Original Assembly &

Operating Instructions
for
Refrigeration Unit
BL 008-01
Satisloh Nr. 55-050-351
Table of Contents

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

This document is included in the technical documentation of the companies Lahntechnik

GmbH / Duotemp Kältetechnik GmbH. All rights pertaining to this documentation, especially
the right to reproduction and distribution as well as the translation thereof lies in the hands
of the companies Lahntechnik / Duotemp Kältetechnik GmbH GmbH, even in cases of
copyright registrations.
No part of this documentation may be reproduced or reprinted, duplicated or distributed
under usage of electronic systems in whatever form without previous written consent from
the companies Lahntechnik GmbH / Duotemp Kältetechnik GmbH.
Errors and technical modifications reserved.
Lahntechnik GmbH / Duotemp Kältetechnik GmbH is not liable in any way whatsoever for
mistakes or possible mistakes in this documentation. Liability for direct and indirect
damage, the results thereof being related with the delivery or non-making use of this
documentation is excluded insofar as the law permits.

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:

The construction, layout and development of this refrigeration unit are

based on and according to the following national and international
regulations:

EC Machinery Directive 2006/42/EC

EC Low Voltage Directive 2006/95/EC

EC-EMC-Directive 2004/108/EC

EC Pressure Equipement Directive RL/97/23 EC

EN 378:2008 T1/T2/T3/T4 Refrigerating Systems and Heat Pumps

EN 60529 Degrees of Protection provided by Enclosures

EN ISO 12100-1, -2 Safety of Machinery

EN ISO 13857

EN 60204-1 Safety of Machinery - Electrical Equipment of Machines

EN 61000-6-2 Electromagnetic Compatibility (EMC)- Generic Standards – “Emission“

EN 61000-6-2 Electromagnetic Compatibility (EMC)- Generic Standards – “Immunity”

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.
Place Symbol
Elektric
Cooling tank, cooling
system with pump,
refrigeration unit with
cooling medium
piping
Complete aggregate
Complete aggregate
Complete aggregate
Complete aggregate
02-2010
Description
Danger through electric current
As with all electrical work, there is the
danger of electric shocks, short-
circuits etc.
Danger through burns
e.g. during maintenance, cleaning or
fault corrections
Danger of tripping-over through
cables and leads
Danger through materials and
other substances (or the other
components thereof)
Danger through internal/external
contact with vapors and liquids
Danger through suspended loads
5
How can I avoid the danger?
⇐ All maintenance work, especially electrical
work, may only be carried out by suitably
trained and qualified persons
⇐ Isolate the refrigeration aggregate from the
mains supply before staring maintenance work
⇐ The main switch is to be fitted with a suitable
padlock
⇐ Wait till parts cool down to under 40°C
⇐ Use protective gloves:
⇐ Lay-out all conduit so that no-one can trip-over
it and/or thereby damage it or themselves
⇐ All information about dangers has to be made
easily accessible to the operators and made
available nearby
⇐ Only suitable trained personnel
⇐ Observance of the danger datasheets
⇐ Customer-sided filling of cooling medium is to
be documented
⇐ Do not stand under suspended loads
⇐ Make us of suitable and certified lifting
machinery (total weight- see technical data
page Fehler! Textmarke nicht definiert.
⇐ Always wear safety shoes:
2.1 Material-related dangers

Cooling agent and cooling oil

Physical data, heat resistance, chemical resistance, reactivity data, as well as chronic and acute
toxicity data are documented in safety datasheets of the manufacturer. Customers are hereby
recommended to acquire these documents.

The customer´s-own cooling medium should be documented on the side of the customer.

Corrosion tendencies on plant components: generally there is no danger of corrosion.

The tank for the cooling systems and pumps, as well as the housing components are generally
manufactured in stainless steel (CrNi-St). Therefore it cannot be ruled out that certain cooling
agents can cause corrosion over the years and thereby the possibility for leakages, especially
when the concentrations are not adhered to.

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.

2.2 Process-related dangers and process documentation

The pipework & instrument flowchart is presented in the operating instructions.

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.

Technical standards are mentioned in the operating instructions.

Technical and safety-related data are listed in the operating instructions.

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.

2.3 Analysis of process dangers

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.

It is recommended to carry out the analysis every 5 years.

It is recommended to deploy employees from different disciplines for the analysis.

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:

¾ lead to life-endangering inuries to persons

¾ lead to damage to the equipment
¾ lead to unforeseeable further dangers

4. Unpacking and Handling

Before and during unpacking of the equipment, a visual check must be made to detect any
possible damage that occurred in transit.
Please be on the look-out for loose parts, dents, scratches, etc.
Any possible damage is to be reported immediately to the carrier (Note the 'Provisions for
Cases of Damage'). Otherwise the 'General Terms and Conditions for Supplies and
Services' of ZVEI (Zentralverband der Elektrotechnischen Industrie, (Central Association of
the Electrical Engineering Industry) Frankfurt/M.) in the latest version apply.
Before the packaging material is disposed of, it must be checked to see whether there are
any loose functional parts in it.
For the processing of claims under the warranty, we would ask for the exact details of the
defect (possibly a photo) as well as for the indication of the type designation and the serial
number of the equipment.
In order to protect the equipment from damage, it may only be transported and stored in the
position in which it is used. Non-observance will result in the loss of warranty.

02-2010 8
5 Transport

Place Symbol Description How can I avoid the danger?

⇐ Do not stand under suspended loads

Complete aggregate
⇐ Make us of suitable and certified lifting
machinery (total weight- see technical data
page Fehler! Textmarke nicht definiert.
Danger through suspended loads
⇐ Always wear safety shoes:

- Take heed of the dimensions and weight in the corresponding datasheets

- Transport only with pallete bogey, fork-lift truck or lifting crane
- Transport the aggregate without water and standing
- all cran hooks if available must be evenly loadable
The use of less than the existing crane hooks are not allowed.
-

6. Storage

- Storage conditions for the product

The device is to be stored dry, free of dust and frost-free.

02-2010 9
7. Assembly and Installation

- Stipulations for mounting/anchouring

- Installation plan for application of the medium, cooling agent and electrics (flowchart,
dimensioned drawing, electric plan)
- Mounting & assembly conditions
- Permitted environment (temperature, humidity, vibration, electromagnetic radiation,
impacts, ...)
- Emission descriptions(e.g. vibration, noise, radiation, ...)

7.1 Hydraulic connection

Connections and the laying of piping for liquids are to be carried out by skilled and qualified
persons observing the technical rules. Facilities for bleeding the external medium circuit are
to be fitted.

7.2 Electrical connection

Electrics for cooling device according to current diagramme (see appendix).
Rotational direction is to be checked at the pump (cable connection), at the ventilator
(optical), at the compressor (loud noise). In case of the wrong rotational direction check if it
is only one component in the wrong direction, or all components. If it is only one
component, then a phase has to be changed for the component (exchange L1 and L2). If
all components are in the wrong direction then a phase has to be exchanged at the main
connection for all components involved (exchange L1 and L2).
Provide for protection by fuse(s) in accordance with the equipment’s power consumption
(see technical data on the rating plate).
ATTENTION: The mains voltage and the mains frequency
must match the rated values shown on the equipment's rating
plate.
Work on electrical systems may only be carried out by skilled
and specialised personnel. The relevant local safety
regulations are to be observed.

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).

Outside mounting without protection is not permitted.

02-2010 10
 For fault-free operation of the equipment, as well as the providing corresponding free space
around for maintenance work, the minimum distances recommended are to be adhered to.

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.

7.4 General Information

For transportation, we recommend that the equipment’s liquid tank be emptied. For
handling please always keep the equipment in the operating position.
Work on the equipment may only be carried out by trained and qualified persons. The
appropriate safety and environmental protection regulations are to be observed. See
declaration of conformity and/or chapter 1.
The equipment was checked in the works to ensure its tightness.
It has been certified that the item of equipment was subjected to an electrical safety check
in the works before being dispatched. Hence, according to BGV A3, this relieves the
owner/operator of the obligation to carry out a check or to have a check carried out on the
electrical system of the equipment to ensure that it is in the proper working state before
the equipment is put into operation for the first time.

Operating the unit with water temperature below <12°C requires

antifreeze in adequate dosage to avoid damage caused by freezing
up, preferably Antifrogen N.
Please note that though the insert limit extends downwards the
refrigerating capacity changes considerably. Moreover the pump
capacity has to be checked. Please consult an expert before
reorganizing!

02-2010 11
8. Application, Function and Description

8.1 Description- refrigeration unit

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.

Option: Mixing Valve Control

The option Mixing Valve Control is typically used in two cases:

1. To realize different temperature levels in chillers with more than one cooling circuit
2. To realize highly accurate control of outlet temperature in systems with more than one
cooling circuit, different media, that cannot be cooled via a joint evaporator, as well as
significant variations of required cooling capacity across the different cooling circuits
3.
The option Mixing Valve Control is realized using a central water reservoir, which is cooled
down to a temperature level below the lowest required outlet temperature. From this water
reservoir for each cooling circuit either a separate heat exchanger (water / outlet medium)
is supplied or water is directly taken with a separate consumer pump into a water outlet.
Temperature control is realized via electronic controllers and temperature sensors in the
outlet of the heat exchanger or in the outlet itself in case the heat exchanger is used. The
controller actuates a 3-way-mixing-valve in the water circuit. The mixing valve controls the
outlet medium temperature in the respective cooling circuit by adjusting the mixing ratio
between cold water and warm inlet water.

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.

Option: Excessive flow valve

Instead of the constant bypass, which protects the pump from a customer-sided closed
slide valve and the cooling medium runs constantly between forward and reverse flow via
the bypass, there is a pressure-controlled bypass installed in some of the units, according
to the customer requirements. This only opens above a preset pressure and ensures that
the system is never exposed to a pressure higher than that preset.

Option: Level early-warning

The use of a second level indicator enables the issuance of an early-warning when the
level in the reservoir sinks and there is a danger of a shut-off via the normal level indicator.
This allows sufficient time to refill the vessels, without the low cooler level causing a switch-
off.

Option: Reference-driven regulation

In this case no fixed values are set at the regulator. The refrigeration unit orientates itself
around a reference value via a second sensor, for example at the surrounding temperature
or at the machine bed. The temperature of the refrigeration unit is then carried through
according to the change in the refence value. What is carried through can be limited to a
certain temperature range e.g. under 15 °C or on the other hand above 35°; here the
refrigeration unit can be set automatically to a fixed value which has to be entered.

Option: Dirt trap / Filter

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.

Option: Automatic water feed

A floating switch connected to the customer-sided mains water supply automatically feeds
water into the medium tank as soon as the water level sinks.

Option: Flow monitor

In order to be able to protect the customer-sided machine or the customer´s application 2
monitoring systems are required. One is to monitor the temperature, which takes place
through the regulator and one to monitor the flow. If the customer does not monitor the
machine or his application himself, then a flow monitor can be fitted in the refrigeration unit
return flow, which issues a signal when there is no flow or less than a minimum threshold
amount. There are flow monitors with display and without display. The signal can serve as
a warning or activate a switch-off. Generally this option is combined with under & over-
temperature messages.

Option: Accumulative error message center

All error messages flow together into the error message center where a signal is given out.
The contact is potential-free. The accumumative error message center contains not only
the unit´s-own safety facilities but also the customer-relevant monitoring facilities. Details
can be sourced from the circuit diagram.

8.2 Safety facilities

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.

8.3 Monitoring facilities

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.

9. Putting into Operation and Operating

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.

9.1 Safety checks before putting into operation

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.

9.2 Safety checks during operation

The owner/operator is obliged to maintain documentation of safety-related inspections for

the refrigeration aggregate (available through the supplier). It is to be ensured that such
details are available to a technical expert in case of repairs and repeat inspections. A
suitable operating manual is available from 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.

9.3 Training and performance

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.

9.4 Accident analyses

If there is an accident, which is caused by the direct or as a result of operating the

refrigeration unit, it is recommended to include the supplier into the analysis of the accident.

9.5 Management of changes in personnel

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.

An on-site list of competent operators would serve this purpose.

9.6 Preparation for putting into operation

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.

9.7 Switching on- putting into operation

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

¾ Wait till parts cool down to under 40°C

Danger through burns
Cooling tank, ¾ Use protective gloves:
cooling system e.g. during maintenance, cleaning or
fault corrections

Maintenance procedures are to be adhered to.

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.

10.1 Maintenance for the operator

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.

10.2 Notes on the replacement of components

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.

12 Taking out of Operation

Should the refrigeration unit be taken out of operation for longer periods of time, we
recommend switching the refrigeration unit free of voltage and removing the cooling
medium from the pumps, pipework and filter. Liability for frost damage or damage resulting
from the effects of algae will not be accepted under any situation whatsoever.

13 Breakdown: What is to be done if ...?

Should for some reason a fault/error appear during operation of the cooling equipment,
then the table which appears in the appendix will help to find a solution. In case of
uncertainty, it is always advisable to call a specialist.

02-2010 18
 In case of emergency the Emergency telephone number 0049 (0) 170 582 64 84 is
available at all times.

14 Information about Spare Parts

See enclosed list.

15 Details about Disposal and Recycling

Environment-related requirements for the recycling, re-using and disposal of operational

materials and the refrigeration aggregate according to DIN EN 378 and ROHS Guidelines
are to be strictly adhered to. The owner/operator is solely responsible.

16 Rules for the Owner/Operator

16.1 Rules referring to the refrigeration unit

The owner/operator of the cooling equipment is obliged:

• to only allow suitably trained persons to work on the unit
• to ensure that the operating instructions are read and observed iun case of a change of
the operating personnel (especially safety instructions)
• to make sure the operating instructions are always at the workplace
• to ensure that the care & maintenance instructions are followed
• to make sure thaat the neccessary activities (e.g. maintenance) are only carried out by
suitable trained & qualified persons and groups of persons
• to train & qualify such persons and groups of persons if it is so required
• to ensure that the equipment is used only for the purpose it was designed and built for
The operators of refrigeration, air-conditioning & heating pump equipment are obliged by
law to carry out regular leakage inspections with certified personnel at certain regular
intervals. 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.
• It is recommended to periodically inspect and list all elements in the prescribed process-
related safety program from the owner operator. Updated information is to be entered
into this documentation.

16.2 Planning for emergencies and assignment

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.

Operating personnel must be able to understand the operational language.

02-2010 20
APPENDICES

1 Technical datasheet
2 Dimensional drawing
3 Setup
4 System scheme
5 Pump performance characteristics
6 Electric circuit diagram
7 Troubleshooting table
8 Functional description regulator (optional)
9 Regulator setting (optional)
10 Chemical requirements for circuit water
11 Conformity
12 Spare Parts recommended
 Annex 1: Technical datasheet

Type BL 008-01
Article-No. 1000000600801

Rated refrigeration capacity kW 0,8

Water temperature of °C 15 +/- 0,1K
Rated volume flow of water circuit dm³/min 1)
air volume current at condenser m³/h 2000
Ambient temperature at rated operation °C 32
Ambient temperature, min/max C/°C 10 / 42

Max. allowable working pressure bar 18

High pressure-operated switch Off/On bar/bar 18 / 13

Dooling agent type/quantitiert -/kg R 134a / 0,95

Primary medium -/- Trinkwasser
Tank contents litre 18
Sound pressure at a distance of 1m dB(A) < 70

Electrical rating
Nominal voltage V 230/1~/PE
Rated frequency Hz 50/ 60
Control voltage V 230
Rated power input kW / 0,9
Rated current consumption A / 5,26
Degree of protection IP54

Dimensions
Height mm 895
Width mm 465
Depth mm 505
Empty weight kg ca. 65
mediuminlet ¾“
mediumoutlet ¾“

1) see appendix 5 pump performance characteristics

WARNING: Water additions (e.g. glycol) change the rated capacity data !
 1 2 3 4 5 6 7 8

A A

Lamellenverflüssiger
plate fin condenser
Hochdruckschalter
high pressure switch
18 bar Diff.5

PSH
B B

Medium Austritt 3/4" Medium Eintritt 3/4"

medium outlet 3/4" medium inlet 3/4"
Filtermatte
air filter

Flüssigkeitssammler Verdichter
liquid receiver compressor
Temperaturregler Niveaugeber Filtertrockner
C temperature controller levle control
C
Befüllung DN40 filter drier
20°C +/- 1,5K
tank filling DN40

°C Magnetventil
solenoid valve
00,0 Heißgasbypass
Pumpe
Expansionsventil hot gas bypass
pump
expansion valve

D M
3~
TC D

PSL
Niederdruckschalter
low pressure switch
Ein/on: 1,2 bar Diff. 1,8

PWT Verdampfer
PWT evaporator
E Wassertank isoliert E
watertank isolated

Tankentleerung
tank drain

F Datum 04.08.08 - F
Anlage/annex
Bearb. Papzien +
Geprüft: Papzien BL 008-01 Blatt :
Änderung Datum Name Norm DIN EN 1861 Urspr. Ersatz für : Erstell - Datum: 04.08.08 Folge :

1 2 3 4 5 6 7 8
 Anlage 4 / annex 4

Pumpenkennlinie T 601/50Hz
pump performance characteristic

40

35

30

25
Förderhöhe / lift of pump [m]

20

15

10

0
0 10 20 30 40 50 60
Förderstrom / delivery volume [dm³/min]

File: Pumpenkennlinie T601_50Hz Stand 05-99

 0 1 2 3 4 5 6 7 8 9

neutral_LTN_DT_F26_003

Kunde Satisloh
Anlagenbezeichnung 1 BL 008-01
Anlagenbezeichnung 2 Satisloh NR 55-050-351
Anlagenbezeichnung 3
Anlagenbezeichnung 4
Kommission

Elektrische Daten:

Netzanschluß 230 V AC
Frequenz 50-60 Hz
Stromaufnahme 5,26 A
Leistungsaufnahme 0,898 W
Steuerspannung 230 V AC

Bearbeitet am 08.09.2010 von (Kürzel) F.K.Z. Zimmermann Anzahl der Seiten 7

2
Datum 13.07.2009 Titel- / Deckblatt =
Bearb. +
Gepr BL 008-01 Blatt 1
Änderung Datum Name Urspr Ersatz von Ersetzt durch Blatt 7
 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

Seite Seitenbeschreibung Datum Bearbeiter X

1 Titel- / Deckblatt 13.07.2009 becker
2 Inhaltsverzeichnis : 1 - 10.a 13.07.2009 becker
3 Hauptstromkreis 09.07.2009 becker
4 Steuerstromkreis 13.07.2009 becker
5 Steuerstromkreis 09.07.2009 becker
10 Klemmenplan : X2 13.07.2009 becker
10.a Klemmenplan : X2 09.07.2009 becker

1 3
Datum 13.07.2009 Inhaltsverzeichnis : 1 - 10.a =
Bearb. +
Gepr BL 008-01 Blatt 2
Änderung Datum Name Urspr Ersatz von Ersetzt durch Blatt 7
 0 1 2 3 4 5 6 7 8 9

L1 / 4.0

N / 3.1

1 3 5
-F1
1,1-1,6 A
1,25 A
I> I> I>
1 3 5 2 4 6
-Q1
4.5 2 4 6

1 3 5
-Q2
4.3 2 4 6

-W5 -W6
3x1 3x1

fertiges fertiges intern

Anschlusskabel Anschlusskabel x1
-C3
sw
x2
1 2
1 2 x1 bl bk x1
-C1 -C2 -M3
M
-M1
M x2 -M2
M x2 1~
1~ 1~ br
PE
PE PE

-X1 L N PE

230V 50-60HZ 692 W 86 W

Schuckostecker 3,63 A 0,38 A 120 W
Verdichter Ventilator 1,25 A
compressor fan Pumpe
compresseur ventilateur pump

2 4
Datum 08.09.2010 Hauptstromkreis =
Bearb. F.K.Z. +
Gepr BL 008-01 Blatt 3
Änderung Datum Name Urspr Ersatz von Ersetzt durch Blatt 7
 0 1 2 3 4 5 6 7 8 9

230V 50-60Hz
3.9 / L1

-X2 1 -X2 1
-X2 1 -X2 1
5
-Q2
6
-W4
BK
7x1 1 1
BK BK -X2 7 4.3 / -K1.1
1 1
-K1.1 / 4.7

-W7 bk

-K1 1 L1/2
-K1.2
-F11 P
L1/1 L1/3
L3/4 18 bar-diff 6 bar 2
-A1:L3/1 Hochdruckschalter
-K1.1 rt
1,0
00,0°C L3/5
-A2:L3/2 -111:L2/3 -112:L2/4 -113:L2/2 -112:L2/4 -113:L2/2 -W7 bk -W4 -W4
7x1 4 7x1 5
-X2 8

-W4 rt
1,0
rt
1,0
7x1 2

x1
Θ -W4
7x1 3 -W8
x2 4x1 -X2 PE
B1
1 -K3 1/L -K4 1/L
1
Fühler Medium -F12 P A1 A1
1,2bar-diff 1,8 bar
Niederdruckschalter 4 2 A2 A2
br
-W8 -PE
-F10 4x1 2 3
Niveauwächter bl

-X2 9 10

2/T 2/T
rt rt rt
1,0 1,0 1,0

-X2 10 -X2 11
15
-W10 Magnetventil Flüssigkeitsleitung
-K2 -W9 3x1
Magnetventil Bybass 1
4.4 18
4 min 3x1 1
x1
x2
M5
M4
x2
A1 A1 A1 x1
-W9 -W10
-Q2 -K2 -Q1 -X2 PE
3x1
rot -X2 PE
3x1
2 1,0 2
Pumpe A2 -R1 4 min A2 Kühlung A2

-X2 2 -X2 2 -X2 2 -X2 2 -X2 2 -X2 2

/ N 0V

1 2 3.7 15 18 4.5 1 2 3.4

3 4 3.8 3 4 3.4
5 6 3.8 5 6 3.4
5 6 4.4
13 14 5.4

3 5
Datum 13.07.2009 Steuerstromkreis =
Bearb. +
Gepr BL 008-01 Blatt 4
Änderung Datum Name Urspr Ersatz von Ersetzt durch Blatt 7
 0 1 2 3 4 5 6 7 8 9

13
-Q2
4.3 14

1
-X2 10 11 PE
PE

-W2
3x1 1 2 PE

-X3 1 2 PE

Niveaugeber-Meldung

Hartingstecker 4pol
4m lang

4 10
Datum 09.07.2009 Steuerstromkreis =
Bearb. +
Gepr BL 008-01 Blatt 5
Änderung Datum Name Urspr Ersatz von Ersetzt durch Blatt 7
 0 1 2 3 4 5 6 7 8 9

Klemmenplan Klemme_LTN_DT_F13_003

Leiste
Externe Ziele
X2 Interne Ziele

Zielbezeichnung Verdrahtung Brücke Funktionstext Brücke Verdrahtung Zielbezeichnung Platzierung

A1:L3/1 1mm² 1 1mm² Q2:1 3.7

Q2:5 1mm² 1 1mm² K3:1/L 4.6

1 1mm² K3:1/L 4.6

1mm² K4:1/L 4.8

F11:1 1mm² 7 Hochdruckschalter 1mm² Q2:6 4.4

F12:1 1mm² 8 = 1mm² F11:2 4.4

PE 1mm² PE PE

2 N 1mm² A2:L3/2 4.0

R1 1mm² 2 = 1mm² Q2:A2 4.3

R1 1mm² 2 = 1mm² K2:A2 4.4

2 = 1mm² Q1:A2 4.5

K3:A2 1,0mm² 2 = 1mm² x1 4.6

K3:A2 1,0mm² 2 = 1mm² x2 4.8

K4:A2 1,0mm²

F12:4 1mm² 9 Niederdruckschalter 1,0mm² K2:A1 4.4

F12:2 1mm² 10 = 1mm² K3:2/T 4.6

K3:2/T 1mm² 10 Magnetventil Bybass 1mm² x2 4.6

X2 1mm² PE PE Magnetventil

X3:1 1mm² 10 1mm² Q2:14 5.4

x1 1mm² 11 1mm² K4:2/T 4.8

X3:2 1mm² 11 1mm² Q2:13 5.4

X2 1mm² PE PE Magnetventil

5 10.a
Datum 13.07.2009 Klemmenplan : X2 =
Bearb. +
Gepr BL 008-01 Blatt 10
Änderung Datum Name Urspr Ersatz von Ersetzt durch Blatt 7
 0 1 2 3 4 5 6 7 8 9

Klemmenplan Klemme_LTN_DT_F13_003

Leiste
Externe Ziele
X2 Interne Ziele

Zielbezeichnung Verdrahtung Brücke Funktionstext Brücke Verdrahtung Zielbezeichnung Platzierung

X3:PE 1mm² PE 1mm² PE:1 5.5

10
Datum 09.07.2009 Klemmenplan : X2 =
Bearb. +
Gepr BL 008-01 Blatt 10.a
Änderung Datum Name Urspr Ersatz von Ersetzt durch Blatt 7
 Apprendix 7: Troubleshooting Table

Fault Cause Remedy

Unit doesn´t run a) Current supply severed a) Check main fuse, check mains
supply
b) Main switch in OFF-position
b) Switch On main switch
c) Regulator faulty
c) Check regulator
d) Control voltage not disconnected
d) Disconnect control voltage
e) HP- switch defective
f) LP- switch defective e) a) Inform refrigeration spe-
cialist
g) Floating switch defective
f) a) Inform refrigeration spe-
h) Flow monitor defective cialist
g) Inform customer service
h) Inform customer service
Motor circuit-breaker or Consult circuit diagram and identify
regulator problems part, then continue in the table
Cooling aggregate runs, a) Dirty air filter a) Remove dirt
however insufficient
cooling power b) Dirty condensor b) Inform refrigeration specialist
c) Shortage of cooling agent c) b) Check pump, pipework
d) Not enough medium quantity d) Provide for sufficient air
supply/exhaust
e) Air intake/exhaust blocked
e) Look for abnormal heat source

f) Too much heat development in

user
High pressure switches off a) Temperature of intake air too hot a) Clean condenser, check intake
system, provide for a better
b) Condenser fans do not turn
aeration
c) Dirty air filter b) Check condenser fans
d) Dirty condensor
c) Clean air filter
e) Housing is open and system
d) Clean condenser
intakes “wrong” air
e) Install cover plates
f) Hot air short-circuit: unit intakes its
own hot air f) Provide for a good air exhaust
g) Medium temperature beyond of g) Fill anew with cooler medium
upper limit value

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
- pipework
- control valves
- contamination
- contaminated plate exchanger
- Closed slide valves
f) Shortage of medium
g) Pump defective
h) Ambient temperature too low
Compressor switches off Motor circuit-breaker has responded,
because compressor uses too much
current
Pump switches off Motor circuit-breaker has responded,
because pump uses too much current
Shortage of medium Medium missing in tank
- Check system on cleanliness
- Check slide valve
f) Check medium level, refill if so
reqd.
g) Check pump
h) Increase ambient temperature
Pump motor is overheated or
defective. Inform refrigeration
specialist
Pump motor is overheated or
defective. Call technical
assistance!
Check medium level, refill if so
reqd.
JUMO dTRON 316 JUMO dTRON 308

JUMO dTRON 308 JUMO dTRON 304

JdTRON 304
JdTRON 308
JdTRON 316
Compact Controller
with program function

B 70.3041.0
Operating Manual
06.05/00442056
) Please read this Operating Manual before commissioning the instrument. Keep the manual in a
place which is accessible to all users at all times.
Please assist us to improve this operating manual. Your comments will be appreciated.
Phone +49 661 6003-0
Fax +49 661 6003-607

All necessary settings are described in this operating manual. If any difficulties should still arise du-
ring start-up, please do not carry out any unauthorized manipulations on the unit. You could
endanger your rights under the instrument warranty!
Please contact the nearest subsidiary or the head office in such a case.

E
When returning modules, assemblies or components, the regulations of EN 100 015 “Protection of
electrostatic sensitive devices” must be observed. Only use the appropriate ESD packaging for
transport.
Please note that we can not accept any liability for damage caused by ESD.
ESD=electrostatic discharge
 Contents
1 Introduction 5
1.1 Description .................................................................................................... 5
1.2 Typographical conventions ......................................................................... 6

2 Identifying the instrument version 7

2.1 Type designation .......................................................................................... 7
2.2 Scope of delivery .......................................................................................... 8
2.3 Accessories .................................................................................................. 8

3 Mounting 9
3.1 Mounting site and climatic conditions ....................................................... 9
3.2 Dimensions ................................................................................................... 9
3.2.1 Type 703044 ................................................................................................... 9
3.2.2 Type 703042/43 ............................................................................................ 10
3.2.3 Type 703041 ................................................................................................ 10
3.3 Side-by-side mounting .............................................................................. 11
3.4 Fitting in position ........................................................................................ 11
3.5 Removing the controller module .............................................................. 12

4 Electrical connection 13
4.1 Installation notes ........................................................................................ 13
4.2 Electrical isolation ...................................................................................... 14
4.3 Connection diagrams ................................................................................. 15
4.3.1 Type 703041 ................................................................................................. 15
4.3.2 Type 703042/43/44 ...................................................................................... 16
 Contents
5 Operation 19
5.1 Displays and keys ....................................................................................... 19
5.2 Level concept ............................................................................................. 20
5.3 Level inhibit ................................................................................................. 20
5.4 Entries and operator prompting ............................................................... 21
5.5 Operation of the fixed-setpoint controller ............................................... 22
5.6 Operation of the program controller ........................................................ 23
5.6.1 Entering programs ........................................................................................ 24
5.6.2 Shifting the program profile .......................................................................... 26

6 Operator level 27

7 Parameter level 29

8 Configuration 31
8.1 Analog inputs “InP” .................................................................................... 33
8.2 Controller “Cntr” ........................................................................................ 37
8.3 Generator “Pro” .......................................................................................... 39
8.4 Limit comparators “LC” ............................................................................. 42
8.5 Outputs “OutP” ........................................................................................... 46
8.6 Binary functions “binF” .............................................................................. 49
8.7 Display “diSP” ............................................................................................. 52
8.8 Timer “tFct” ................................................................................................ 53
8.9 Interfaces “IntF” ......................................................................................... 54

9 Tuning (optimization) 55
9.1 Autotuning (self-optimization) ................................................................... 55
9.2 Check of the tuning .................................................................................... 58

10 Extra codes 59
10.1 Math and logic module .............................................................................. 59
10.2 Difference, humidity and ratio controllers ............................................... 59
 Contents
11 Retrofitting of modules 61

12 Appendix 63
12.1 Technical data ............................................................................................. 63
12.2 Alarm messages ......................................................................................... 66

13 Index 67
Contents
 1 Introduction
1.1 Description

The controller series consists of four freely programmable instruments in different DIN
formats for controlling temperature, pressure and other process variables. The high-
contrast, multicolor LCD 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 status indicators, and displays for the unit,
ramp function and manual operation.
Just four keys on the front panel are needed for operation, parameterization and
configuration. 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, autotuning (self-optimization), 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.
An RS422/485 or a Profibus-DP interface can be used to integrate the instrument into
a data network.
The electrical connection is made at the back of the instrument, via screw terminals.

5
1 Introduction
1.2 Typographical conventions
Warning signs
V Danger This symbol is used when there may be danger to
personnel if the instructions are ignored or not followed
correctly!

* Caution This symbol is used when there may be damage to

equipment or data if the instructions are ignored or not
followed correctly!

E Caution This symbol is used where special care is required when

handling components liable to damage through
electrostatic discharge.

Note signs
H Note This symbol is used when your special attention is drawn
to a remark.

v Reference This symbol refers to further information in other operating

instructions, chapters or sections.

H Action This symbol indicates that an action to be performed is

instruction described.
The individual steps are marked by this asterisk, e.g.
h Press X

Representation Menu items Texts from the setup program are shown in italics, for
example: edit program.

Blinking
IIIIIIIIIIIIIIIII
display
IIIII

IIIII

IIIIIIII IIIIIIII

6
 2 Identifying the instrument version
2.1 Type designation
Basic type
703041 Type 703041, format 48mm x 48mm
incl. 1 analog input, 2 relay outputs and 2 binary inputs or 2 logic outputs
703042 Type 703042, format 48mm x 96mm (portrait format)
incl. 1 analog and 2 binary inputs, 2 relays and 2 logic outputs
703043 Type 703043, format 96mm x 48mm (landscape format)
incl. 1 analog and 2 binary inputs, 2 relays and 2 logic outputs
703044 Type 703044, format 96mm x 96mm
incl. 1 analog and 2 binary inputs, 2 relays and 2 logic outputs

Basic type extensions

1 Basic type 1
Version
8 standard, with factory settings
9 programming to customer specification
logic outputs (2 are available as standard)
1 0 / 12V
2 0 / 18V

Type 703042/43/44 Type 703041 (no option 3)

1. 2. 3. Option slot Max. number Max. number Option 1 Option 2
0 0 0 not used X X
1 1 1 analog input 2 (universal) 1 1 X X
2 2 2 relay (changeover) 2 1 X -
3 3 3 2 relays (make contact) 2 1 X -
4 4 4 analog output 2 2 X X
5 5 5 2 binary inputs 2 1 X X
6 6 6 solid-state relay 1A 2 2 X X
7 7 7 RS422/485 interface 1 1 X X
8 8 8 Profibus-DP interface 1 1 X X
X = available in this option slot, - = not available in this option slot

Supply
2 3 110 — 240V AC -15/+10%, 48 — 63Hz
2 5 20 — 53V AC/DC, 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 difference controller (requirement: 2 analog inputs)
2 1 9 humidity controller (requirement: 2 analog inputs)

Approvals
0 0 0 none
0 6 1 Underwriters Laboratories Inc. (UL)

/ 1 – – / ,

703041 / 1 8 1 – 1 4 0 – 2 3 / 0 0 0 , 0 6 1

7
2 Identifying the instrument version
2.2 Scope of delivery
- 1 controller
- 1 seal
- mounting brackets
- brief operating instructions
- 1 CD including DEMO-software & operating manuals as pdf-file
(Actual DEMO-software can be downloaded at www.JUMO.net.
To enable DEMO-software to full rights, contact your local JUMO subsidiary.)

2.3 Accessories

PC interface PC interface with TTL/RS232 converter and adapter

(socket connector) for setup program
Sales No. 70/00350260

Setup Versions:
programs Setup program with program editor1
Sales No. 70/00445417
Setup program with program editor
and startup1
Sales No. 70/00445443

Program editor Program editor (software)1

Sales No. 70/00445444

1. Requirements: Windows® 98/NT4.0/ME/2000/XP, PC Pentium II,

128 Mbyte RAM, 30 Mbyte free on hard disk, CD-ROM, one free serial
interface

8
 3 Mounting
3.1 Mounting site and climatic conditions
The conditions on the mounting site must meet the requirements specified in the
technical data. The ambient temperature on the mounting site can be from 0 to 55 °C,
with a relative humidity of not more than 90 %.

3.2 Dimensions

3.2.1 Type 703044

Setup plug

9
3 Mounting
3.2.2 Type 703042/43

Setup plug

3.2.3 Type 703041

Setup plug

10
 3 Mounting
3.3 Side-by-side mounting
Minimum spacing of panel cut-outs
Type horizontal vertical
without setup plug:
703041 (48mm x 48mm) 11mm 30mm
703042 (portrait format: 48mm x 96mm)) 11mm 30mm
703043 (landscape format: 96mm x 48mm) 30mm 11mm
703044 (96mm x 96mm) 11mm 30mm
with setup plug (see arrow):
703041 (48mm x 48mm) 11mm 65mm
703042 (portrait format: 48mm x 96mm)) 11mm 65mm
703043 (landscape format: 96mm x 48mm) 65mm 11mm
703044 (96mm x 96mm) 11mm 65mm

3.4 Fitting in position

Type 703042/43/44 h Fit the seal that is supplied onto the

instrument body.
h Insert the controller from the front into
the panel cut-out.
h From behind the panel, slide the
mounting brackets into the guides on
the sides of the housing.
The flat faces of the mounting brackets
must lie against the housing.
h Push the mounting brackets up to the
back of the panel, and tighten them
evenly with a screwdriver.

Type 703041 h Fit the seal that is supplied onto the

instrument body.
h Insert the controller from the front into
the panel cut-out.
h From the back of the panel, push the
mounting frame onto the instrument
body and press it against the back of
the panel, compressing the springs,
until the latches snap into the notches
provided and it is firmly fixed in position.

Care of the front The front panel can be cleaned with normal commercial washing, rinsing and cleaning
panel agents. It has a limited resistance to organic solvents (e.g. methylated spirits, white
spirit, P1, xylol etc.). Do not use high-pressure cleaning equipment.

11
3 Mounting
3.5 Removing the controller module
The controller module can be removed from its housing for servicing.
h Press together the knurled areas
(top and bottom, or left and right for
landscape format) and pull out the
controller module.

H When inserting the controller module, make sure that the latches (below the
knurled areas) snap into place.

12
 4 Electrical connection
4.1 Installation notes
- The choice of cable, the installation and the electrical connection must conform to
the requirements of VDE 0100 “Regulations on the Installation of Power Circuits
with Nominal Voltages below 1000 V” or the appropriate local regulations.
- The electrical connection must only be carried out by qualified personnel.
- If contact with live parts is possible while working on the unit, it must be
disconnected from the supply on both poles.
- A fuse interrupts the supply circuit in the event of a short-circuit. The load circuit
must be fused for the maximum relay current, in order to prevent the output relay
contacts becoming welded in the event of a short circuit.
- Electromagnetic compatibility conforms to the standards and regulations cited in
the technical data.
v Chapter 12.1 “Technical data”
- Run input, output and supply cables separately and not parallel to one another.
- Sensor and interface cables should be shielded cables with twisted conductors.
Do not run them close to current-carrying components or cables. Ground the
shielding on one side.
- Do not connect any additional loads to the supply terminals of the instrument.
- The instrument is not suitable for use in areas with an explosion hazard (Ex areas).
- In addition to faulty installation, incorrect settings on the controller (setpoint, data
of the parameter and configuration levels, internal alterations) can also interfere
with the correct operation of dependent processes, or even cause damage. Safety
devices should always be provided that are independent of the controller (such as
overpressure valves or temperature limiters/monitors) and only capable of
adjustment by specialist personnel. Please observe the relevant safety regulations
for such matters. Since adaptation (self-optimization) can not be expected to
handle all possible control loops, an unstable parameterization is theoretically
possible. The stability of the actual value that is produced should therefore be
checked.

13
4 Electrical connection
4.2 Electrical isolation

14
 4 Electrical connection
4.3 Connection diagrams

4.3.1 Type 703041

H
.

V
The electrical connection must only The instrument version can be
be carried out by specialist personnel. identified by the typecode.

1 2 3 Terminal strip 3

L1(L+)
1 1
N(L-)
2 2
3 3 3
4 4 4
5 5
6 6 6
7 7 7
8 8 8

Terminal strip 2

Terminal strip 1

15
4 Electrical connection
4.3.2 Type 703042/43/44

H
.

V
The electrical connection must only The instrument version can be
be carried out by specialist personnel. identified by the type code.

1 2 3 1 2 3
L1(L+) L1(L+)
1 1 1 1
N(L+) N(L+)
2 2 2 2
3 3 3 3
4 4
4 4 4 4
5 5
6 6

5 6 5 6
8 8
6 7 6 7
9 9
7 8 7 8
8 9 8 9
11 11
10 10
12 12
13 13
9 9
10 15 10 15
11 16 11 16
12 17 12 17

Terminal strip 3

16
 4 Electrical connection
Terminal strip 2

Terminal strip 1

17
4 Electrical connection

18
 5 Operation
5.1 Displays and keys

(1)
(2) (6)
(3)
(5)

(4) PGM EXIT

(1) 7-segment display (factory setting: process value)

four-digit, red, decimal place is configurable
(automatic adjustment on display overflow)
(2) Active setpoint (factory setting: SP1)
SP1, SP2, SP3, SP4 (SP=setpoint); green;
(3) 7-segment display (factory setting: setpoint)
four-digit, green; decimal place is configurable;
also used for operator prompting (display of parameter and level symbols)
(4) Keys
(5) Indication
yellow, for
- switch status of binary outputs 1—6 (display lights up = on)
- ramp/program function is active
- manual operation is active
(6) 16-segment display + dim. units
two-digit, green; for the unit °C/°F and symbols for h, min, %
In addition, the current segment number (program), the parameter set or any
two-place letter/number combination can be displayed through the setup
program.
The displays are configurable.
v Chapter 8.7 “Display “diSP””

19
5 Operation
5.2 Level concept
The parameters for making the settings on the instrument are arranged at different
levels.

H Time-out
If no key is pressed for 30sec, the instrument returns to normal display.
v Chapter 6 “Operator level”
v Chapter 7 “Parameter level”
v Chapter 8 “Configuration”
v Setup/Display - Operation/Time-out

5.3 Level inhibit

The access to the individual levels can be prevented.
Code Operator level Parameter level Configuration level
0 enabled enabled enabled
1 enabled enabled inhibited
2 enabled inhibited inhibited
3 inhibited inhibited inhibited
h Go to code entry with P and D (simultaneously for >5sec).
h Alter code with P (display blinks!)
h Enter code with I and D. Ex-factory: all levels enabled.
h Return to normal display with X or automatically after approx. 30sec
The parameter and configuration levels can also be inhibited via the binary function.
v Chapter 8.6 “Binary functions “binF””

20
 5 Operation
5.4 Entries and operator prompting

Entering values When entries are made within the levels, the parameter symbol is shown in the lower
display.
Select parameter Alter parameter

P
I/D I
IIIIIIIIIIIIIIIII

IIIII

IIIII
IIIIIIII IIIIIIII
D

h Select parameter with I or D

h Change to entry mode with P (lower display blinks!)
h Alter value with I and D
The value alters dynamically with the duration of the key stroke.
h Accept the setting with P, or automatically after 2sec
or
h Cancel entry with X.
The value is not accepted.

Entering times When entering times (e.g. timer time), the time unit is shown in addition.
Select parameter Alter parameter

P
I/D I
IIIIIIIIIIIIIIIII
IIIII

IIIII

IIIIIIII IIIIIIII
D

The highest time unit of the display is shown for the unit.
If, for instance, “h” is shown for the hour, then the time format for the value is hh:mm.
h Select parameter with I or D
h Change over to the entry mode using P (lower display blinks!)
h Alter value with I and D
The value alters dynamically with the duration of the key stroke.
h Accept the setting with P or automatically after 2sec
or
h Cancel entry with X.
The value is not accepted.

21
5 Operation
5.5 Operation of the fixed-setpoint controller

Normal display Manual mode

Altering the In normal display:

setpoint
h Alter the present setpoint with I and D
(the value is accepted automatically)

Manual mode In manual mode, the controller output can be altered by hand.
h Change to manual mode with X (press for more than 2 seconds)
The output appears in the lower display. The hand symbol and the unit “%” light up in
addition.
h Alter the output with I and D
In the case of a modulating controller, the actuator is opened or closed using the keys.
The various levels can be accessed from the manual mode.
h Return to the normal display with X (press for more than 2 seconds)
The output entry on a changeover is configurable. The manual mode can be inhibited.
v Chapter 8.2 “Controller “Cntr””
Additional operating options for the fixed-setpoint controller can be implemented via
the binary functions.
v Chapter 8.6 “Binary functions “binF””

22
 5 Operation
5.6 Operation of the program controller
Normal display Program is running

Altering the setpoint Program pause

Normal display No program run in normal display, the controller controls to the selected setpoint.

Altering the From normal display:

setpoint
h Change to setpoint input with D
h Alter the present setpoint with I and D
(the value is accepted automatically)

Starting the From normal display:

program
h Start program with I
(the ramp symbol lights up!)
A delay time can be configured through the setup program. When the delay time has
elapsed, “Strt ” is shown in the lower display, and then the program is processed.

Canceling the When the program is running:

program
h Cancel program with I

Pausing the When the program is running:

program
h Pause program with X (press for more than 2 seconds)
(the lower display blinks!)
h Continue with X (press for more than 2 seconds)

The program is canceled in the event of a power failure.

Additional program control functions via binary functions.
v Chapter 8.6 “Binary functions “binF””

23
5 Operation
5.6.1 Entering programs

Function A setpoint profile can be implemented with a maximum of 8 program segments.

Entry on the The instrument must be configured as a program controller/generator.

instrument
v Chapter 8.3 “Generator “Pro”” (Function)
Configurable time base: mm:ss, hh:mm und dd:hh (s=seconds, m=minutes, h=hours,
d=days).
v Chapter 8.3 “Generator “Pro”” (unit)
The segment setpoints (SPP1 — SPP8) and segment times (tP1 — tP8) are set at the
operator level (program data).

24
 5 Operation
The program segments (up to eight) are defined by the segment setpoint and the seg-
ment time.

P P
I
IIIIIIIIIIIIIIIII

IIIII

IIIII
IIIIIIII IIIIIIII
D

P
I
IIIIIIIIIIIIIIIII

IIIII

IIIII
IIIIIIII IIIIIIII
D

P
I
IIIIIIIIIIIIIIIII

IIIII

IIIII
IIIIIIII IIIIIIII
D

P
I
IIIIIIIIIIIIIIIII
IIIII

IIIII
IIIIIIII IIIIIIII
D

Entry through The setup program (accessory) features a user-friendly program editor, with a
setup program graphical presentation of the program profile.

Additional - Start at the process value

functions via the - Response to over/underrange
setup program
- Repeat program
- Setpoint input (ramp/step)
- Process is controlled to the most recent setpoint
- Delay time
- Program editor/management with graphical preview
- Up to four control contacts can be programmed segment by segment
- Parameter sets can be assigned segment by segment

25
5 Operation
5.6.2 Shifting the program profile
The function “External setpoint with correction” can be used to shift the program
profile upwards or downwards (configurable through the setup program only).

The external setpoint is defined via an analog signal.

v Chapter 8.2 “Controller “Cntr””

26
 6 Operator level
Access

Process data The four setpoints are displayed and edited here, and additional process variables are
“Proc” shown in accordance with the configuration.
Symbol Meaning
S P 1 Setpoint 1 (editable)
S P 2 Setpoint 2 (editable)
S P 3 Setpoint 3 (editable)
S P 4 Setpoint 4 (editable)
S Pr Ramp setpoint (only if configured)
InP1 Measurement of analog input 1
InP2 Measurement of analog input 2 (only if available)
F1 Calculated result of math formula 1 (only if available)
F2 Calculated result of math formula 2 (only if available)
y Controller output
trun Program run time (only with program controller/generator)
trES Residual program time (only with program controller/generator)
t1 Timer: time 1 (only if configured)
t2 Timer: time 2 (only if configured)

27
6 Operator level
Definition of the program times
w

(1) (2)

(3) (4)

tx t
(1) Program time (3) Segment time
(2) Residual program time (4) Residual segment time

User data “USEr” Any number of parameters (up to eight) can be displayed and edited here using the
setup program.
v Setup/Configuration level/Display - Operation/User data
The user himself can assign the symbol that is to be displayed for each parameter.
Otherwise the standard symbol is used. Any letters and numbers are permitted that
can be displayed in a 7-segment display.

Program data A program with up to eight segments is defined here, via the segment setpoints
“Pro” SPP1 ... SPP8 and segment times t P 1 .. . tP 8 .
This can only be accessed when the instrument is configured as a program controller/
generator.

28
Aspect: colourless, clear, free from oil and grease

Water constituents + caracteristic values Unit

pH-value under consideration of the SI-index 7 to 9

Saturation index (SI) (Delta pH-value) - 0,2 < 0 < + 0,2
Total hardness of water °dH <6
Conductivity müS/cm 10 .. 500
Filtered substances mg/l < 30
Chlorides mg/l < 100
Free chlorine mg/l < 0,5
Hydrosulphide H2S mg/l < 0,05
Ammonia (NH3/NH4+) mg/l <2
Sulphate mg/l < 100
Hydrogen carbonate mg/l < 300
Hydrogen carbonate / Sulphate mg/l >1
Sulphide mg/l <1
Nitrate mg/l < 100
Nitrite mg/l < 0,1
Dissolved ferrum mg/l < 0,2
Manganese mg/l < 0,1
Free aggressive carbon acid mg/l < 20
EC - Declaration of conformity

The manufacturer: Lahntechnik GmbH,

Taunusstraße 10
D-56377 Nassau
Tel.: +49(0)2604-9555-0

herewith declares that the following products:

Product designation: Water recooler / Oil recooler

Type designation: AC, BL, BR, CH, LM, UC

comply with all essential requirements of the Machinery Directive (2006/42/EC).

In addition, the machinery is in conformity with the EC Directives (2006/95/EC) relating to
electrical equipment and (2004/108/EC) relating to electromagnetic compatibility and
(RL/97/23/EC) relating to pressure equipment.

The following harmonized standards were used:

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

DIN EN 60204-1 Safety of Machinery – Electrical Equipment of Machines, Part 1:

General Requirements

DIN EN 378:2008 Part 1 to 4 Refrigerating Systems and Heat Pumps

The manufacturer is certified according to DIN ISO 9001:2008 by ZDH-Zert, Reg.-No.: Q1 0105127

Responsible for documentation: Mr. Lars Gemmer, Tel.: +49(0)2604-9555-112

Nassau, 10 Dec. 2009

Dieter Keuser
Managing Director
 Annex 12: Spare Parts Recommendation

unit type BL 008-01

item no. 1000000608001

recommende- ME designation 1 designation 2 order no.

damount
1 piece compressor for R134 a SC 18 GHX 3001009900120
1 piece axial fan R09R-3123A- 3101189900090
1 piece pump T-601 3502009900273
1 piece microprocessor controller PTR 3401609900201
with sensor
1 piece contactor 3RT 1016-2AP01 3802139900103

32-2008 13