Electronic laboratory regulator

type

KM-RX1004

OPERATING MANUAL
 Note!

It is essential to read and observe this operating manual before

installation and commissioning!
Observe and follow the safety instructions!
This operating manual contain the most important information
about installation, the electrical connection as well as operation,
parameterization and configuration of the device.
For further information, please refer to the operating manual
B 702030.0 available as PDF document. This manual also contains
the complete technical data of the device..

Contact
SAF Wärmetechnik GmbH
Weinheimer Str. 2a
D-69509 Mörlenbach

Tel.: +49 (0)6209 – 79796 – 0

Fax: +49 (0)6209 – 79796 – 29
E-Mail: info@saf-gmbh.de
Web: www.saf-gmbh.de

Changes and mistakes excepted!

Rev.: 04/2020

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Content
1. Introduction .................................................................................................... 5
1.1. Information on copyright and data protection ............................................... 5
1.2. Information for the operator .......................................................................... 5
1.3. Notes on signs and symbols ............................................................................ 6
1.4. Scope of delivery ............................................................................................. 7
2. Safety .............................................................................................................. 8
2.1. Intended use ................................................................................................. 10
2.2. Remaining risk ............................................................................................... 11
2.3. Safety instructions for the operating personnel ........................................... 12
2.4. Safety instructions for maintenance ............................................................. 13
3. Product description....................................................................................... 14
3.1. Execution and technical data ........................................................................ 14
3.2. USB interface ................................................................................................ 15
4. Assembly and connection ............................................................................. 16
4.1. Connection diagram ...................................................................................... 16
5. Commissioning .............................................................................................. 17
5.1. Connection diagram for the control of heating mantles .............................. 18
5.2. Adaption ....................................................................................................... 18
5.3. Setting ........................................................................................................... 19
6. Operation, configuration and parameter setting ......................................... 20
6.1. Operation ...................................................................................................... 20
6.1.1. Display and operating elements ................................................................... 20
6.1.2. Self-tuning, setpoint and manual operation ................................................. 20

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6.1.3. Ramp function / firing curve ......................................................................... 21
6.1.4. Level concept ................................................................................................ 21
6.1.5. Operator level (OPr) ...................................................................................... 22
6.2. Configuration (ConF) ..................................................................................... 23
6.2.1. Analog input .................................................................................................. 24
6.2.2. Controller ...................................................................................................... 25
6.2.3. Ramp function / firing curve ......................................................................... 26
6.2.4. Limit value monitoring .................................................................................. 27
6.2.5. Timer ............................................................................................................. 29
6.2.6. Outputs ......................................................................................................... 30
6.2.7. Binary function.............................................................................................. 32
6.2.8. Display and operation ................................................................................... 33
6.3. Parameterization (PArA) ............................................................................... 34
7. Maintenance and repair ............................................................................... 35
8. Decommissioning and disposal ..................................................................... 36

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1. Introduction
This operating manual is an essential aid for the successful and safe operation of the
temperature regulator type KM-RX1004 (hereinafter referred to as product). The
operating manual contains important information on how to operate the product
safely, properly, and economically. Observance of these instructions helps to avoid
dangers and to increase the reliability and service life of the product. The operating
manual must always be available and must be read and applied by every person who
assembles, commissions, operates and maintains the product.

1.1. Information on copyright and data protection

This operating manual must be treated confidentially. It should only be made
available to authorized persons. It may only be made available to third parties with
the written consent of the manufacturer. All documents are protected in accordance
with the copyright law. The passing on and duplication of documents, even in part,
as well as the exploitation and communication of their contents are not permitted,
unless this is expressly conceded in writing. Contraventions are punishable by law
and oblige to compensation.

1.2. Information for the operator

The operating manual is an essential part of the product. The operator must ensure
that the operating personnel take note of this operating manual and comply with the
specifications contained herein.

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1.3. Notes on signs and symbols
In this operating manual the following designations or symbols are used for safety
instructions and particularly important information:

Danger!

Draws attention to a potentially hazardous situation that could

result in extremely serious personal injury or material damage to
the product or its surroundings if the designated instruction is not
followed.

All warnings must be strictly observed!

Observe the safety instructions mentioned in each case and be particularly careful in
these cases!

Pass on all safety instructions to other users!

In addition to the instructions in this operating manual, the generally applicable

safety and accident prevention regulations must be observed!

Note!

This indicates special circumstances, the observance of which

ensures safe, proper and efficient handling of the product. All
instructions should be fulfilled in the interest of the intended use of
the product. Please pass on all instructions to other users as well!

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1.4. Scope of delivery
Check that the scope of delivery is complete and undamaged. Contact your supplier
immediately if parts are missing or defective.

• 1 x Laboratory regulator type KM-RX1004

• 1 x Operating manual

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2. Safety

Note!

Before commissioning the product, the safety instructions, the

installation instructions and the operating manual enclosed with
the product must be read and observed.

Please read the safety instructions carefully and observe the listed points! It is about
the safety of persons and equipment!

The product is primarily designed as a temperature regulator for electric heating

systems. Improper and improper use, installation, configuration, or operation in a
facility for a purpose other than that for which it was intended can cause
considerable personal injury and material damage!

The product must not be installed in the Ex-area! If process variables from the Ex-
area are processed with the product installed outside the Ex-area, all supply lines of
the product that lead into the Ex-area must be routed through approved safety
barriers!

Proper and safe operation of the product requires that it is carefully transported,
stored, professionally assembled and installed. This product may not be operated
unattended and may only be installed and commissioned by qualified persons who
are familiar with the installation, commissioning and maintenance of comparable
products and the equipment in which the product is used. The operating personnel
of the facility in which the product is used must be instructed in the operation of the
device by qualified persons.

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Please note

• the contents of this operating manual for the installation and operation of
the device, in particular the installation instructions, the commissioning and
the notes in bold
• the relevant safety regulations for the installation and operation of
electrical systems
• to keep this operating manual in a safe place for later use

The regulations mentioned in this operating manual apply in all EU countries. When
using the device in a country outside the EU, the relevant national regulations must
be observed.

Danger!

The product is an electrical equipment.

Therefore, it may only be commissioned by trained personnel.
Connection, maintenance and repair must only be carried out by
trained, qualified and competent personnel

Danger!

The product is not a safety temperature limiter according to

DIN EN 60730-1!

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2.1. Intended use
The product is only considered to be operated as intended if the following points are
considered and observed:

• The product may only be operated in the limited power range.

• The product may only be operated in the limited operating temperature
range.
• Only authorized persons may work on the product.
• The safety and operating instructions in this operating manual must be
observed.
• The operating instructions of the operator must be observed.
• The statutory accident prevention regulations must be observed.

The following is considered improper operation:

• operation in hazardous areas,

• operation by unauthorised persons,
• operation in disregard of safety regulations,
• operation with deactivated, modified / defective safety devices

Any other use or use beyond this is considered improper use. The operator alone is
liable for any damage resulting from this. This also applies to unauthorised
modifications to the product.

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2.2. Remaining risk
Even if all safety regulations are observed, a residual risk remains when operating
the product.

All persons working with the product must be aware of these residual risks. They
must follow the instructions that prevent these residual risks from leading to
accidents or damage.

Danger!

Penetration of moisture by water or chemical liquids!

(can cause dangerous to life-threatening electric shocks!)
If moisture gets on or into the product, do not touch it.
Immediately disconnect the product from the power supply by
disconnecting the power supply and secure it against unauthorized
reconnection.
Do not put a damp or wet product back into operation!

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2.3. Safety instructions for the operating personnel

Note!

The product must be operated in accordance with the respective

national regulations, regulations of the employers' liability
insurance associations and the Occupational Safety Act.

Danger!

The product may only be used in a technically perfect condition and

for its intended purpose, in a safety-conscious and risk-conscious
manner and in compliance with these operating manuals!
All faults and especially those that could impair safety must be
eliminated immediately!
The product must not be operated unattended.
Any person entrusted with the installation, commissioning,
operation or maintenance of the product must have read and
understood these operating instructions completely before starting
work - in particular point 2 "Safety". The legally permissible
minimum age must be observed.
The operating manual must always be kept to hand with the
product.
No liability is accepted for damage and accidents resulting from
failure to observe the operating manual.
Only use trained and instructed personnel!

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2.4. Safety instructions for maintenance
The product must be checked by the operator at regular intervals for safety and
proper functioning in accordance with the applicable regulations.

Only testing in accordance with DGUV V3 is permitted!

Danger!

Repairs to the product can cause serious injury or death by electric

shock)!
Repairs may only be carried out at the manufacturer's works!

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3. Product description
This ready-to-plug-in temperature regulator in a stable plastic housing is designed
for a total power output of up to 2300 W (10 A). The temperature regulator is
particularly suitable in the laboratory for the temperature control of heating mantles
or other heating systems. The main switch isolates the temperature regulator 2-pole
from the mains. A support clamp is located on the rear side as a clamping device for
attaching the temperature regulator to a stand.

3.1. Execution and technical data

Nominal voltage : 230 V / 50 Hz

Nominal power : max. 2300 Watt resistive load

Control behaviour : PID (Control accuracy 0,5%)

Sensor breakage protection : Yes

Temperature range : 0 – 1200°C

Sensor type : Pt100, NiCr-Ni (type K) or FeCu-Ni (type J)

Sensor connection : Clamps

Alarm output : Clamps

Load connection : Earthed socket, max. 10 A resistive load

Power supply : 1,5 m supply cable with earthed plug

Main switch : 2-pole (illuminated)

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 Housing : Plastic ABS and PC

Dimensions : 205 x 75 x 140 mm (B x H x T)

Operating temperature : 0 – 50°C

Switching output : Relay 10 A resistive load

Display : LED-Display

Protection class : I

System of protection : IP20

EMC compatibility according to EN 61326

Electrical safety according to DIN EN 61010

3.2. USB interface

On the top of the housing you have the possibility to connect the control insert to
your computer via a “USB-A to Mini-B plug” cable.

The software for configuration and parameter setting via computer can be
downloaded via the following link:
https://www.jumo.net/zpv/software/softwaredownload?filename=322.exe&id=403

(Note: We assume no liability or guarantee for the topicality of the provided link.
Despite careful control of the content, we do not assume any liability for the content
of external links. For the content of the linked page is solely the operator responsible).

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4. Assembly and connection
The installation site must be free of vibrations. The product must not be installed
near motors, transformers, contactors and other inductive loads. The ambient
temperature at the installation location may be 0 - 50°C at a relative humidity of <
75% (without condensation). Aggressive gases and vapors can destroy the device.

The instrument is only intended for the intended applications.

4.1. Connection diagram

Note: Suitable temperature sensors upon request

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5. Commissioning
Before commissioning the product, the following must be observed:

• Do the nameplate details match your order data

• The mains voltage must correspond to the voltage specification on the type
plate
• The rated power of the connected consumer must not exceed the power
output on the type plate (ohmic load).
• A protective device must be provided to protect the cable from excessive
temperature in case of overload. The line protection according to VDE 0721
Part 1 §19 must ensure that the nominal value of the fuse is adapted to the
respective consumer and must be connected in series before the
temperature regulator. The maximum fuse rating is 16 A. A cable cross-
section of at least 1.5 mm² is recommended.
• Set the main switch on the front panel to "0".
• Plug the grounding plug into a grounding socket (please observe 5.1)
• Plug the consumer into the earthed socket and mount the temperature
sensor to the clamps.
• The alarm output is used to signal faults (e.g. over / undertemperature), it
is led out via clamps.

The required tests according to the standards and regulations mentioned under
point 2 "Safety" must be carried out and documented after completion of the electric
heating system or equipment.

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5.1. Connection diagram for the control of heating mantles

1 Heating mantle

2 Laboratory regulator

3 RCD adapter

5.2. Adaption
The product is delivered pre-configured with the basic settings described in the
operating manual. The operator must adapt the product to the controlled system of
the plant in which it is used. In particular, the maximum setpoint value must be
defined during commissioning.

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5.3. Setting
According to the following product operation, first set the control setpoint
temperature.

Then adjust the appropriate type of sensor to the sensor used. (see 6.2.1)

If necessary, you can also change other parameters.

Due to the PID behavior of the controller, the ACTUAL temperature usually oscillates
well above the adjusted SET temperature during the first heat-up. By activating self-
optimization in the controller, the control behavior can be optimized and thus the
overshooting of the ACTUAL temperature at the beginning can be avoided. (see
6.1.2)

Only experienced personnel should change the parameters.

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6. Operation, configuration and parameter setting
6.1. Operation
6.1.1. Display and operating elements

6.1.2. Self-tuning, setpoint and manual operation

Starting from the normal display, the following functions are available:

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6.1.3. Ramp function / firing curve

6.1.4. Level concept

The parameters for setting the controller are organized in different levels:

The different levels are also accessible in manual mode.

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Level locking (all levels are free at the factory):

6.1.5. Operator level (OPr)

Depending on the configuration, the following parameters are available:

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6.2. Configuration (ConF)

Note!

In the product, parameters are hidden if the required equipment is

not available. Factory settings are shown in bold in the following
tables.

Analogue sector:

For some parameters at the configuration level, the user can select from a range of
analog values. The following list shows all available signals.

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6.2.1. Analog input

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6.2.2. Controller
The controller receives the actual value from the analogue input.

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6.2.3. Ramp function / firing curve
The device can be operated as a fixed value controller with or without the ramp
function. A firing curve is also supported.

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6.2.4. Limit value monitoring
The device has two functions for limit value monitoring (Li1, Li2) each with 8 different
alarm functions (AF1 to AF8). Both output signals are available for the binary
functions.

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6.2.5. Timer
The timer issues an output signal which is available for the binary functions. Time-
limited control or a time dependent target value switching can therefore be realised.

The timer value is not ensured during a power failure.

The timer remains inactive after the power returns.

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6.2.6. Outputs
The configuration of the controller outputs is divided into binary outputs (OutL) and
analog outputs (OutA). The switching states of the binary outputs 1 to 3 (5) are
represented by the LEDs K1 to K3 (K5) (LED lights up = output active).

Binary outputs:

The instrument has one relay output (make contact, output 1) as standard and can
optionally be equipped with two (four) additional binary outputs (relay or logic
output; outputs 2 to 5).

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Analogue output:

The device can be optionally equipped with an analogue output (output 2).

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6.2.7. Binary function
Different functions can be triggered with the binary signals from the binary inputs,
limit monitoring and timer.

The binary functions for starting and stopping react to the rising edge of the
triggering signal. All other binary functions are status-controlled and high-active.

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6.2.8. Display and operation
Both displays and the function key can be individually adapted to the respective
requirements.

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6.3. Parameterization (PArA)

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7. Maintenance and repair
Repairs may only be carried out at the manufacturer's factory!

Inspection intervals according to DGUV regulation 3 must be observed!

Exchange of the internal fuses for the electronics module and the shockproof socket:

If the controller module has no function, the fuse for the controller unit may be
defective.

If the temperature regulator is working, but the connected consumer has no

function, the fuses of the shockproof socket can be defective.

The fuse holder for the controller unit is located on the rear of the controller. The
caps for the power fuses are located in the safety socket, which can be opened with
a screwdriver.

Replace the fuse with new fuses of the same value (controller module 1x 20 x 5 mm,
1 A fast acting; shock-proof socket 2x 20 x 5 mm, 10 A slow-blow).

Installation in reverse order.

Note on the stand clamp:

A stand clamp is located on the back of the controller to clamp support rods up to Ø
12 mm or to attach the controller to a stand.

This support clamp cannot be removed, as it also serves as a support for the
internal structure of the controller.

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8. Decommissioning and disposal

Only take the unit out of operation when it is switched off,

disconnected from the mains and secured!

Electronic devices are recyclable materials and do not belong in

the household waste! Dispose of the product at the end of its
service life in accordance with the applicable legal regulations.

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