Operating Instructions

Transcription

350L
Temperature Control Units
150S • 300S • 300(DG) • 301(DG) • 350L
Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Notes on safety
Range of application
Setting up
Switching the unit on
Switching the unit off
Changing the consumer. Shutting the unit down for more than one month. Switching the unit back on
Maintenance
Ordering replacement parts
Shipping the unit
Optional equipment
Troubleshooting
Technical data
27
28
28
30
32
32
32
34
34
34
35
36
Guidelines for connecting hoses
39
Service
41
1. Notes on safety
•
•
•
•
•
•
•
•
Emergency off: Press the yellow/red main switch on the temperature control unit (when present) or
pull out the plug.
Thermal oil is combustible under certain conditions, therefore:
– Do not place the unit in the vicinity of heat sources (e.g. oven in die-casting plants).
– Keep thermal insulation clean at all times. Insulation soaked in thermal oil is a fire hazard.
– Repair leaks in the temperature control circuit (unit, connection lines, consumer, etc.) immediately.
Burning thermal oil can be extinguished with:
– AFFF spray foam fire extinguisher.
– Powder fire extinguisher (avoid using near dust-sensitive equipment, e.g. process controllers, computers, etc.)
– CO2 fire extinguisher (Backflash hazard, suitable only under certain conditions).
The suitable fire extinguisher shall be provided by the operator under consideration of the equipment
found in the room and all applicable safety regulations.
Never operate the unit without the side panels in place.
Protect the unit from sprays and cleansers containing solvents.
Injury hazard from leaking hot thermal oil.
– Before detaching connecting hoses in the temperature control circuit, cool the unit down and then
switch it off, depending on the magnitude of the outlet temperature.
– Check if the pump has stopped.
In equipment in which a malfunction of the temperature control system can be hazardous to operating
personnel or lead to destruction of the equipment, independent monitoring equipment to monitor the
process and switch the equipment off safely.
The unit shall not be placed in areas subject to explosion.
BA 150S-350L/0703/d/f/e
27
•
These Operating Instructions belong in the hands of the set-up and operating personnel.
Please ensure that the Operating Instructions are read. You will thereby save yourself unnecessary
costs and problems during the set-up as well as prevent downtime.
2. Range of application
The temperature control unit serves to heat or cool injection moulds and diecasting dies, extruders, calenders,
mixers and other consumers in areas not subject to explosion.
The units are designed for use with thermal oil up to the following maximum outlet temperatures: Model 150S:
150 °C (special version to 180 °C), Model 300S, 300(DG), 301(DG): 300 °C. Model 350L: 350 °C. For technical data,
see Section 12.
3. Set-up
3.1 Unpacking
Do not tip the unit. The heat transfer fluid remaining from the test run could run out, which could soak the insulation.
3.2 Placing the unit
The unit is designed for an ambient temperature of 10 to 40 °C. When placing the unit, ensure that there is sufficient ventilation. The distance between units or between a unit and the wall must be at least 4 cm
Place the unit on a level base and engage the wheel brakes.
The unit shall not be placed in the vicinity of heat sources, e.g. ovens in diecasting plants, as thermal oil is combustible under certain conditions.
3.3 Consumer checks
Before connecting the hoses between the consumer and the temperature control unit, the following checks shall
be performed on the consumer:
1 Check conduits for blockage.
2 Remove fluid and dirt residue using compressed air. Foreign bodies such as splinters can damage the pump.
3 Remove rust, scaling and oil residue, as these strongly restrict heat transfer between the consumer and the
heat transfer fluid and increase the pressure drop in the consumer. The Regloplas descaling unit, REG, can be
used to descale (→”Regloplas Temperature Control Units” brochure, “REG” Data sheet). The Regloplas System Cleaner, SR80, can be used to remove oil deposits (→ ”Regloplas Temperature Control Units” brochure,
“SR80” Data sheet).
4 When switching between water or steam to thermal oil, all water residue in the consumer and in the
connection hoses must be removed completely: Accident hazard during heat-up due to the pressure of
the steam thus created.
Proceed as described in Section 7.3.
3.4 Water quality
To prevent damage to the temperature control unit cooler, the water used must meet the following requirements:
Total hardness 4–18 °d
Ph value
7–9 KKG*
Conductance
max.1000 µS/cm
*KKG = Lime/carbon dioxide balance
3.5 Connection hoses
See also page 39.
– Outlet and inlet: Use only pressure and temperature resistant hoses (→ ”Accessories for temperature control
units” brochure).
For pipes, the thermal expansion must be taken into account.
The connection hoses shall be laid out such that they are protected from accidental contact.
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BA 150S-350L/0703/d/f/e
– Cooling water inlet: The pressure must be at least 3 bar. Use only pressure-resistant hoses. (→ ”Accessories
for Temperature Control Units” brochure). For the connection to the public mains, follow applicable guidelines
and safety regulations (e.g. connecting the unit via a system separator).
– Cooling water outlet: Must be free of backflow and always open. The hose shall be fastened such that any
vapour escaping at the beginning of the cooling process do not present a hazard.
Unsealed coolers can release thermal oil into the wastewater.
– Overflow of the expansion vessel: Must always be open.
For safety reasons, the cooler must always be connected.
3.6 Electrical connections
1 Mains voltage and frequency must match the information found on the rating plate.
2 Check the back-up fuse value according to the information in the electrical schematic in the electrical part of
the unit.
3 All applicable guidelines and safety regulations shall be followed when connecting the unit to the mains.
4 Markings of the connection cable strands in accordance with IEC standards:
3P E
yellow/green
black-brown/blue
3.7 Filling the heat transfer fluid
After checking the consumer, and connecting the hoses and electrical cables, proceed as follows:
1 Switch on the main switch on the unit (when present).
2 Open the vent and shutoff valves (when present).
3 Using a funnel, pour the thermal oil into the filling port slowly, until the level control’s red indicator lamp (when
present) of the level control at the top of the unit to the rear near the filling port extinguishes. Minimum filling
quantity in accordance with Section 12 of the Technical Data.
Warning: Every time the unit is filled with thermal oil, the unit and the temperature control circuit must be
vented as follows:
Switch the unit on. To prevent overheating of the heating elements due to initial trapped air in the temperature
control circuit, the outlet pressure in the unit is monitored by a minimum pressure switch. It will interrupt
heating when the pressure is too low (0.7 bar) and the flow alarm will be activated. To prevent the heater from
being switched on before the controller is switched on, a set-point value of approximately 10 °C is set and the
unit is vented at this value for approximately 10 minutes.
Recommended thermal oil: Regloplas RO150 (only for model 150S), RO300 or Therminol 66 (→ ”Accessories
for temperature control units” brochure).
As a preventative measure, we recommend the addition of the SR80 system cleaner (→ ”Regloplas temperature control units”, ”SR80” data sheet).
4 Do not close the vent valve at the consumer until thermal oil flows from it regularly.
5 As newly filled thermal oil usually contains moisture, the moisture must be removed as described in Section
7.3, Operations 4 and 5.
BA 150S-350L/0703/d/f/e
29
4. Switching on
4.1 Switching on with the RT30 controller (Fig. 1, Table 1)
1 Switch the unit/pump on using the corresponding switch.
After it is switched on, the RT30 runs a functional test for approximately 5 seconds. During this test, all displayed values will blink.
Once the test has been successfully completed, the actual value will appear in
the upper display and the set-point value in the lower.
2 Check the pump’s direction of rotation using the direction of rotation arrows.
If the direction of rotation is incorrect, switch the two phases in the unit’s plug.
Important: The rotary switch (when present) on the front plate must be in the
”+” position, i.e. pumping mode.
3 Continue filling the thermal oil only as long as the pump runs without interruption and the red display lamp of the level controller goes out, that is, sufficient
thermal oil is circulating in the temperature control circuit (unit, connecting
hoses, consumer, etc.).
4 Check the temperature control circuit (unit, connecting hoses, consumer, etc.)
for leaks.
5 Close the vent valve only when water runs out of it regularly.
Fig. 1: Controller RT30
Element
Meaning
Lamp
lights
MAIN
AL 1
Pump,
Control
Heating
Cooling
Level
control
Motor
contactor
Safety
thermostat
––
In operation
In operation
Insufficient
heat transfer
fluid in circuit
Thermal relay
has released
Temperature
too high
Table 1: Control and display elements with RT30 controller
4.1.1 Setting elements
– Set the set-point value using the ”∆“ and “∇“ keys.
– Neutral zone: This is set at the factory to +2 °C. Between the set-point value and the selected value of +2 °C,
the unit will neither heat nor cool.
4.1.2 Malfunction indicator
In the event of a sensor break, the message “Sbr” will be displayed. In the event of a sensor short circuit, the
message “Err” will be displayed.
In both cases, cooling is switched on, to ensure that the consumer is protected against overheating (display lamp
“Al 1”).
4.2 Switching on with the RT50 control system (Fig. 2)
1 Once the main switch on the unit has been turned on, “OFF” will appear in the display. The RT50 is now ready
for operation.
2 Switch on by pressing the “ON/OFF“ key. Depending on the programming, the set-point and actual values as
well as information on the operational state of the control system and unit will appear on the display.
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BA 150S-350L/0703/d/f/e
4.3 Operating and display elements (Fig. 2)
1 LCD display.
2 Keys for programming and selecting the display.
3 Alarm reset key.
4 On/Off key.
5 Key for leak-stop mode.
6 Key for suction and blow-out.
7 Key for switching between set-point values SP1 and SP2.
8 Key for operation with timer.
9 Keys for entering set-point value and programming.
10 Status line.
1
10
2
3
9
4
5
8
7
6
Fig. 2: Eléments de commande et d’affichage
Set-point and actual value displays
Once the control system has been switched on using the “ON/OFF“ key, the set-point temperature SP1 or SP2
(SP = Set-point) will appear in the lower part of the display, and in the upper part the actual value of the outlet
temperature S1 of the internal sensor in the heat transfer fluid or S2, the temperature of the external sensor in
the consumer (S = Sensor).
Keys for entering the set-point value and programming
Increasing or decreasing the set-point value, selecting the program position, changing the programmed values.
Timer key
If the RT50 is equipped with a timer, it is activated by this key. The unit is switched on and off via the timer.
Leak-stop key
Pressing this key puts the unit into leak-stop mode. Leak-stop mode is possible only when the set-point value is
between 0 and 250 °C max.
In leak-stop mode, the heating capacity is at a maximum of 60% to keep the thermal load on the oil due to the
reduced pumping capacity low.
The leak-stop function can be stopped by pressing the “ON/OFF“ key (wait until “OFF“ appears on the display).
The unit will then switch over to normal mode.
Suction key (evacuation).
Pressing this key initiates the evacuation sequence. The consumer connected to the unit is evacuated by the
pump.
Evacuation is possible only when the temperature of the heat transfer fluid is below the value programmed for
the run-out temperature “RT50 Operating Instructions“, Section 7.2, P 4.3). If this is not the case, the unit will
first cool the heat transfer fluid to this value.
The pump is switched off. Once the pump run-out time (“RT50 Operating Instructions“, Section 7.2, P 4.9), has
elapsed the pump is switched on again in the opposite direction of rotation. The pump then evacuates the consumer during the programmed evacuation time (“RT50 Operating Instructions“, Section 7.2, P, P 4.6).
After the programmed evacuation time, the unit switches off automatically. The suction process can be interrupted by pressing the “ON/OFF“ key. Pressing the “ON/OFF“ key again.
Alarm Reset key
Function:
– Manual reset of the alarm relay (e.g. switching off a horn). Once the malfunction has been corrected, the alarm
display can be erased by pressing the key once more.
– Manual acknowledgment of the automatic switch from control of the consumer temperature or cascade control to control of the outlet temperature in the event of a defective or missing S2 sensor in the consumer.
SP key
Switchover between set-point value 1 (SP1) and set-point value 2 (SP2).
Note: Set-point value switchover is possible only when no alarm is active.
Operation with code
To prevent the set/programmed values from being inadvertently changed, we strongly recommend the use of a
code. There are 4 possibilities:
– Entered value code
BA 150S-350L/0703/d/f/e
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– Set-point value code
– User setting 1 code
– User setting 2 code
Programming these codes is described in the “RT50 Operating Instructions”, Section 7.2, item 15.
Save/Reset to Factory or user setting
The RT50 control system offers the possibility to reload the factory settings easily and at any time.
In the same way, two different, customer-specific settings can be reloaded (user settings 1 and 2).
Programming these codes is described in the “RT50 Operating Instructions”, Section 7.2, item 14.
5. Switching off
5.1 Switching off with the RT30 controller
1 Cool the unit and the temperature control circuit to 80 °C or below.
2 Switch off the pump using the switch (→ Table 1).
5.2 Switching off with the RT50 control system
5.2.1 Using the On/Off key
The switching off process is initiated by pressing the “ON/OFF” key or via the timer. The switching off process
runs automatically depending upon the temperature of the heat transfer fluid as follows:
– Pump and control are switched off. The RT50 is still under power (stand-by mode). The display indicates
“OFF”.
5.2.2 By previous evacuation of the consumer
See Optional equipment, Section 10.
6. Changing the consumer. Shutting the unit down for more than one month. Switching the
unit back on
Before removing connection hoses, ensure that the unit is switched off and that all circuits are free of pressure.
The unit must be evacuated completely and stored in a dry location between 10 und 40 °C when not used.
Depending on the storage location, condensed water can develop, so the procedure described in Section 7.3, 2–5,
must be performed.
7. Maintenance
7.1 Periodic checks and maintenance procedures
To make the maintenance procedures easier, the RT50 control system is equipped with a service-interval display.
We recommend entering the corresponding service interval (e.g. 2000 hours). For programming, see “RT50 Operating Instructions”, Section 3.9.
We recommend that the following cleaning procedures are performed every time heat transfer fluid is added or
replaced. Please note that the following information is for 8 hours of operation daily. For operations with more
than one shift, these checks and maintenance procedures shall be performed in correspondingly shorter intervals.
Defective components shall be repaired or replaced immediately.
• Checks and maintenance procedures shall be performed by qualified personnel.
• Maintenance procedures on the electrical equipment shall be performed by a qualified electrician.
• Main plug shall not be pulled out until the unit is switched off.
• When working with pumps with magnetic couplings, be aware of danger from magnetic fields:
– People with pacemakers and/or implanted metal components must maintain sufficient distance
from the unit or should not perform maintenance operations on the pump.
– When pushing the magnetic coupling together, hold the motor such that no fingers could be
trapped as a result of magnetic strength.
– Maintain the necessary distance from computers, diskettes, credit cards, electrical watches, etc.
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BA 150S-350L/0703/d/f/e
7.1.1 Daily checks/maintenance
Check the temperature control circuit (unit, connecting hoses, consumer, etc.) for leaks. Fix any leaks immediately. Replace oily insulation immediately and remove any oil spills.
7.1.2 Monthly checks/maintenance
1 Check the inlet opening for the pump cooling for blockage. Clean unit from the inside to the outside using
compressed air.
7.1.3 Semi-annual checks and maintenance
1 Remove level switch and clean (→ Service).
2 Check the function of the safety thermostat.
Attention: The temperature control circuit (unit, connecting hoses, consumer, etc.) must be suitable for the
check temperature.
Enter the set-point value at the controller as follows: Model 150S: 160 °C (Version to 180 °C: set value to 190 °C).
Models 300S, 300(DG), Model 301(DG): 320 °C. Model 350L: 370 °C.
Heat the unit (temperature control circuit) to this temperature. With the RT30 controller, the “Safety thermostat” lamp will light up. The heat must switch off.
With the RT50 system, the outlet limit (“RT50 Operating Instructions”, Section 7.2, P 3.2) or maximum setpoint value (P 4.4) may need to be entered correspondingly. The alarm “Safety thermostat triggered” will appear on the display. The unit must now cool.
Attention: After these checks have been completed, reset to the original set-point value.
3 Check the electrical equipment such as grounding wires, contactors, firm positioning of the connection cables,
etc.
4 Check the oil after approximately 1000 hours of operation (corresponds to approximately half a year under 1
shift operation). The only way to tell if the oil can continue to be used is by analysing it, preferably performed
by the heat transfer fluid manufacturer. The dark colour is not indicative of the condition of the oil.
Approximately 1 litre of used oil is needed for the analysis. For safety reasons (escaping oil vapour is a fire
hazard), the oil must be removed at a low temperature (approximately 30 °C). The sample should be marked
with: address, date of removal, outlet temperature and type of heat transfer fluid.
The analysis is generally provided by the manufacturer at the actual cost.
5 Dismantle the solenoid valve for the cooler in accordance with the drawing (→ Service): Check the membrane
for scaling and damage. Ensure that the core and spring bolts move smoothly. Clean or replace components as
necessary.
7.1.4 Annual checks/maintenance
Always change the oil after approximately 2000 hours of operation (corresponds to about 1 year in 1 shift operation). This value is a guideline. Depending on operating conditions (temperature, narrow consumer cross-section,
primarily heating, etc.), the oil may need to be changed more frequently (→ 7.2).
7.2 Changing the thermal fluid
Change the thermal fluid as follows:
1 Evacuate the unit and consumer completely through their corresponding draining port.
2 Depending on the number of operating hours, clean the unit and consumer as described in Sections 7.3 and
7.4.
3 Refill as described in Section 3.7.
7.3 Switching the consumer from water to thermal oil
Procedure when condensation forms
1 Check the consumer for scaling and clean with the REG descaling unit (→ ”Regloplas Temperature Control
Units”, “REG” data sheet).
2 Attention: All water residues in the temperature control circuit (connection hoses, unit, consumer, etc.) must
be removed completely. Any vapour pressure presents a hazard during the heat-up phase. Procedure:
3 Fill thermal oil as described in Section 3.7.
4 Allow the unit to run at a temperature of 100 °C for at least 30 minutes.
BA 150S-350L/0703/d/f/e
33
5 When no more boiling sounds can be heard, increase the temperature to the desired operating temperature in
10 °C increments.
If boiling sounds continue, allow the unit to run at the same temperature unit no more boiling sounds can be
heard.
The unit is now ready for operation with thermal oil.
7.4 Cleaning
Please note when using solvents for cleaning: Due to danger of explosion, do not blow out the unit. It
must be rinsed thoroughly. When using a solvent, the manufacturer’s regulations on usage must be followed.
Thermal oil and solvents are combustible under certain conditions. Cleaning must not be performed in the
vicinity of heat sources.
We recommend that the following cleaning procedure be performed every time the heat transfer fluid is added or
changed. Conditions which are less than optimal will require that these procedures be made with greater frequency. This is particularly true for points 5 and 6.
1 Evacuate the unit through the draining port.
2 Clean the filter in the temperature control circuit.
3 Check the cooler for scaling; clean with the REG descaling unit if necessary.
4 Remove and clean the heating elements if the oil was very dirty or if the manometer pressure was high.
6 Dismantle the solenoid valve for the cooler in accordance with the sketch (→ Service): Check the membrane
for scaling and damage. Ensure that the core and spring bolts move smoothly. Clean or replace components as
necessary.
8. Ordering spare parts
Use only original spare parts.
To ensure quick and accurate delivery of spare parts, we need the following information
1 Type of temperature control unit
2 Model number
3 Voltage
4 Frequency
You will find this data on the unit’s rating plate.
5 Part number of the component. You will find this information on the corresponding drawing in these Operating
Instructions (→ Service) as well as on the schematic in the electrical section of the unit.
9. Shipping
Before shipping the unit, evacuate it completely through its draining port. Due to danger of freezing (collapse if
the cooling hoses), blow the cooler out at a low temperature as follows:
1 Enter a set-point value of 0 °C at the controller.
2 Ensure that the cooler’s solenoid valve is open.
3 Blow out the cooler with compressed air at a maximum pressure of 6 bar.
Do not tip the unit. Heat transfer fluid remaining in the unit could run out, presenting the danger of saturate the
insulation, the electrical components and thus danger of fire.
Use the original packing material.
Mark the “Top” clearly.
10. Optional equipment
10.1 Leak-stop mode and evacuation of the consumer through suction
By reversing the pump’s direction of rotation, the heat transfer fluid can be removed through the consumer by
means of vacuum.
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BA 150S-350L/0703/d/f/e
To note
– In leak-stop mode, the oil is subject to high thermal loading due to the greatly reduced pump capacity. For this
reason, the oil must be checked and changed, if necessary, more frequently. For the procedure, see Section
7.1.3, item 4, and Section 7.1.4.
– When suctioning, the volume of heat transfer fluid must be less than the volume of the expansion vessel (see
“Technical data”, Section 12). Otherwise, the unit will overflow.
Leak-stop mode with the RT30 controller
1 Switch the unit off as described in Section 5.1.
2 Set the rotary switch to”–“.
3 Switch the pump on.
Do not set the set-point value higher than 250 °C.
Leak-stop mode with the RT50 controller
Pressing the “Leak Stop” key switches the unit to leak-stop mode. Leak-stop mode is possible only when the setpoint value is between 0 and 250 °C (see “RT50 Operating Instructions”, Section 7.2, item 4.4).
Suction with the RT30 controller
1 Switch the unit off as described in Section 5.1.
2 Set the rotary switch to ”–“.
3 Switch the pump on.
4 Keep the rotary switch in the “A” position to evacuate the consumer.
Suction with the RT50 control system
Pressing the “Suction” key initiates the suction program. The consumer connected to the unit will be evacuated.
Suction is possible only when the medium temperature S1 lies below the programmed pump run-out temperature
(see “RT50 Operating Instructions”, Section 7.2, item 4.3). If this is not the case, the unit will cool to this temperature before initiating the program.
The suction procedure and the leak-stop function can be interrupted by pressing the “ON/OFF” key.
Pressing the “ON/OFF” key again will return the unit to normal mode.
During leak-stop mode, the set-point value shall not exceed the run-out temperature (“RT50 Operating Instructions”, Section 7.2, item 4.3).
10.2 Flow measurement (RT50 only)
Using the 䉴 key, move to “Display actual value”. Press the same key again to read the flow rate. To return to
the operating level, press the same key once more.
11. Troubleshooting
For RT30 controller malfunction messages, see Section 4.1.2.
For RT50 control system malfunction messages, see the “RT50 Operating Instructions”, Section 6. 3.
BA 150S-350L/0703/d/f/e
35
Temperiergerät
Régulateur de température
Temperature Control Unit
350L
Gerätenummer / Numéro d'appareil / Serial number
1260’0018’0001 – 1260-0018’0002
Technische Daten
Caractéristiques
Technical data
Max. Vorlauftemperatur
Température max. de sortie
Max. outlet temperature
350 °C
Wärmeträger
Fluide
Fluid
Oel
Huile
Oil
Füllmenge
Filling quantity
Volume de remplissage
32 l
Regler
Régulateur
Controller
RT50
Messart
Principe de mesure
Measuring mode
Pt100
Heizleistung
Puissance de chauffage
Heating capacity
24kW
Kühlleistung
bei Vorlauftemperatur
bei Kühlwassertemperaur
Puissance de refroid.
110kW
à la temp. de sortie
340°C
à la temp. de l'eau de refroid. 20°C
Cooling capacity
at outlet temperature
at cooling water temp.
Pumpenleistung/Typ
Fördermenge
Druck
Capacité de pompe/type
Débit
Pression
Pump capacity/type
Flow rate
Pressure
FM 65
max. 90 l/min
max. 10bar
Anschlüsse
Kühlwassernetz
Vor-Rücklauf
Raccordements
Réseau d'eau de refroid.
Sortie-retour
Connections
Cooling water mains
Outlet/inlet
3/4"
Flansch DN 20/PN 40
3/4"
Flasque DN 20/PN 40
3/4"
Flange DN 20/PN 40
Betriebsspannung
Tension d'alimentation
Operating voltage
3x400 V/50 Hz
Leistungsaufnahme
Puissance consommée
Power consumption
26.8 kW/41 A
Abmessungen B/H/T
Dimensions L/H/P
Dimensions W/H/D
470/1467/1491 mm
Farbe
Couleur
Colour finish
RAL 5013
REGLOPLAS
Temperiergerät
Régulateur de température
Temperature control unit
Type 350 L
Gerätenummer Numéro de l’appareil Number of unit
1260-0018
69
72
P1
73
61
2
64
E21-23
41
56
Y6
Y16
78
68a
Y13
68
66
60
67
46
S3
Q1
37
F3
58
B1
F5
84
40
35
M10
9
24.08.07
75
REGLOPLAS
Stückliste
Liste de pièces
Parts list
Pos./It.
2
35
37
40
41
46
56
58
60
61
64
66
67
68
68a
69
70
72
73
78
82
84
Artikel
Schloss
Pumpe
Ausdehnungsgefäss
System mit Isolation
Kühler
Schwimmer
Rückschlagventil
By-Pass
Filter Wassernetz
Manometer
Oelstandsanzeige
Wassernetz
Wasserablauf
Ablass-Stutzen
Ablass-Stutzen Pumpe
Einfüllstutzen
Ueberlauf
Vorlauf
Rücklauf
Pressluftanschluss
Strömungswächter
Dreiwegventil
Article
Serrure
Pompe
Vase d’expansion
Système avec isolation
Refroidisseur
Flotteur
Soupape de retenue
By-pass
Filtre réseau d’eau
Manomètre
Indicateur de niveau d’huile
Réseau d’eau
Sortie d’eau
Bouchon de vidange
Bouchon de vidange pompe
Tube de remplissage
Trop-plein
Sortie
Entrée
Connexion air comprimé
Surveillance de flux
Vanne à 3 voies
Item
Lock
Pump
Expansion vessel
System with insulation
Cooler
Float
Check-valve
By-pass
Filter water mains
Pressure gauge
Oil level gauge
Cooling water mains
Water drain
Drain plug
Drain plug pump
Filler pipe
Overflow
Outlet
Inlet
Conntction for compressed air
Flow monitor
Three-way valve
B1
Temperaturfühler intern
Sonde de température interne
Temperature sensor internal
E21-23
Heizung
Chauffage
Heater
F3
F5
Minimaldruckschalter
Sicherheitsthermostat
Pressostat de pression min.
Thermostat de sécurité
Min pressure switch
Safety thermostat
M10
Motor
Moteur
Motor
P1
Regler
Régulateur
Controller
Q1
Hauptschalter
Interrupteur principal
Main switch
S3
Schwimmerschalter
Interrupteur flotteur
Level switch
Y6
Y13
Y16
Magnetventil Kühlung
Magnetventil Absaugung
Magnetventil Pressluft
Electro-vanne refriodissement
Electro-vanne aspiration
Electro-vanne air comprimé
Solenoid valve, cooling
Solenoid valve, suction
Solenoid valve, compressed air
24.08.07
Pumpe / Pompe / Pump
FM 65
601.107
1
2
Ersatzteile
1 Pumpenkopf mit Magnetkupplung
2 Motor mit Magnetkupplung
Pièces de rechange
1 Tête de pompe avec accouplement magnétique
2 Moteur avec accouplement magnétique
Replacement parts
1 Pump head with magnetic drive
2 Motor with magnetic drive motor
36
BA 300L(D) 0601/dfe
RT50
Programming
Instructions
Outlet
S1
Set value
SP1
65
ºC
80ºC
Programming instructions control system RT50
Valid from software version 345
1. General comments
1
1
3. Operating elements and displays
1
4. Switching on
2
5. Switching off
3
6. Displays
3
7. Programming
18
8. Programming example
18
9. Control options
18
10. Operation with interface
18
11. Appendix
19
Subject to change without notice
1.
General comments
The Regloplas RT50 microprocessor control system consists of a control component with operating and display elements,
as well as a performance component with several inserts for accessories such as interfaces etc.
The RT50 control system was developed for use in temperature control unit (hereafter referred to as “units“). It enables
dialog between one or more units and the production facility computer as well as operation independent of the computer.
3. Control and indicating elements (Fig. 1)
1
2
3
4
5
6
7
8
9
10
LCD display.
Keys for programming and selection of displayed value.
Alarm reset key.
On/off key.
Key for leak-stop mode.
Key for drainage and blowing out modes.
Key for switching between SP1 and SP2.
Key for operation with timer.
Keys for setting the set-point value and programming.
Status line.
1
10
2
3
9
8
7
6
4
5
Fig. 1: Operating elements and displays
Set-point and actual value display
When the unit is turned on via the ON/OFF key, the set temperature
SP1 or SP2 (SP= set-point value) appears in the lower part of the
display while the upper part of the display indicates the outlet
temperature (actual value) S1 of the sensor in the heat transfer fluid
or S2 of the external sensor in the consumer (S=sensor).
Key for setting the set-point value and programming
Increase and decrease the set-point value and change programmed values.
Timer key
Activates the timer, when present. The timer turns the controller on and off.
PA RT50 0309/e
1
Leak-stop key
Pressing this key will switch the unit over to leak-stop mode. Leak-stop mode is possible only when:
If water is the heat transfer fluid, the set-point value should lie in the runout temperature range
(Section 7.2, P 4.3) of 0 to 80 °C max.
If oil is the heat transfer fluid, the set-point value should be in the range of 0 to 250 °C.
With leak-stop mode and oil, the max. heating capacity is 60 %, to keep the oil’s thermal load due to reduced pump
capacity low.
Leak-stop mode can be interrupted by pressing the ON/OFF key. Pressing the ON/OFF key again (after waiting for OFF to
appear on the display) will return the unit to its normal mode.
Suction key
Pressing this key initiates the evacuation program. The consumer connected to the unit is evacuated either by the pump
via suction or by blowing out with compressed air.
Evacuation is only possible when the temperature of the heat transfer fluid is below the programmed runout temperature
(Section 7.2, P 4.3). If this is not the case, the unit will cool the heat transfer fluid to this level.
The pump is switched off. Once the pump’s run-down time (Section 4.9) has elapsed, the pump is switched on again in
the opposite direction of rotation. It then empties the consumer during the programmed value for evacuation time
(Section 7.2, P 4.6).
The blow-out program using compressed air is activated once the pump’s run-down time has elapsed.
After the programmed evacuation time, the unit will switch itself off automatically. The suction and blow-out programs
can be interrupted by pressing the ON/OFF key.
Pressing the ON/Off key again (after waiting for OFF to appear on the display) will return the unit to its normal mode.
Note: In pressurised water units, the pressure relief valve closes 5 °C above the value runout temperature,
i.e. at max. 85 °C, and opens at the programmed runout temperature during the cooling process.
Alarm reset key
Functions:
Manual resetting of the alarm relay (e.g. horn switched off). As soon as the malfunction has been corrected, the
alarm display can be switched off by pressing this key once more.
Manual acknowledgment of the automatic switch-over from consumer temperature control or cascade control to
outlet temperature for defective or missing sensor S2.
SP key
Switch-over from set-point value 1 (SP1) to set-point value 2 (SP2) and vice versa.
The set-point values can also be activated by an external digital signal.
A switch-over can only take place if no alarm is active.
Operation with code
To prevent the set or programmed values from being changed inadvertently, we strongly recommend the use of a code.
There are four possibilities:
- Code input value
- Code set-point value
- Code user setting 1
- Code user setting 2
They can be programmed as described in Section 7.2, P 15.
The input value code for the RT50 is set to 50 at the factory.
Save/Reset for factory and user settings
The RT50 control system offers the possibility to change the factory setting simply and at any time.
In the same way, two different customer-specific settings can be reloaded (user settings 1 and 2).
Programming is described in Section 7.2, P 14.
4. Switching on
Once the main switch has been turned on, OFF will appear on the display. The RT50 is now ready for operation.
Switch the unit on by pressing the ON/OFF key.
Depending on the programming, the set-point and actual values as well as information on the operating condition of the
control system and unit.
See also Section 6.
If the unit is equipped with the suction equipment and the phase sequence is wrong, two phases are switched
automatically, so that the pump operates in positive pressure mode.
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PA RT50 0309/e
5. Switching off
The switching off procedure is initiated by pressing the ON/OFF key or by the timer.
The switching off program runs automatically as follows, depending on the temperature of the heat transfer fluid:
- Pump and control system are switched off. The RT50 is still powered (stand-by mode).
The display shows OFF.
- The pump continues to run. The unit cools until the temperature of the heat transfer fluid reaches the programmed run
temperature (Section 7.2, P 4.3). The pump and controller are then switched off. The RT50 stays in stand-by mode.
The display indicates OFF.
6. Displays
The following boxed text can appear on the display:
6.1 Operating displays
Outlet (upper value) as actual value: S1, internal sensor. S2, external sensor. Inlet sensor
S3.
Set-point value: SP1, SP2 or Extern.
External control via external set-point value entry.
External set-point Cascade control with external sensor S2.
Suction The unit will cool to the programmed runout temperature and then switch itself off automatically.
Service due This message indicates that the unit is due for maintenance. However, the unit can still be operated normally.
Programming: Section 7.2, P 3.8.
6.2 Status displays
Unit On, Off.
1 hour Timer operation.
Leak-stop
Leak-stop clock
Suction
Ser_A3 Interface and unit address (e.g. 3).
6.3 Alarm displays
The alarm display blinks every second. Malfunctions must always be corrected by qualified personnel.
For control Outlet sensor, Inlet or External.
If a sensor becomes defective, the will switch automatically to cooling.
During cascade control, a defective external sensor (S2, consumer) will cause the unit to control to the internal sensor S1.
The actual value of the internal sensor temperature at the time of sensor malfunction will be used as the new set-point
value. The alarm must be acknowledged.
Level too low
Wrong phase sequence
The pump will switch off a few seconds after it is switched on. Pump and control system remain switched off.
Motor current exceeded
Malfunction of motor contactor One or more phases is missing or no response was received from the motor contactor via
the auxiliary contact.
Safety therm. triggered The unit cools automatically.
Heater thermostat triggered (Model P140S). The unit cools automatically.
Maximum set-point exceeded The unit cools automatically.
Flow monitor triggered The heat switches off automatically.
Flow rate too low The heat switches off automatically.
PA RT50 0309/e
3
Dev. set-point/Actual, Set-point/External actual Set-point/Inlet have been exceeded or fallen short of. Unit and control
system continue to run normally.
Heating contact malfunction Cause: Despite command, the contact did not pick up.
Set-point or actual value is too high for leak-stop mode
External set-point signal interrupted or not present The unit cools automatically.
Analog/Digital transformer defective Unit and control system are switched off.
Program memory defective Unit and control system are switched off.
Microprocessor malfunction Unit and control system are switched off.
Calibrated values changed or wrong Unit and control system run normally.
Unit data in memory wrong or lost Unit and control system are switched off.
Press the alarm reset key twice: The initialisation data are imported anew.
If the initialisation data can be imported successfully, the normal display appears. If not, the alarm appears again.
Timer battery defective or dead Unit and control system continue to run normally.
Unit mains voltage too low Unit and control system are switched off.
Two flow monitors are connected at the same time
The message goes away as soon as only one flow monitor is connected.
No data available The factory or user settings contain no data.
Memory not present or defective e.g. memory not inserted.
6.4 Additional messages
In addition to the messages listed under 6.1. through 6.3, one of eight possible additional messages may be overlaid. See
Section 7.2, item 16.
7. Programming
7.1 Programming keys
See also Fig. 1.
Functions
S
- Change the set-point value.
T
- Change the line within the corresponding programming level.
- Change the value of the corresponding input line.
X
- Switch from the operating level to the program overview.
- Switch from one programming level to another.
W
- Back to the operating level.
- Back to the program overview.
7.2 Programming process
- The sheet, “Menu RT50” in the Appendix is critical to understanding the following:
- Numbering refers to the sheet, “Menu RT50”.
- The following text contains a “P” before the section number to differentiate the programming section from the rest of
the sections.
- Display depends on special equipment.
- Programming can be done with the control system switched on or off.
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PA RT50 0309/e
P1
Show actual value
On this level, the following actual values are shown:
P 1.1
Outlet
Outlet temperature. Temperature S1 of the heat transfer fluid (Sensor Sn1).
P 1.2
External
Consumer temperature. External sensor Sn2 in consumer.
P 1.3
Inlet
Inlet temperature S3 at unit entrance.
P 1.4
Heating/cooling cap.
Shows the current power as a percentage of the nominal power.
Example: Nominal power of the unit 9 kW. Value shown 33 %, i.e. the currently required power for the control
system is 3 kW.
A negative number indicates cooling.
P 1.5
Flow rate
Flow rate in l/min or GPM.
P 1.6
Pump current L1
Current, phase 1 of the pump motor in A.
P 1.7
Pump current L2
P 1.8
Pump current L3
P 1.9
Operating hours
Number of the unit’s operating hours.
P 1.10
Service after
Hours remaining until next maintenance service.
P 1.11
Software version
Software version being used.
P 1.12
Interface
Built-in interface (hardware), e.g. RS 485.
P 1.13
Protocol
Protocol installed (software), e.g. Profibus.
P 1.14
Address
Unit address when operating with an interface.
P 1.15
Day/time
Programmed day of the week and time
P2
Select language
P 2.1
Sprache Deutsch
P 2.2
Language English
P 2.3
Langue Française
PA RT50 0309/e
5
P3
User configuration
For P 3.1 and 3.2 see also Section 11, Abb. 2.
P 3.1
Deviation Set/Actual
Values for deviation above () or below (), with respect to
Set-point/outlet
Set-point/external
Set-point/inlet
Entry
xx °C
Setting range 0 to 99 °C
P 3.2
Outlet limit
Limitation of the maximum and minimum outlet temperatures, i.e.
Outlet limit, max
Outlet limit, min
Entry
xx °C
P 3.3
Minimum flow rate
Entry
xx l/min
Setting range 2 to 50 l/min
P 3.4
Interface
Address
Protocol
Number entry as described in Section 10.
P 3.5
Temperature display
Display in °C
Display in °F
P 3.6
Flow rate display
Display in l/min
Display in GPM
P 3.7
Set-point at start
Last active set-point
When switched on, the unit will control to the last active set-point.
Always SP1will control to the last set-point 1 (SP1) entered.
Always SP2
When switched on, the unit will control to set-point 2 (SP2).
P 3.8
P 3.9
6
Next service
The number of elapsed operating hours shows on the display.
Enter the number of operating hours until the next service procedure.
The value entered must be higher than the number of Operating hours shown.
Setting range: 0 to 99999 (value in hours).
PA RT50 0309/e
P4
Unit configuration
P 4.1
Heat transfer fluid
The type of heat transfer fluid is entered at the factory, depending on the type of unit.
Heat transfer fluid Water
Oil
P 4.2
External sensor type
Type pf external sensor Sn 2.
Resist. Therm. Pt 100
Thermocoup. K NiCr-Ni
Thermocoup. J Fe-CuNi
Thermocoup. T Cu-CuNi
P 4.3
Run-out temperature
See also Section 11, Fig. 2.
Before the unit is switched off by the OFF key or when suction is activated, the unit will first cool to the
temperature set in the next step.
Units with direct cooling: Value must be 0. This initiates automatic pressure release for 30 seconds after the unit is
switched off by the OFF key.
First cool to
Entry
xx °C
(then autom. off)
Setting range 0 to 80 °C. 0 = Function off. Leak-stop and suction modes not possible.
P 4.4
Maximum set-point
See also Section 11, Fig. 2.
The maximum set-point value can be set in this position. The value will vary with the type of unit. The value set
must not exceed the value Tmax. on the rating plate.
Max. setting
Set-point
Entry
xxx °C
See rating plate
on unit
Setting range 0 to 420 °C.
P 4.5
Evacuation options
Evacuation with pump
Evac. w/comp. air
P 4.6
Evacuation time
The suction or blow out time will vary with the type of heat transfer fluid used.
Evacuation time
Entry
xxx s
Setting range 0 to 500 s. Only displayed when accessory present.
P 4.7
Pump current
Pump current on
Rating plate
x.x A
Entered at the factory in accordance with the information provided on the rating plate.
Can be changed by ±10 % as needed.
PA RT50 0309/e
7
P 4.8
Pump dir. of rotation
The pump’s direction of rotation will be corrected automatically upon incorrect phase sequence.
(Possible only when the Suction option is present).
Dir.of rot. will be
corrected
yes
no
P 4.9
Pump run-out time
Maximum possible run-out time of the pump in s before the change in direction of rotation for evacuation by
means of suction or leak-stop mode.
Pump run-out time
before change in dir. of rot. xx s
Setting range: 3 to 30 s.
P 4.10
Power failure behav.
Last state
After a power outage, the unit will operate as it did before the power outage.
Stays off
After a power outage, the unit remains switched off.
P 4.11
Heating 2
Heating 2
Heating 2
P 4.12
inactive
active
Only possible in units with 2 heating levels.
Heating cycle time
Heating cycle time
Entry
xx s
Setting range 1 to 30 s
P 4.13
Cooling cycle time
Cooling cycle time
Entry
xx s
P 4.14
Suppress heating
Suppression of the heating command. The heating command will be suppressed during the period of time set.
Heating command
Suppress
xxx ms
Setting range 0 to 200 ms
P 4.15
Suppress cooling
Suppression of the cooling command. The cooling command will be suppressed during the period of time set.
Cooling command
Suppress
xxx ms
Setting range 0 to 200 ms
P 4.16
Pump. cooling medium
Activation of the extra pump in the cooling circuit (cooling system "SK").
Extra pump
no
Extra pump
yes
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PA RT50 0309/e
P 4.17
Func. of ext. contact
Switch on/off via external contact:
Ext. contact
Code 0
When the external contact is closed, the unit is switched off and the ON/OFF key blocked.
Ext. contact
Code 1
When the external contact is opened, the unit is switched off and the ON/OFF switch blocked.
Ext. contact
Code 2
The unit can be switched on and off via the external contact as follows:
Closing the external contact: Unit switches off.
Opening the external contact: Unit switches on.
Ext. contact
Code 3
The unit can be switched on and off via the external contact as follows:
Closing the external contact: Unit switches on.
Opening the external contact: Unit switches off.
For codes 2 and 3: Switching on and off via the ON/OFF key is always possible.
P 4.18
Level alarm
Pump run-out time
Entry
xx s
After the level monitor has been triggered due to insufficient level of heat transfer fluid, the pump will continue
to run after its set run-out time to prevent the unit from being switched off suddenly.
Refill time window
Entry
xx s
The refill time window is the maximum time the refill valve can be open. If the level is still insufficient after this
time has elapsed, the alarm message Level too low remains.
No. of insufficient
Levels before
Alarm
Entry
xx
The number of level insufficiencies before the alarm is triggered. It is set to 1 for approximately 30 minutes after
the last level insufficiency. Valid only for units using water as the heat transfer fluid (Section 4.1).
0 = Alarm counter off
Setting range 1 to 40
Alarm suppression
time after switch on
Entry
xx min
Once the power has been switched on (main switch) the heat transfer fluid can be refilled as often as desired
during the time period set.
0 = Function off.
Setting range 0 to 15 min
P 4.19
Pressure relief valve
Time delay
Valve
xx s
Time delay until the pressurised water unit’s pressure relief valve Y 8 opens.
0 = No delay. The set value may not be 0 for P 140S units.
Valid only when using water as the heat transfer fluid (Section 4.1).
PA RT50 0309/e
9
P 4.20
Viscosity
When flow measurement available, enter the kinematic viscosity in mm2/s at 20 °C.
When water is used as the heat transfer fluid (Section 4.1) the value 1.0 is entered automatically.
Kinematic
viscosity of medium
at 20 °C / 68 °F
Entry xx.x mm2/s
P5
Control
P 5.1
Type of control
Select the desired type of control:
PID Outlet
PID External
PID Inlet
Casc. External/outlet
Casc. Inlet/outlet
Casc. Cavity control
With sensor in outlet
With sensor in consumer
With sensor in inlet
With sensor in consumer and in outlet
With sensor in inlet and in outlet
With sensor in outlet and in mould cavity
At this level the operator selects the sensor(s) to be used. The control system can, for example, be set to
PID outlet, even if a sensor is in the consumer.
P 5.2
Control par. PID selection
Control par. PID fix
Control par. PID man.
The operator can choose between PID fix and PID man. For the fixed parameter sets, the operator can choose
between set 1 (strong reaction to control deviations) and set 10 (weak reaction to control deviations).
The units are set to set 5 when they leave the factory.
P 5.3
Par. set heating fix
Parameter set heating
Entry
xx
Par.set cooling fix
Parameter set cooling
Entry
xx
P 5.4
P heating in % Tmax
Entry
x.x %
Proportional band in %
xx °C
The proportional band in °C appears on the display, with reference to Tmax.
Setting range 0 to 50.0 %
I heating
Entry
xxxx s
10
Run-out time (integral) in seconds.
PA RT50 0309/e
D heating
Entry
xxx s
Rate time (differential) in seconds.
Capacity lim. heating
Entry
xxx %
Setting range 10 to 100 %
No heating command below the set value.
P cooling in % Tmax.
Entry
xx.x %
Proportional band in %
xx °C
The proportional band in °C appears on the display, with reference to Tmax.
Setting range 0 to 50.0 %
I cooling
Entry
xxxx s
Run-out time (integral) in seconds.
D cooling
Entry
xxx s
Rate time (differential) in seconds.
Capacity lim. cooling
Entry
xxx %
No cooling command below the set value.
Cooling dead zone
Entry
x.x °C
The cooling dead zone is the zone over the set-point in which cooling commands are suppressed.
Setting range 0 to 9.9 °C
P 5.5
Control par. casc. sel
Control par. casc. fix
Control par. casc. man
P 5.6
Fix cascade par. set
Entry
xx
P 5.7
Cascade amp.
Setting range 0 to 99.9
Cascade integral
Cascade differential
M.Diff.heat Int/Ext
Max. acceptable temperature difference between internal and external sensor during heating.
Setting range 0 to 420 °C. Enter a value not higher than Tmax.
M.Diff cool Int/Ext
Max. acceptable temperature difference between internal and external sensor during cooling.
PA RT50 0309/e
11
Setting range 0 to 420 °C. Enter a value not higher than Tmax.
P heat aux controller
I heat aux controller
D heat aux controller
P cool aux controller
I cool aux controller
D cool aux controller
Dead zone aux contr
These parameters should be entered by a control specialist.
P6
Offset
Offset can be used to compensate for errors caused by instrument leads, measurement errors from sensors,
etc.
P 6.1
Offset outlet sensor
Entry
0.0 °C
Setting range ±20 °C
P 6.2
Offset ext. sensor
Entry
0.0 °C
P 6.3
Offset inlet sensor
Entry
0.0 °C
P 6.4
Offset analog input
Entry
0.0 °C
P 6.5
Offset analog out. 1
Entry
0.0 °C
P 6.6
Entry
0.0 °C
P7
Analog output 1
On this level the measuring method is first chosen for analog output 1 and then the corresponding upper and
lower values are entered.
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PA RT50 0309/e
P 7.1
Outpt 1 Outlet 4-20mA
Lower end of scale
^
Entry 4 mA =
0.0 °C
Upper end of scale
Entry 4 mA ^=
0.0 °C
Entry P 7.2 to P 7.18 as P 7.1.
P8
Analog output 2
On this level (P 8.1 to P 8.21), analog output 2 is placed. It is programmed in the same way as analog output 1
was, as described in Section 7.1. The exception is that no upper and lower values can be entered for the outputs
Actual TE-FE and Actual TE-Cu.
P9
Analog input
The analog input is programmed in the same way as the analog output as described in Section 7.1
P 9.1
Analog input inactive
P 9.2
Analog input 4-20 mA
P 9.3
Analog input 0-20 mA
P 9.4
Analog input 0-10 V
P 10
Common alarm
On this level, the alarm relays (common alarm), when present, can be activated at the next malfunction.
P 10.1
Alarm repeat time
Entry
0s
Once this time has elapsed and the alarm has been acknowledged, the alarm (horn, lamp) is reactivated.
P 10.2
Alarm heating 1
Alarm H1 inactive
Alarm H1 active
P 10.3
Alarm heating 2
Alarm H2 inactive
Alarm H2 active
P 10.4
Alarm flow rate
Alarm flow inactive
Alarm flow active
P 10.5
Alarm flow monitor
Alarm flow ind. inact
Alarm flow ind. act
PA RT50 0309/e
13
P 10.6
Alarm level
Alarm level inactive
Alarm level active
P 10.7
Alarm pump current
Alarm P.curr. inact
Alarm P.curr. active
The following alarms always trigger the common alarm relay:
Sensor outlet defect
Sensor extern defect.
Contr. w/outlet sens
Phase seq wrong
Malf. motor contactor
Safetytherm.triggered
Cooling on
Max setpoint exceeded
Cooling on
Dev. sp/outl exceeded
Dev sp/outl exceeded
Dev sp/ext act excd.
Dev sp/ext act exdc.
Dev sp/inlet exceeded
Dev sp/inlet exceeded
Ext sp signal interrupted or not present
Analog-dig transf def
Memory chip defect
Malf. microprocessor
Calibration values changed or wrong
Unit mains voltage too low
No data present
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PA RT50 0309/e
P 11
Relay configuration
P 11.1
Relay K1 function
Relay K1 pick up
Relay K1 release
P 11.2
Relay K1 selection
The following selection is available:
K1 Common alarm
K1 Heat 1
K1 Heat 2
K1 Flow rate
K1 Flow indicator
K1 Level 1
K1 Level 2
K1 Pump current
K1 Dev set/outlet
K1 Dev set/outlet
K1 Dev set/extern
K1 Dev set/extern
K1 Dev set/inlet
K1 Dev set/inlet
K1 Temp. breakover
Actual value of the active sensor, through which the relay picks up or releases.
K1 Temp. breakover
Entry
xxx °C
Setting range 0 to Tmax.
K1 Band deviation
Band deviation, with respect to the active set point. For example, an entered value of 20 corresponds to a band
of 20°C above and below the set point.
K1 Band deviation
Entry
xx °C
K1 Control on
K1 Timer active
K1 Pump runs
K1 Level 1 reached
K1 Level 2 reached
K1 Heat 1 on
K1 Heat 2 on
K1 Cooling on
P 11.3
Relay K2
Programmed as described under Relay K1.
P 11.4
Relay K3
P 11.5
Relay K4
PA RT50 0309/e
15
P 12
Programming the timer
10 steps are available for programming the timer. A weekday or group of days of the week, a time, and the type
of time (On/Off time) must be programmed for each step. This means that to turn the unit on and off again
requires 2 steps.
The unused steps are set to inactive. On the second sublevel, it can be seen at a glance which steps are active
(On/Off) and which are inactive.
P 12.1
01 Day of the week
01 Monday
01 Tuesday
01 Wednesday
01 Thursday
01 Friday
01 Saturday
01 Sunday
01 Mo-Th
01 Mo-Fr
01 Mo-Sa
01 Mo-Su
P 12.2
Hour/minute
01 Time
Entry
xx:xx
P 12.3
Inactive/On/Off
01: Inactive
01: On
01: Off
The remaining steps are programmed as needed.
To ensure that the On and Off times are correct, the timer must be synchronised.
P 13
Synchronising the timer
P 13.1
Enter day
Day Monday etc.
P 13.2
Enter hour/minute
Enter hour/minute
Entry
00:00
P 14
Reset/Factory/User
For saving and loading set values.
P 14.1
Save as fact. setting
This can be programmed only at the factory.
P 14.2
Reset to fact. set
When this level is left, the factory settings will be reloaded.
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PA RT50 0309/e
P 14.3
Save user set 1
When this level is left, all currently programmed values will be saved as User settings 1.
P 14.4
Reset to user set 1
When this level is left, User settings 1 will be loaded.
P 14.5
Save as user set 2
When this level is left, all currently programmed values will be saved as User settings 2.
P 14.6
Reset to user set 2
By entering the correct code and leaving this level, User settings 2 will be loaded.
P 15
Change code
P 15.1
Code <Entry value>
Code
Entry
xxxx
The code must first be entered here.
Code <Entry value>
Change entry xxxx
The new code can be entered here. When this level is left, the new code is activated.
P 15.2
Code <Set-point>
Entry as 15.1
P 15.3
Code <Fact setting>
Entry as 15.1
P 15.4
Code <User setting 1>
Entry as 15.1
P 15.5
Code <User setting 2>
Entry as 15.1
P 16
Additional display
Select the additional display. It will appear after this level is left, in the operating level as the second to last line.
P 16.1
P 16.2
P 16.3
P 16.4
P 16.5
P 16.6
P 16.7
P 16.8
P 16.9
No additional display
Outlet
External
Inlet
Heat/cool cap.
Flow rate
Operating hours
Service after
Day/time
PA RT50 0309/e
17
8. Programming example
The sheet entitled “Programming example” shows the entry of an individual code and the programming of the deviation
between set-point value and actual value. See also sheets entitled “Menu RT50” and “Temperature limit values” in the
Appendix.
Entering the value 5 °C means that when the actual value exceeds the set-point value entered, the alarm Deviation Setpoint/Actual will appear on the controller display.
9. Types of control
The RT50 control system works with the following computer programs (control algorithms):
- PID control to outlet, inlet or external sensor. For this type of control, there are 10 fixed parameter sets for each of
heating and cooling as well as a manual set.
Cascade control with external and outlet sensors or outlet and inlet sensors. This type of control also has 10 fixed
parameter sets as well as a manual set.
9.1 Fixed parameter sets
To save the operator the time-intensive determination of the P, I und D control parameters for heating and cooling, the
fixed parameter set which best matches the application can be loaded.
In most cases, the operator can determine the best fixed parameter set for his application, by following these simple
rules:
1. Basic setting: Parameter set 5
2. If the set-point value entered is not attained after a reasonable amount of time, the next lower parameter set should be
selected (Example parameter set 4 instead of 5).
3. If the actual value exceeds the set-point value, or the set-point oscillates, the next higher fixed parameter set is chosen.
If none of these parameter sets results in the desired control, because the controlled system deviates from the standard,
an individual set can be entered.
Note: The set-point is reached most quickly when the actual value exceeds the set-point a bit. If an overshoot is not
acceptable, the operator must expect a somewhat longer heat-up time.
9.2 Fixed cascade set
Notes and procedure as described in Section 9.1.
10. Operation with data interface (optional equipment)
Control of the unit from the process control computer by connecting the “unit/process control computer”.
For selection of the protocol and address, see Section 3.4 of the Programming section.
Available protocols:
1
Arburg
4800 Bd
20 mA-CL
2
Engel
4800 Bd
20 mA-CL
3
Bühler Datacess
4800 Bd
RS 422 spec.
4
Firsttech
4800 Bd
20 mA-CL
5
Stork
1200 Bd
20 mA-CL
6
Ferromatik Milakron
4800 Bd
20 mA-CL
7
Klöckner Desma
4800 Bd
20 mA-CL
8
Demag Ergotech
4800 Bd
20 mA-CL
9
Krauss Maffei
4800 Bd
20 mA-CL
10
Dr. Boy
4800 Bd
RS 232
11
Euromap 17
9600 Bd
RS 485
12
Euromap 17
4800 Bd
RS 485
13
Euromap 17
2400 Bd
RS 485
14
Euromap 17
1200 Bd
RS 485
15
Sächsische Kunststofftechnik
4800 Bd
RS 485
16
CAN Demag Ergotech
615 kBit/s
Can RS 485
17
Müller-Weingarten
4800 Bd
RS 422 spec.
18
Engel
4800 Bd
RS 232
19
SPI
19200 Bd
RS 485
20
SPI
9600 Bd
RS 485
21
SPI
4800 Bd
RS 485
22
SPI
2400 Bd
RS 485
23
SPI
1200 Bd
RS 485
24
Bühler Dataspeed
4800 Bd
RS 485
25
Frech Datacontrol
9600 Bd
RS 485
26
Frech Datacontrol
4800 Bd
RS 485
27
Frech Datacontrol
2400 Bd
RS 485
28
Frech Datacontrol
1200 Bd
RS 485
29
CAN Demag Ergotech
500 kBit/s
CAN RS 485
18
PA RT50 0309/e
30
31
32
33
34
CAN Demag Ergotech
CAN Demag Ergotech
Euromap 17 Billon
Profibus DP
Ferromatik Milakron
250 kBit/s
125 kBit/s
9600 Bd
12 MBit/s
4800 Bd
CAN RS 485
CAN RS 485
RS 485
RS 485
RS 485
11. Appendix
Terminal markings
Temperature limit values
Technical data
Menu RT50
Programming example
Construction
PA RT50 0309/e
19
Terminal labels
No.
Label
Function
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
Output L
Output L
Output L
Output L
Output PE
Output N
Output L
Output PE
Output N
Output L
Output PE
Output N
Output L
Output PE
Output N
Output L
Output PE
Output N
Output L
Output PE
Output N
Output L
Input L NC
Output L
Input L NO
Input
Output L
Input L1
Output L1
Input L2
Output L2
Input L3
Output L3
Connection PE
Input PE
Input N
Input L
Output L
Input
Output L
Input
Output L
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Output
Ground
Output
Ground
Protection pumping
Reserve 1
Reserve 2
Motor cooling SK
Motor cooling SK
Motor cooling SK
Flush valve
Flush valve
Flush valve
Cooling valve
Cooling valve
Cooling valve
Refill valve
Refill valve
Refill valve
Valve pressure release
Blow out valve/air inlet
Contactor heater 1
T-Max switch
T-Max switch common
T-Max switch
Heater 1 acknowledgement
Heater 1 acknowledgement
Motor current measurement
Pump
Mains connection
Mains connection
Mains connection
Acknowledgement reserve
Acknowledgement flow
Acknowledgement flow
Sensor Sn2+ connection
Sensor Sn2– connection
Sensor Sn1+ connection
Sensor Sn1– connection
Digital input reserve 3
Comm. digital input reserve 2 + 3
Digital input level
Digital input level
Digital output 1, 24V DC
Ground to digital output 1
Digital output 2, 24V DC
Ground tp digital output 2
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Sensor Sn3 (Print for options)
Not used
Not used
76
77
78
79
80
81
82
83
84
85
86
87
88
Input
Input
Input
Input
Input
Input
Input
Output
89
90
91
92
93
94
95
96
97
98
Output
Input
Input
Input
Input
Input
Input
Input
Input
Output
99
100
101
102
103
104
105
106
107
108
109
Output
Input
Output
Output
Output
Input
Gemeinsam
Input
Input
Input
Output
111
112
113
114
115
20 mA-CL
20 mA-CL
RS 485–
RS 485–
RS 485–
116
RS 485–
117
118
121
122
123
124
125
131
132
133
134
135
136
137
138
149
150
RS 485–
Output PE
RxD
CTS
TxD
+5V
GND
CAN-L
CAN-H
V+
Rt
Bus-L
Bus-H
Ground
Shield
Output
Input
Input
Input
Output
Label
Function
Not used
Not used
Not used
Not used
Not used
External heating signal
External cooling signal
External heating/cooling active
External on/off signal
External set-point 2(SP2)
Acknowledgement monitor flow
Acknowledgement level 2
Common for inputs
81–87 and 89–90
Flow measurement F150
External on/off signal
Ext. set-point signal 2(SP2)
Acknowledgement flow monitor
Acknowledgement level 2
Common for inputs
91–97 and 99 –100
Analog 1(+)
Analog 2(+)
Thermoelement TC (+)
Analog set-point (+)
Analog for 101–104 (–)
Common for inputs
106 –108
Interface TxD+ RxD+
Interface TxD– RxD–
Interface
Interface
Interface,
TxD+ RxD+/A/DATA
Interface,
TxD– RxD–/B/DATA*
Interface, ground
RS422 Bühler/Müller-Weing.
CAN ISO High speed
CAN ISO High speed
Flow measurement 4-20 mA
Flow measurement 4-20 mA
Heating area.
Cooling area.
Set-point value.
Pump run-out temperature, measured with sensor S2
(absolute value). Section, 7.2, P 4.3.
Lower limit value of medium temperature, with respect to the set-point value,
measured with sensor S1. Section 7.2, P 3.1.
Upper limit value of fluid temperature, with respect to the set-point value,
measured with sensor S1.
Lower limit value of consumer temperature, with respect to the set-point value,
measured with S2. Section 3.1.
Upper limit value of consumer temperature, with respect to the set-point value,
measured with sensor S2. Section 3.1.
Maximum adjustable set-point value (absolute value). Section 7.2, P 4.4.
Trigger temperature of the electromechanical safety thermometer in unit (absolute value).
Set at the factory.
H
K
SP
TN

*
*
TSP
Tmax.
Temperature limit values
Abb. 2 Temperature limit values
Technical Data
Temperature range
0 to 420 °C
Control method
Outlet control: PID, with 1 of 10 pre-programmed PID-parameter
sets or with a manually adjustable PID set.
Separate parameter sets for heating and cooling.
Consumer control: Cascade PI/PID, with 1 of 10 pre-programmed
PID-parameter sets or with a manually adjustable cascade set
PI/PID.
Control parameter input
Via keyboard and LCD display.
Data storage
Memory chip with min. 10 years of data preservation.
Clock switch with lithium battery and about 10 years of data
preservation.
Limit values
Adjustable maximum set-point limit value.
Programmable minimum and maximum deviation of the medium
and consumer temperatures from the set-point value.
Monitoring systems
Control and power systems have permanent self-monitoring.
Sensor breakage and short-circuit (only for Pt 100).
Limit values for temperature, pump flow (all 3 phases), level,
function of the heating and pump contactors, as well as flow rate*.
Data plausibility monitoring in memory, monitoring of the service
interval, flow monitor, calibrated values of the pump motor phase
sequence in normal and leak-stop mode*, as well as external setpoint value signal*.
Inputs
Temperature sensor
Outlet
External (consumer)*
Inlet*
External Set-point value input
Heating/cooling commands, external*
Set-point value changeover
Serial interface*
Outputs
Heating/Cooling
Relay functions*
Analog outlets1 and 2*
Data interfaces*
Data transmission to master computer
(Hardware)
Data transfer to other
Regloplas units
Transmission protocol
22
Pt 100.
Choose Pt 100, J (Fe-CuNi), K (NiCr-Ni), or T (Cu-CuNi).
Pt 100.
Normalised and scaleable analogue interface with 0/4 to 20 mA or
0 to 10 V DC.
Via potential-free contacts.
Via keyboard (key SP) or via potential-free external contacts.
See "Data interfaces".
Triac outputs for contactors or valves or solid-state relays.
Individually adjustable cycle times for heating and cooling.
Up to 4 optional relays as either common alarm or with individual
functions such as temperature switching point, deviation, etc.
Galvanically separate analogue outputs with scaleable signal 0/4 to
20 mA or 0 to 10 V DC. Each output can be assigned an actual or
set-point value.
In addition, the thermal e.m.f. of a J, K or T thermocouple output at
analog output 2.
CL-20 mA; RS232; Bühler Datacess; Bühler Dataspeed; RS485;
CAN; SPI; Profibus-DP.
RS 422 (max. 32 units); CL-20 mA (2 to 4 units); RS485 (max. 32
units); CAN (max. 5 units); Bühler Dataspeed (max. 16 units);
Profibus DP (max. 32 units).
See section 10 "Data interfaces".
PA RT50 0309/e
Display
Modern, white backlit DOT matrix LCD display with black writing.
Simultaneous display of actual and set-point values, and an extra
line for an important display value as well as a status line are
shown on the display.
Disturbances
Shown on the display
Precision
Class precision/Linearization
Deviation of display
Pt 100: 0.3 %. Thermocouple: 0.3%
Pt 100: ± 1 digit. Thermocouple: ± 2 digits
Operation
Operation via short-stroke keys with pressure points on the
membrane keyboard.
Simple menu system in multiple languages via scroll keys.
Set-point value and parameter setting protected by programmable
codes.
Mains voltage
Switched mode power supply unit; 85 to 265 V AC
Degree of protection
Display unit with membrane keyboard: IP54
Service
Insertable memory chip, attached to the temperature control unit,
allows the operator to switch the electronics quickly and simply
without losing any data.
The user data are read automatically into the new electronic
component.
Integrated operating hours counter and service interval display.
Front dimensions
96 x 96 mm.
Notes
* Optional equipment.
PA RT50 0309/e
23
Menu RT50
65
Outlet
S1
80ºC
Set value
SP1
1 Show actual value
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
Outlet
112 °C
External
110 °C
Inlet
Heating/coolingcap.
Flow rate
Pump current L1
1.2 A
Pump current L2
1.2 A
Pump current L3
1.3 A
Operating hours
14725
Service after
275 h
Software version
5005
Interface
RS 485
Protocol
PROFIBUS
Address
3
Day/time
Do 07:16
9 Analog input
9.1
9.2
9.3
9.4
0
0
Analog input inactive
Analog input 4 –20 mA
Analog input 0 –20 mA
Analog input 0 –10 V
0
2 Select language
2.1 Sprache Deutsch
2.2 Language English
2.3 Langue Français
*
10 Common alarm
10.1
10.2
10.3
10.4
10.5
10.6
10.7
Alarm repeat time
Alarm heating 1
Alarm heating 2
Alarm flow rate
Alarm flow monitor
Alarm level
Alarm pump current
* Beispiele
Die Zahlen vor den Textzeilen beziehen sich auf die Betriebsanleitung.
3 User configuration
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
0
4 Unit configuration
Deviation set/actual
Outlet limit
Minimum flow rate
Interface
Temperature display
Flow rate display
Set-point at start
Next service
Operating hours
14725 *
11 Relay configuration
10.8 Relay K1 function
10.9 Relay K1 selection
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
ºC
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.20
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
12.9
12.10
5 Control
5.1
5.2
5.3
5.4
5.5
5.6
5.7
Heat transfer fluid
External sensor type
Runout temperature
Maximum set-point
Evacuation options
Evacuation time
Pump current
Pump dir. of rotation
Pump run-out time
Power failure behav.
Heating 2
Heating cycle time
Cooling cycle time
Suppress heating
Suppress cooling
Pump. cooling medium
Func. of ext. contact
Level alarm
Pressure relief valve
Viscosity
12 Programming the timer
01: Inactive
02: Inactive
03: Inactive
04: Inactive
05: Inactive
06: Inactive
07: Inactive
08: Inactive
09: Inactive
10: Inactive
Show actual value
Select language
User configuration
Unit configuration
Control
Offset
Analog output 1
Analog output 2
Analog input
Common alarm
Relay configuration
Programming the timer
Synchronising the timer
Reset/Factory/User
Change code
Additional display
0
Type of control
Control par. PID selection
Control par. casc. sel
13 Synchronising the timer
13.1 Enter day
13.2 Enter hour/minute
6 Offset
6.1
6.2
6.3
6.4
6.5
6.6
0
7 Analog output 1
Offset outlet sensor
Offset ext. sensor
Offset inlet sensor
Offset analog input
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
7.13
7.14
7.15
7.16
7.17
7.18
0
14 Reset/Factory/User
14.1
14.2
14.3
14.4
14.5
14.6
Save as fact. setting
Reset to fact. set
Save as user set 1
Reset to user set 1
Save as user set 2
Reset to user set 2
Output 1
Output 1
Output 1
Output 1
Output 1
Output 1
Output 1
Output 1
Output 1
Output 1
Output 1
Output 1
Output 1
Output 1
Output 1
Output 1
Output 1
Output 1
0
Outlet 4 –20 mA
Outlet 0 –20 mA
Outlet 0 –10 V
Ext. 4 –20 mA
Ext. 0 –20 mA
Ext. 0 –10 V
Inlet 4 –20 mA
Inlet 0 –20 mA
Inlet 0 –10 V
Set 1 4 –20 mA
Set 1 0 –20 mA
Set 1 0 –10 V
Set 2 4 –20 mA
Set 2 0 –20 mA
Set 2 0 –10 V
Flow 4 –20 mA
Flow 0 –20 mA
Flow 0 –10 V
15 Change code
15.1
15.2
15.3
15.4
15.5
Code ‹Entry value›
Code ‹Set-point›
Code ‹Fact setting›
Code ‹User setting 1›
Code ‹User setting 2›
8 Analog output 2
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
8.13
8.14
8.15
8.16
8.17
8.18
8.19
8.20
8.21
Output 2
Output 2
Output 2
Output 2
Output 2
Output 2
Output 2
Output 2
Output 2
Output 2
Output 2
Output 2
Output 2
Output 2
Output 2
Output 2
Output 2
Output 2
Output 2
Output 2
Output 2
0
Outlet 4 –20 mA
Outlet 0 –20 mA
Outlet 0 –10 V
Actual TE– FE
Actual TE–CA
Actual TE–Cu
Extern 4 –20 mA
Extern 0 –20 mA
Extern 0 –10 V
Inlet 4 –20 mA
Inlet 0 –20 mA
Inlet 0 –10 mA
Set 1 4 –20 mA
Set 1 0 –20 mA
Set 1 0 –10 V
Set 2 4 –20 mA
Set 2 0 –20 mA
Set 2 0 –10 V
Flow 4 –20 mA
Flow 0 –20 mA
Flow 0 –10 V
16 Additional display
16.1
16.2
16.3
16.4
16.5
16.6
16.7
16.8
16.9
No additional display
Outlet
5 °C
External
24 °C
Inlet
23 °C
Heat/Cool cap.
–100%
Flow rate
Operation hours
14725
Service after
275 h
Day/time
Do 07:16
*
Programming example:
Deviation set /actual
upper limit entry 5 °C
Outlet
S1
Set value
SP1
3 User configuration
3.1
3.2
3.3
3.4
3.5
3.6
3.7
65
ºC
80ºC
Show actual value
Select language
3.1 User configuration
Unit configuration
Control
Offset
Analog output 1
0
Deviation set/actual
Outlet limit
Minimum flow rate
Interface
Temperature display
Flow rate display
Set-point at start
Set-point/outlet
Set-point/outlet
Set-point/external
Set-point/external
Set-point/inlet
Set-point/inlet
Set-point/outlet
Entry
0 °C
Code
Entry
0
If correct:
Code
Entry
282
Legend
Level change
If wrong:
Change of line
or value
or code entry
Code
Entry
Wrong
Code
The number in front of the text lines refers to the instruction manual.
0
Set-point/outlet
Entry
5 °C
Fuse
F 801
2.5 A H
Socket for
relay-board
K3 45807
Socket for
relay-board
K3 45807
Plugg. connection
X 801
RJ45
6 sockets for
options
Socket for
relay-board
K3 45807
Socket for
relay-board
K3 45807
Replacement fuse
2.5 A H
Regloplas AG
Flurhofstrasse 158
CH-9006 St. Gallen
Tel. + 41 71 282 58 00
Fax + 41 71 282 58 40
E-mail [email protected]
Internet www.regloplas.com
BA 150S-350L/0703/d/f/e