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OPERATION MANUAL CC® This operation manual is a translation of the original operation manual. VALID FOR: K1x, K2x CC®-K6(s), CC®-Kxx Variostat® Ministat® 125(w), 2xx(w) CC®-4xx(w/wl) CC®-5xx(w/wl) CC®-8xx(w) CC®-90x(w) V1.3.0en/06.07.15//14.06 Liability for errors and misprints excluded. CC®...
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OPERATION MANUAL „Pilot ONE“ Layout of the “Home” screen K6 - Connections CC® Liability for errors and misprints excluded. V1.3.0en/06.07.15//14.06...
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OPERATION MANUAL K1x and K2x - connections V1.3.0en/06.07.15//14.06 Liability for errors and misprints excluded. CC®...
OPERATION MANUAL Table of contents V1.3.0en/06.07.15//14.06 Introduction Details on the declaration of conformity ............14 Safety ......................14 1.2.1 Symbols used for Safety Instructions .............. 14 1.2.2 Proper operation ..................... 15 1.2.3 Reasonably foreseeable misuse ..............15 Responsible bodies and operators – Obligations and requirements....16 1.3.1 Obligations of the responsible body ...............
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3.2.2 Information about Huber thermal fluids ............36 To be noted when planning the test ............. 36 “Pilot ONE®” controller ................37 3.4.1 Functional overview of “Pilot ONE®” .............. 37 Clock/event function ..................39 3.5.1 Rechargeable accumulator ................39 3.5.2 Programmable event function ................
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Cooling/heating baths: K1x and K2x start thermoregulation ..... 69 5.2.1.2 Cooling/heating baths: K1x and K2x stop thermoregulation ..... 69 Interfaces and software update Interfaces at the “Pilot ONE®” controller ............70 6.1.1 10/100 Mbps Ethernet for RJ45 network sockets .......... 70 6.1.2 USB-2.0 interface ....................
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Connection jack for Pt100 process control sensor ......... 72 Firmware update ..................72 Service/maintenance Messages from the temperature control unit ..........73 Electrical fuse ....................73 Replacing the “Pilot ONE®” ................73 Maintenance ....................74 7.4.1 Function check and visual inspection ............. 74 7.4.2 Clean liquefier fins (air-cooled temperature control unit) ......
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OPERATION MANUAL CC® Liability for errors and misprints excluded. V1.3.0en/06.07.15//14.06...
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Foreword Dear customer, You have opted for a temperature control unit from Peter Huber Kältemaschinenbau GmbH. You have made a good choice. Thank you for your confidence in our products. Read through this operation manual carefully prior to start-up. Strictly follow all notes and safety in- structions.
Introduction OPERATION MANUAL Chapter 1 Introduction Details on the declaration of conformity The equipment complies with the basic health and safety requirements of the European Directives listed below: ▪ Machinery Directive 2006/42/EC ▪ Low Voltage Directive 2006/95/EC ▪ EMC Directive 2004/108/EC Safety 1.2.1 Symbols used for Safety Instructions...
Flow-through coolers and calibration baths must be used only in combination with Huber temperature control units. Thermal fluids suitable for the overall system are used. The chilling and heating capacity is provisioned at the pump connections or - where pre- sent - in the tempering bath.
Also observe on page 15 the section »Proper operation«. Huber temperature control units are constructed to be permanently sealed and are carefully checked for leak tightness. Temperature control units with more than 150 g natural refrigerant are equipped with an additional gas warning sensor.
▪ Until 31.12.2016: Annual leak tests of stationary refrigeration systems by certified personnel (such as service engineers of Peter Huber Kältemaschinenbau GmbH). Valid for a filling capacity of 6 kg to 30 kg of fluorinated greenhouse gases.
▪ As of 01.01.2017: Regular leak tests of stationary refrigeration systems by certified personnel (such as service engineers of Peter Huber Kältemaschinenbau GmbH). The required test interval is based on the refrigerant filling capacity and the type of refrigerant, converted to CO equivalent.
It is replaced by a software engineering tool. The threshold value for the overtempera- ture protection can be set only if a code, randomly generated by “Pilot ONE”, is entered correctly. As with the mechanical tool, accidental settings are thus prevented.
Introduction OPERATION MANUAL Chapter 1 ON / Temperature control active After turning on the temperature control unit, thermoregulation is always started. An INFO appears for a few seconds. This makes it possible to suppress the automatic start. Power Failure Auto If temperature control is active during a power outage, the process will automatically continue after the power outage.
Introduction Chapter 1 OPERATION MANUAL 1.5.2 Water cooling Example: Water cool- Water connection 1.5.3 Consequence of inadequate energy dissipation Room air/cooling water Consequences of, for instance, contamination of the liquefier fins, inadequate clearance between temperature control unit to wall/bath wall, room air/cooling water too warm, cooling water differ- ential pressure too low, suction strainer contamination: The refrigerant in the coolant circuit can no longer fully discharge the admitted energy to the room air/cooling water.
Commissioning OPERATION MANUAL Chapter 2 Commissioning In-plant transport Temperature control unit transported in a horizontal position DAMAGE TO THE COMPRESSOR Only transport the temperature control unit in an upright position. ▪ If fitted, use the lugs located on the top of the temperature control unit for transportation. Do not transport the temperature control unit alone and without aids.
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Commissioning Chapter 2 OPERATION MANUAL ▪ Transient surges, as would normally occur in the power supply system ▪ Applicable degree of soiling: 2. ▪ Surge category II. Observe page 20 of section »Exemplary illustrations of the cooling variants«. Wall clearance to Clearance to the temperature control unit in cm temperature control Air cooling...
The responsible body is responsible for the insulation of connection valves. ▪ We exclusively recommend reinforced hoses for connecting to the cooling water supply. Cooling water and insulated temperature control hoses can be found in the Huber catalogue under Acces- sories.
See the data sheet from page 83 in section »Annex« for information on the ma- terials used. Take suitable measures to maintain the warranty conditions. For information about water quality, see www.huber-online.com. Usage of un-filtered river or sea water as cooling water DAMAGE TO THE TEMPERATURE CONTROL UNIT ...
OPERATION MANUAL Chapter 2 To minimize cooling water consumption, Huber temperature control units with water cooling are equipped with a cooling water regulator. This limits the flow of cooling water to the amount re- quired by the current load situation. If only low cooling capacity is called off, only a small amount of cooling water is consumed.
Commissioning Chapter 2 OPERATION MANUAL Note the volume displacement caused by a sample (e.g. Erlenmeyer flask). Place your sample into the empty bath. Only then fill in a sufficient amount of temperature control medium. Also note that the level of the temperature control medium drops when you remove the sample. This may cause a safety shutdown (low level protection) during an enabled thermoregulation.
Install burst disks on the glass apparatus itself (at the feed and discharge lines). Install a bypass upstream of the valves/quick-release couplings for the glass apparatus. Matching accessories (e.g. bypasses to reduce pressure) can be found in the Huber catalog. CC®...
Commissioning Chapter 2 OPERATION MANUAL Example: Connecting an externally closed application To enable your application to be operated correctly and eliminate air bubbles from the system, you must ensure that the >Circulation flow< [1] connection from the temperature control unit is at- tached to the lower connection point of the application and the >Circulation return<...
Commissioning OPERATION MANUAL Chapter 2 2.11.2 Connection via direct wiring Connection/adjustment to the power supply not carried out by an electrician MORTAL DANGER FROM ELECTRIC SHOCK Have the connection/adjustment to the power supply carried out by an electrician. Damaged power cable/power cable connection MORTAL DANGER FROM ELECTRIC SHOCK ...
Commissioning Chapter 2 OPERATION MANUAL Installing the power cable connection (K6) - one power supply from the building (only valid for 230 V version) PROCEDURE Connection of the cooling bath and the hanger thermostat with ONE power supply (only valid for 230 V version) ...
Commissioning OPERATION MANUAL Chapter 2 2.11.4.2 Utilization as a cooling/heating baths (with hanger thermostat) There are two possibilities for the connection with the building’s power supply. 1. Connection with two separate power supplies (valid for 100 V, 115 V and 230 V versions) The cold bath and the hanger thermostat are each separately connected to the building’s power supply.
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Commissioning Chapter 2 OPERATION MANUAL Installing the power cable connection (K1x + K2x), cooling/heating bath (only valid for 230 V version) PROCEDURE Connection of the cooling bath and the hanger thermostat with ONE power supply (only valid for 230 V version) ...
(RS232 and RS485), an analogue current loop interface (0/4 - 20 mA or 0 - 10 V) and various digital control options (In/Out). The removable operating panel (“Pilot ONE”) can also be used as a remote control. If you require a cable extension, please contact your dealer or the Sales Department at Peter Huber Kältemaschi- nenbau GmbH.
Function description Chapter 3 OPERATION MANUAL Information on the thermal fluids Non-compliance with the safety data sheet for the thermal fluid to be used INJURIES Risk of injury to the eyes, skin, respiratory tract. The safety data sheet for the thermal fluid to be used must be read prior to use and its con- tents respected.
3.2.2 Information about Huber thermal fluids For thermal fluids we recommend the media listed in the Huber catalog. The name of a thermal fluid is derived from its working temperature range and its viscosity at 25 °C. Thermal fluid product...
“Pilot ONE®” controller Figure »“Pilot ONE”« is shown on page 6. The basic version of the “Pilot ONE” (Basic) can be upgraded in two stages (from Basic to Exklusiv and from Exklusiv to Professional or from Exklusiv to Professional with DV-E-grade).
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Function description OPERATION MANUAL Chapter 3 Overview of E-grade E-grade Function E-grade Basic E-grade functions Exclusive Professional TAC (True TAC (True Controller parameterization predefined Adaptive Adaptive Control) Control) Sensor calibration for control sensor (internal Pt100, 2-point 5-point 5-point external Pt100 and return flow sensor) Monitoring (low level, overtemperature ...
3.5.1 Rechargeable accumulator “Pilot ONE” is fitted with a clock that continues to run even when the temperature control unit is switched off. The energy required for this purpose is provided by a rechargeable accumulator, which is automatically charged when the temperature control unit is switched on. The accumulator is dimensioned so that the clock can also continue to run for prolonged switch-off intervals (up to several months).
Function description OPERATION MANUAL Chapter 3 3.5.2 Programmable event function The “Calendar Start” offers a programmable event function. This enables you to enter a time at which the event is repeatedly triggered on a daily basis (until the activity in the menu is reset). 2 event types are currently selectable: 3.5.2.1 Event function “Alarm clock event”...
▪ Start/stop etc. 3.8.2 The categories For clarity we have grouped the Operation and Setting of Pilot ONE in various categories. A category is selected by tapping it. 3.8.3 The sub-categories The sub-categories are parts of a category. This is where you will find the entries that we have grouped together for you in the selected category.
Function description OPERATION MANUAL Chapter 3 Function examples 3.9.1 Display of software version PROCEDURE Go to the “Categories Menu”. Tap on the category “System Settings”. Tap on the category “System Info”. Tap on the sub-category “Software Version”. The software versions of the electronics will be displayed: Display of software versions...
- Max. permissible power ried at the start of draw (230 V machines) Pilot ONE) Com.G@te (only if Com.G@te is connected) - Analogue interface Config. input - Meaning AIF input Input off ...
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Function description OPERATION MANUAL Chapter 3 Description Standard value Your setting - Setting output range -40 °C … 100 °C - Calibration No calibration - RS232/RS485 Hardware RS RS232 ...
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No user menus avail- Favourites menu able Pilot ONE Ethernet - IP address 0.0.0.0 - Subnet mask 255.255.255.0 ...
To reset the cut-out values of the overtemperature protection to the factory setting from within the controller of Pilot ONE, enter for “Heater” 35 °C and for the expansion vessel 45 °C. “Process Safety” is factory set to “Stop” and is automatically reset to “Stop” when restoring the factory settings.
Enter the volume using the number keypad that appears. Confirm your entry by tapping on “OK”. Tap on the cooling bath used. This selection list is displayed only when the Pilot ONE was con- nected to a cooling bath.
Enter the volume using the number keypad that appears. Confirm your entry by tapping on “OK”. Tap on the cooling bath used. This selection list is displayed only when the Pilot ONE was con- nected to a cooling bath.
Enter the volume using the number keypad that appears. Confirm your entry by tapping on “OK”. Tap on the cooling bath used. This selection list is displayed only when the Pilot ONE was con- nected to a cooling bath.
Set the cut-out value of the overtemperature protection at least 25 K below the combustion point of the thermal fluid. The maximum settable cut-out value of the OT corresponds, for HUBER thermal fluids, to the specified upper working temperature of the thermal fluid. The usable working temperature range may be less, if the overtemperature protection is correctly set.
Setup mode Chapter 4 OPERATION MANUAL Read the safety warning and confirm by tapping on “OK”. Read the Note and confirm by tapping on “OK”. Tap on the dialog entry “OT limit: heating”. Confirm your choice by tapping on “OK”. ...
Confirm your entry by tapping on the “OK” touchbutton. The temperature control circuit Every temperature control unit with a Pilot ONE control panel has its own PID controller for internal and process temperature control. For many temperature control tasks it is sufficient to use the factory-set control parameter.
Setup mode Chapter 4 OPERATION MANUAL additional RS485 interface is added to your temperature control unit. Optionally you can integrate the temperature control unit in a Profibus environment. For more information, see the pages from 70, section »Interfaces and software update«. The capacity adjustment of the temperature control unit is optimized so that the specified pro- cesses are run through in the fastest possible time.
Setup mode OPERATION MANUAL Chapter 4 4.2.3 Temperature control to process temperature Certain temperature control tasks require that the temperature is recorded elsewhere for best results than described. Setting the temperature to process temperature makes alternatives availa- ble. When setting the temperature to process temperature, an additionally connected external Pt100 temperature sensor is used in conjunction with a master controller (cascade controller).
If the adjustment of the temperature does not correspond to the quality of the illustrations shown above, you can adjust the control parameters. With Huber temperature control units, there are various ways of finding the optimum control parameters. Depending on the facilities of the tempera- ture control unit, you can choose the following processes: ▪...
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All the necessary technical data for the thermal fluids listed for Pilot ONE are stored in the control- ler. If the thermal fluid that you use is not shown in the list, choose the most similar thermal fluid with regard to temperature range and viscosity.
Setup mode Chapter 4 OPERATION MANUAL 4.2.8.1.3 Dialog entry: “With Preliminary Test” (only with Unistat) In some complex applications, the “Fast Identification” of the control circuit may not yet lead to optimum control. This can happen, in particular, if the hydraulic build-up cannot be adjusted to the necessary circulation volumes.
Setup mode OPERATION MANUAL Chapter 4 turbance influence. Please note the specifications on page 36 in section »To be noted when plan- ning the test«. The adjustment behavior can be selected at any time without reactivating the “Find control pa- rameters”.
Setup mode Chapter 4 OPERATION MANUAL Tap on the sub-category “Configuration auto”. Tap on the sub-category “Fluid Properties”. Tap on the sub-category “Select Fluid”. Select the thermal fluid used from the list. Confirm your choice by tapping on “OK”. 4.2.8.3.2 Sub-category: “Bath/Circulation Volume”...
Setup mode OPERATION MANUAL Chapter 4 4.2.9 Category: “Configuration manual” Use of the “Expert mode” without a thorough knowledge of I&C technology. MATERIAL DAMAGE TO THE APPLICATION Only use this mode if you have a thorough knowledge of I&C technology. In “Expert mode”, “Configuration auto”...
Sub-category: “Control structure” With this function, you have two different control structures available. „Huber PID controller“: Default setting “Classic PID controller”: This setting is used by the service engineers of Peter Huber Kältemaschi- nenbau GmbH exclusively for service purposes. PROCEDURE ...
Setup mode OPERATION MANUAL Chapter 4 4.2.11 Sub-category: “Display parameters” In this function, the set parameters are displayed. Depending on the previous setting, these will be the “Automatic control parameters” or the “Manual control parameters”. PROCEDURE Go to the “Categories Menu”. ...
Setup mode Chapter 4 OPERATION MANUAL 4.2.13 Setting the setpoint thresholds Overview of the temperature thresh- olds The limits for the minimum and maximum setpoints serve for the safety of your system. They should be set for the application field of the thermal fluid before starting the first temperature control and when changing the thermal fluid.
Setup mode OPERATION MANUAL Chapter 4 4.2.14 Setting the setpoint PROCEDURE Go to the “Home” screen. Tap on the keypad symbol next to “T ”. Setpoint Enter a new setpoint using the number keypad that appears. The following must apply: [Minimum setpoint limit] ≤...
Setup mode Chapter 4 OPERATION MANUAL Tap on the dialog entry “Stop air-purge”. Confirm your choice by tapping on “OK”. Venting is stopped and the pump continues to run for approx. 30 seconds. Wait until the pump stops. ...
Setup mode OPERATION MANUAL Chapter 4 Repeat the increasing of the setpoint by 10 K until the maximum working temperature of the thermal fluid used has been reached. Tap on the “Stop” touch button as soon as no more gas bubbles rise up at the thermal fluid's maximum working temperature.
Normal operation Chapter 5 OPERATION MANUAL Normal operation Automatic operation Hot or cold thermal fluid and surfaces BURNS TO LIMBS Avoid direct contact with the thermal fluids or the surfaces. Wear your personnel protective equipment (e.g. temperature-resistant safety gloves, safety goggles, safety footwear).
Normal operation OPERATION MANUAL Chapter 5 5.1.2 Temperature control via a created temperature control program 5.1.2.1 Starting the temperature control program A temperature control program can be started after filling and complete venting. PROCEDURE Go to the “Categories Menu”. ...
Normal operation Chapter 5 OPERATION MANUAL Cooling/heating baths: Automatic operation of K1x and K2x (without hanger thermostat) 5.2.1 Cooling/heating baths: K1x and K2x thermoregulation Positions of the [37] >mains switch< on K1x and K2x 5.2.1.1 Cooling/heating baths: K1x and K2x start thermoregulation The temperature control process can be started after filling and complete venting.
IT “Best Practices” (firewall) must be observed. Usage: Also - to be able to communicate with the “Pilot ONE” controller - the communication enable must be issued. This is an additional safety feature that prevents persons - possibly unintentionally - con- necting to the wrong machine and implementing incorrect temperature control specifications.
Interfaces and software update Chapter 6 OPERATION MANUAL 6.1.2 USB-2.0 interface The interfaces used must meet the specifications of the generally accepted standards. 6.1.2.1 USB-2.0 interface, host USB-2.0 connection (for connector A), e.g. for data memories. 6.1.2.2 USB-2.0 interface, device USB-2.0 connection (for Mini-B connector) for communicating with a computer.
Chapter 6 6.3.1 Service interface This interface is used by the service engineers of Peter Huber Kältemaschinenbau GmbH exclusively for service purposes. An adapter cable connects this interface to a RS232 serial jack. 6.3.2 RS232 (option) / activation of cooling bath This connector is used to connect the hanger thermostat with the cooling bath.
[37] on the temperature control unit to “0”. Also disconnect the temperature control unit from the current supply. In case of fault, you can replace the “Pilot ONE” yourself. If you have questions or difficulties, please contact your dealer, your local office or our Customer Support.
Disconnect the temperature control unit from the current supply. Release the >Fixing screw for Pilot ONE< [89] at the front of the housing. Carefully pull the “Pilot ONE” away upwards. Carefully insert the replacement “Pilot ONE”.
Inspect water required. Documentation on water Every 12 months body and/or quality quality available at: www.huber- operators online.com *L = Air cooling; W = Water cooling; U = Applicable only for Unistats 7.4.2 Clean liquefier fins (air-cooled temperature control unit)
Service/maintenance OPERATION MANUAL Chapter 7 Switch off the temperature control unit. Do this by turning the >Mains switch< [37] to the “0” position! Disconnect the temperature control unit from the current supply. Drain the thermal fluid from the temperature control unit. Further information on page 66 in section »Draining the bath thermostat«.
Service/maintenance Chapter 7 OPERATION MANUAL Thermal fluid inspection, replacement and circuit cleaning The illustration “Wiring diagram” can be found on page 83 in section »Annex«. 7.5.1 Thermal fluid inspection Thermal fluid is not inspected on a regular basis BURNS DUE TO REDUCED BOILING POINT ...
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Thus clean the temperature control unit and your application the same time. When using Huber thermal fluids to clean the thermal fluid circuit, use ethanol. PROCEDURE Fill the system (minimum fill level) with the cleaning agent. The description can be found on page 64 in section »Filling and venting the bath thermostat and the externally closed application«.
The decontamination process depends on the type and quantity of the materials used. Consult the relevant safety data sheet. You will find a prepared return receipt at www.huber-online.com. You as the responsible body are responsible for carrying out decontamination BEFORE third-party personnel come into contact with the temperature control unit.
Shutting down OPERATION MANUAL Chapter 8 Shutting down Safety instructions and basic principles Connection/adjustment to the power supply not carried out by an electrician and/or connection to a power socket without protective earth (PE) MORTAL DANGER FROM ELECTRIC SHOCK Have the connection/adjustment to the power supply carried out by an electrician. ...
Shutting down Chapter 8 OPERATION MANUAL Switch-off PROCEDURE >Mains switch< [37] set to “0”. Disconnect the temperature control unit from the power supply. Packing Use the original packaging wherever possible! Further information can be found on page 22 in sec- tion »Unpacking«.
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