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Huber Pilot ONE Unistat T305 User Manual

Huber Pilot ONE Unistat T305
100 pages
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Unistat®
T300 Series

Table of Contents

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Huber Pilot ONE Unistat T305 Specifications

General IconGeneral
BrandHuber
ModelPilot ONE Unistat T305
CategoryControl Unit
LanguageEnglish

Summary

Unistat® LED diagram

Operating states

Describes the meaning of illuminated LEDs and their states.

Layout of the "Home" Screen

1 Introduction

1.1 Details on the declaration of conformity

Information on compliance with European Directives.

1.2 Safety

1.2.1 Symbols used for Safety Instructions

Explains pictograms and signal words used in safety instructions.

1.2.2 Representation of safety identifiers

Overview of pictograms used as safety identifiers in the manual.

1.2.3 Proper operation

Guidelines and warnings for correct and safe operation of the unit.

1.2.4 Reasonably foreseeable misuse

Describes potential misuses and their consequences.

1.3 Responsible bodies and operators – Obligations and requirements

1.3.1 Obligations of the responsible body

Outlines duties of the body responsible for the unit's safety and operation.

1.3.1.1 Proper disposal of resources and consumables

Instructions for correct disposal of materials and consumables used.

1.4 General information

1.4.1 Description of workstation

Details about the control panel and workstation setup.

1.4.2 Safety devices to DIN 12876

Information on safety devices as per DIN 12876 standard.

1.4.3 Further protective devices

Information on additional safety features and protective devices.

1.5 Exemplary illustrations of the cooling variants

1.5.1 Consequence of inadequate energy dissipation

Explains issues arising from poor energy dissipation.

2 Commissioning

2.1 In-plant transport

Instructions for moving the unit within the facility safely.

2.1.1 Lifting and transporting the temperature control unit

Procedures for safely lifting and moving the temperature control unit.

2.1.2 Mounting/removing leveling feet

Steps for attaching or detaching the unit's leveling feet.

2.1.3 Positioning the temperature control unit

Guidance on how to correctly position the unit.

2.2 Transportation lock

2.2.1 Releasing the transportation lock (operating position)

How to unlock the transport mechanism for operation.

2.2.2 Tightening the transportation lock (transport position)

How to secure the transport mechanism for transport.

2.2.3 Releasing transportation lock Type C

Specific steps for releasing Type C transport lock.

2.3 Unpacking

2.4 Ambient conditions

2.4.1 EMC-specific notes

Notes regarding electromagnetic compatibility requirements.

2.5 Installation conditions

2.6 Recommended temperature control and cooling water hoses

Advice on selecting and using appropriate hoses.

2.7 Wrench sizes and torques

Table of required tools and torque settings for connections.

2.8 Temperature control units with water cooling

2.9 Temperature control unit for outdoor installation incl. winter operation

2.10 Preparations for operation

2.10.1 Unscrewing/activating the leveling feet (if any)

How to adjust or prepare the unit's leveling feet.

2.10.2 Opening/closing valves

Instructions for operating the unit's valves.

2.10.3 Locking/unlocking the expansion vessel [18]

Procedures for managing the expansion vessel's lock.

2.10.3.1 Mounting the isolating sleeve (locking the expansion vessel)

How to install the isolating sleeve to lock the expansion vessel.

2.10.3.2 Removing the isolating sleeve (unlocking the expansion vessel)

How to remove the isolating sleeve to unlock the expansion vessel.

2.11 Connecting an externally closed/open application

2.11.1 Connecting an externally closed application

Steps for connecting closed-loop external applications.

2.11.2 Connecting an externally open application (bath)

Steps for connecting open-loop external applications.

2.12 Connecting to the power supply

2.12.1 Connection using socket with protective earth (PE)

How to connect via a grounded power socket.

2.12.2 Connection via hard wiring

How to connect the unit using direct electrical wiring.

2.12.3 Converting the power supply connection

How to change the unit's power supply settings.

2.12.4 Connecting the functional earth

How to connect the unit's functional earth terminal.

3 Function description

3.1 Function description of the temperature control unit

Overview of the unit's primary functions and capabilities.

3.1.1 General functions

Describes the general operational characteristics of Unistat units.

3.1.2 Other functions

Details additional features like pump control, cascade control, and interfaces.

3.2 Information on the thermal fluids

3.3 To be noted when planning the test

3.4 "Pilot ONE®" controller

3.4.1 Functional overview of "Pilot ONE®"

Provides a summary of the Pilot ONE controller's functionalities and E-grade variants.

3.6 Clock/event function

3.6.1 Rechargeable accumulator

Information about the internal battery for the clock function.

3.6.2 Programmable event function

How to set up timed events and alarms.

3.7 Operation via the touch screen

3.8 Display instruments

3.8.1 The touchscreen [88]

Detailed description of the touchscreen's functions and use.

3.8.2 The LED-Indicator Temperature [90]

Explanation of the temperature indicator LED.

3.8.3 The LED-Indicator Flow Chart [91]

Explanation of the flow chart indicator LED.

3.8.4 The LED-Indicator Status [92]

Explanation of the status indicator LED.

3.9 Control instruments

3.9.1 The touchbuttons

Details the functions and assignable roles of the touchbuttons.

3.9.2 The categories

Explains how controls are grouped into categories.

3.9.3 The sub-categories

Explains how categories are further divided into sub-categories.

3.9.4 The dialogs

Describes how dialog screens are presented and navigated.

3.10 Function examples

3.10.1 Display of software version

How to view the unit's software version information.

3.10.2 Start & Stop

Procedures for starting and stopping temperature control processes.

3.10.3 Copying the settings to a data carrier

How to save and load unit settings using a USB drive.

3.10.3.1 Saving to a USB flash drive

Step-by-step guide for saving settings to USB.

3.10.3.2 Loading from a USB flash drive

Step-by-step guide for loading settings from USB.

3.10.4 Restore factory settings

How to reset the unit to its default factory configuration.

3.10.4.1 Restore to factory settings without overtemperature protection

Resets settings excluding overtemperature protection parameters.

3.10.4.2 Restore to factory settings including overtemperature protection

Resets all settings, including overtemperature protection.

4 Setup mode

4.1 Setup mode

General information and procedures for accessing setup mode.

4.1.1 Turning on the temperature control unit

Step-by-step guide for powering on the temperature control unit.

4.1.2 Turning off the temperature control unit

Step-by-step guide for powering off the temperature control unit.

4.1.3 Setting the overtemperature protection

How to configure the unit's overtemperature protection settings.

4.1.3.1 General information on the overtemperature protection

Explains the function and importance of overtemperature protection.

4.1.3.2 Setting "OT limit: heating"

How to set the heating limit for overtemperature protection.

4.1.3.3 Setting "OT expansion vessel"

How to set the overtemperature limit for the expansion vessel.

4.1.3.4 Setting "Process Safety"

How to configure the "Process Safety" shutdown mode.

4.1.3.5 Monitoring via "Display OT values"

How to view current overtemperature protection values.

4.1.4 Testing overtemperature protection for functionality

Procedure to verify the overtemperature protection system.

4.1.5 Adjusting the Delta T limiter

How to set the Delta T limit to prevent application damage.

4.1.5.1 Changing the Delta T limiter

Steps to modify the Delta T limiter value.

4.2 The temperature control circuit

4.2.1 Select temperature control: Internal or process

How to choose between internal and external temperature control modes.

4.2.2 Temperature control to internal temperature

How the unit controls temperature using its internal sensor.

4.2.3 Temperature control to process temperature

How the unit controls temperature using an external process sensor.

4.2.4 Delta T limiter

Explains the function of the Delta T limiter.

4.2.5 Monitoring the Pt100 temperature sensors

How the unit monitors the status of Pt100 sensors.

4.2.6 Optimum control parameters for optimum temperature control

How to adjust control parameters for best performance.

4.2.7 Sub-category: “Select auto/expert mode”

How to switch between automatic and expert control modes.

4.2.8 Sub-category: “Configuration auto

Settings for automatic configuration of control parameters.

4.2.8.1 Sub-category: "Find parameters"

How the unit automatically finds optimal control parameters.

4.2.8.1.1 Dialog entry: "Fast Identification"

Details the "Fast Identification" method for parameter tuning.

4.2.8.1.2 Dialog entry: "With Preliminary Test"

Details the "With Preliminary Test" method for parameter tuning.

4.2.8.1.3 Dialog entry: "Estimate Control Parameters"

How to estimate control parameters using thermal fluid data.

4.2.8.2 Sub-category: "Control Dynamics"

How to adjust the dynamics of the control loop (overshoot).

4.2.8.3 Sub-category: "Fluid Properties"

Settings related to the properties of the thermal fluid used.

4.2.8.3.1 Sub-category "Select Fluid"

How to select the thermal fluid from a list.

4.2.8.3.2 Sub-category: "Bath/Circulation Volume"

How to enter the filling volume of the thermal fluid.

4.2.8.3.3 Sub-category: "VPC/Bypass"

How to specify if a bypass is used.

4.2.8.3.4 Sub-category: "Show Fluid"

How to view entered fluid settings.

4.2.8.4 Sub-category: "Display parameters"

How to display set parameters in automatic mode.

4.2.9 Sub-category: “Configuration manual"

Manual configuration of control parameters.

4.2.9.1 Sub-category: "Change parameters"

How to manually adjust control parameters like KP, Tn, Tv.

4.2.9.1.1 Sub-category: "Internal"

How to change parameters for internal temperature control.

4.2.9.1.2 Sub-category: "Jacket"

How to change parameters for jacket temperature control.

4.2.9.1.3 Sub-category: "Process"

How to change parameters for process temperature control.

4.2.9.2 Sub-category: "Display parameters"

How to display manually set parameters.

4.2.9.3 Sub-category: "Control structure"

How to select the PID controller structure.

4.2.10 Sub-category: “Reset parameters"

How to reset control parameters to factory defaults.

4.2.11 Sub-category: “Display parameters"

How to display set parameters in automatic mode.

4.2.12 Setting the setpoint thresholds

How to set minimum and maximum temperature limits.

4.2.13 Setting the setpoint

How to enter and adjust the target temperature setpoint.

4.3 Adjusting the cooling capacity

4.3.1 Cooling water connection

How to connect the unit to the cooling water supply.

4.4 Filling, venting, degassing and draining

4.4.1 Externally closed application

Procedures for closed-loop applications.

4.4.1.1 Filling and venting externally closed application

Steps for filling and venting the system for closed applications.

4.4.1.2 Degassing externally closed applications

How to remove dissolved gases from the thermal fluid.

4.4.1.3 Draining externally closed applications

How to drain the thermal fluid from closed applications.

4.4.2 Externally open application

Procedures for open-loop applications.

4.4.2.1 Filling and venting externally open application

Steps for filling and venting the system for open applications.

4.4.2.2 Degassing externally open applications

How to degas thermal fluids in open applications.

4.4.2.3 Draining externally open applications

How to drain the thermal fluid from open applications.

5 Normal operation

5.1 Automatic operation

How to operate the unit automatically.

5.1.1 Temperature control

How to start and end temperature control processes.

5.1.1.1 Starting the temperature control process

Steps to initiate a temperature control process.

5.1.1.2 Ending the temperature control process

Steps to terminate a temperature control process.

5.1.2 Temperature control via a created temperature control program

How to run pre-programmed temperature control sequences.

6 Interfaces and software update

6.1 Interfaces at the "Pilot ONE®" controller

Details about the connection ports on the Pilot ONE controller.

6.1.1 10/100 Mbps Ethernet for RJ45 network sockets

Information on the Ethernet interface for network connectivity.

6.1.2 USB-2.0 interface

Information on the USB interface for data transfer and connection.

6.2 Interfaces at the "Unistat® Control ONE"

Details about the connection ports on the Unistat Control ONE unit.

6.2.1 Interfaces at the "Unistat® Control ONE" side

Specifics about the interfaces located on the unit's main body.

6.2.1.1 Removing the cover

How to access the unit's internal interfaces.

6.2.1.2 Jack ECS (External Control Signal) standby

Explanation of the External Control Signal interface.

6.2.1.3 Connector POKO (floating contact) alarm

Explanation of the POKO alarm connector.

6.2.2.1 Service interface

Interface used by service engineers for diagnostics.

6.2.2.2 Female RS232 Serial (with adapter cable)

How to connect via RS232 serial port.

6.2.2.3 Connection jack for Pt100 process controller sensor

Connection for external Pt100 temperature sensors.

6.3 Interfaces at the Com.G@te® (optional)

Information on optional Com.G@te module interfaces.

6.3.1 Jack LEVEL (Com.G@te® external only)

Level monitoring connection via Com.G@te.

6.3.2 Connector POKO (floating contact) alarm

POKO alarm connector info (cross-reference).

6.3.3 Jack AIF Reg-E-Prog

Analog interface for programmable inputs/outputs.

6.3.4 Jack ECS (External Control Signal) standby

ECS signal standby interface info (cross-reference).

6.3.5 Jack RS232/RS485 serial

Serial RS232/RS485 connection for remote control.

6.4 Firmware update

Instructions for performing a firmware update.

7 Service/maintenance

7.1 Messages from the temperature control unit

How to interpret and acknowledge unit messages.

7.2 Replacing the "Pilot ONE®" or "Unistat® Control ONE"

Procedures for replacing control components.

7.2.1 Replacing the "Pilot ONE®"

Step-by-step guide to replace the Pilot ONE controller.

7.2.2 Replacing the "Unistat® Control ONE"

Step-by-step guide to replace the Unistat Control ONE unit.

7.3 Maintenance

General maintenance procedures for the unit.

7.3.1 Function check and visual inspection

Regular checks for proper functioning and visual condition.

7.3.2 Replacing temperature control or coolant hoses

How to replace hoses for temperature control or cooling.

7.3.2.1 Replacing temperature control hoses

Steps for replacing temperature control hoses.

7.3.2.2 Replacing coolant hoses

Steps for replacing coolant hoses.

7.3.5 Emptying the drip tray (if present)

How to empty the unit's drip tray.

7.4 Thermal fluid inspection, replacement and circuit cleaning

Procedures for checking, replacing, and cleaning the thermal fluid circuit.

7.4.1 Thermal fluid inspection

How to inspect the thermal fluid for quality and condition.

7.4.2 Thermal fluid replacement

Procedures for replacing the thermal fluid.

7.4.2.1 Externally closed application

Steps for replacing fluid in closed applications.

7.4.2.2 Externally open application

Steps for replacing fluid in open applications.

7.4.3 Rinsing the thermal fluid circuit

How to rinse the thermal fluid circuit.

7.5 Cleaning the surfaces

How to clean the exterior surfaces of the unit.

7.6 Inspect the mechanical seal

How to inspect the unit's mechanical seal.

7.7 Plug contacts

How to handle the unit's plug contacts.

7.8 Decontamination/repairs

Procedures for decontaminating and preparing the unit for repair.

8 Shutting down

8.1 Safety instructions and basic principles

Safety guidelines to follow during shutdown procedures.

8.2 Switch-off

Steps for powering down the unit.

8.3 Draining the cooling water

How to drain the cooling water from water-cooled units.

8.3.1 Draining process

The procedure for draining cooling water.

8.4 Transportation lock

How to engage the transportation lock before moving the unit.

8.5 Packing

Instructions for packaging the unit for transport.

8.6 Shipping

Guidelines for transporting the unit.

8.7 Disposal

How to properly dispose of the unit and its components.

8.8 Contact data

Contact information for customer support and sales.

8.8.1 Telephone number: Customer Support

Phone numbers for customer support.

8.8.2 Telephone number: Sales

Phone number for sales inquiries.

8.8.3 Email address: Customer Support

Email address for customer support.

8.9 Certificate of Compliance

Information regarding compliance certifications.

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