option 2
6 Analog input 2
connection as for
6
Ux
+ P RxD/TxD-P (B) RxD -
analog input 1
7 GND - S 9 RxD/TxD-N (A) TxD + RxD/TxD +
8 Logic input 5+6 Analog output 6 Logic output 6 Logic output 6+9 Logic output 6 DGND TxD - RxD/TxD -
9 7 Ö 7 VP (+5 V) RxD +
Option 3
10 Analog input 2
connection as for
8
Ux
+ P RxD/TxD-P (B) RxD -
analog input 1
11 GND - S 10 RxD/TxD-N (A) TxD + RxD/TxD +
12 Logic input 7+8 Analog output 7 Logic output 7 Logic output 7+0 Logic output 7 DGND TxD - RxD/TxD -
2009-09-30
Data Sheet 70.3041 Page 9/10
Dimensions
Type 703041 Type 703042/43
Type 703044
Close mounting
Minimum spacing of panel cut-outs
Type horizontal vertical
without setup connector:
703041 11mm 30mm
703042 (portrait format) 11mm 30mm
703043 (landscape fmt.) 30mm 11mm
703044 11mm 30mm
with setup connector (see arrow):
703041 11mm 65mm
703042 (portrait format) 11mm 65mm
703043 (landscape fmt.) 65mm 11mm
703044 11mm 65mm
2009-09-30
Data Sheet 70.3041 Page 10/10
Order details
Basic type
703041 Type 703041, format 48mm x 48mm
incl. 1 analog input, 2 relays and 2 logic inputs or 2 logic outputs
703042 Type 703042, format 48mm x 96mm (portrait format)
incl. 1 analog and 2 logic inputs, 2 relays and 2 logic outputs
703043 Type 703043, format 96mm x 48mm (landscape format)
incl. 1 analog and 2 logic inputs, 2 relays and 2 logic outputs
703044 Type 703044, format 96mm x 96mm
incl. 1 analog and 2 logic inputs, 2 relays and 2 logic outputs
Supply voltage
2 3 110 — 240V AC -15/+10%, 48 — 63Hz
2 5 AC/DC 20…30V, 48…63Hz
Extra codes
0 0 0 none
2 1 4 Math and logic module
2 1 7 Ratio controller (requirement: 2 analog inputs)
2 1 8 Differential controller (requirement: 2 analog inputs)
2 1 9 Humidity controller (requirement: 2 analog inputs)
Approvals
0 0 0 none
0 5 6 DIN EN 14597
Type 703044 with GL approval on request
/ 1 – – / ,
703041 / 1 8 1 – 1 4 0 – 2 3 / 0 0 0 ,
A CD with demo setup software and PDF documents (operating manual and other documentation) can be ordered separately.
2009-09-30
Annex 9 Aspect: colourless, clear, free from oil and grease
EC - Declaration of conformity
DIN EN 12100-1 Safety of Machinery – Basic Concepts, General Principles for Design
– Part 1 Basic Terminology, Methodology
DIN EN 12100-2 Safety of Machinery – Basic Concepts, General Principles for Design
– Part 2 Technical Principles
The manufacturer is certified according to DIN ISO 9001:2008 by ZDH-Zert, Reg.-No.: Q1 0105127
Dieter Keuser
Managing Director
Anlage 10: Ersatzteilempfehlung