Programming Manual - Die Cast Machinery, LLC

En
RT100
Programming Manual
SOF1119
V 01/2016
Documentation RT100 Control System
This manual is copyrighted. Unauthorised duplication is prohibited by law.
To the best of our knowledge and belief, the information contained in this
manual is true and correct as of the date of publication. The contents,
however, do not constitute a binding obligation on the part of Regloplas
AG and are subject to change without notice.
© Copyright 2013 Regloplas AG
All rights reserved
Printed in Switzerland
Regloplas AG
Flurhofstrasse 158
9006 St. Gallen
Switzerland
Tel.: +41-71-282 58 00
Fax: +41-71-282 58 40
E-mail: info@regloplas.com
Homepage: www.regloplas.com
V 01/2016
Contents
General Safety Information
1 Safety Symbols ....................................................................................................... 1 Range of Application ............................................................................................... 2 Intended Use ........................................................................................................... 2 Safety Information ................................................................................................... 2 General Information ................................................................................... 2 Process Monitoring .................................................................................... 2 Information for Operators and Personnel .................................................. 3 Changing the Parameterisation ................................................................. 3 Residual Risks ........................................................................................... 3 Using this Documentation ....................................................................................... 4 Additional Documentation .......................................................................... 4 Design and Function
5 Range of Application ............................................................................................... 5 Software Version ..................................................................................................... 5 RT100 Control System - Hardware ......................................................................... 5 Construction ............................................................................................... 5 Operation Concept ..................................................................................... 5 Operating Control and Display Elements................................................... 6 Buttons ....................................................................................................... 6 Status LEDs ............................................................................................... 6 Device Functions ....................................................................................... 6 Symbols ..................................................................................................... 7 RT100 Control System - Displays ........................................................................... 7 Operation and Status Displays .................................................................. 7 Setting the Set-points................................................................................. 7 Parameter Menu ........................................................................................ 8 RT100 Control System - Functions ......................................................................... 8 Powering Up............................................................................................... 8 Power Down ............................................................................................... 8 Leak-stop operation ................................................................................... 8 Draining ...................................................................................................... 9 Operation with Code/Password ............................................................... 10 Operation with Timer................................................................................ 10 Alarm Reset and Alarm History................................................................ 10 Save/Reset of the Setting Values ............................................................ 10 RT100 Control System - Loading firmware/bootloader......................................... 11 USB flash drive ........................................................................................ 11 Loading the firmware/bootloader ............................................................. 12 RT100 Control System - Activating Options ......................................................... 12 Software options ...................................................................................... 12 Technical Data
15 RT100 Control System .......................................................................................... 15 General Data ............................................................................................ 15 Electrical Data .......................................................................................... 15 Inputs ....................................................................................................... 16 RT100 Control System
Contents  i
V 01/2016
Outputs .................................................................................................... 16 Data Interfaces (Option) .......................................................................... 16 Display ..................................................................................................... 16 Precision .................................................................................................. 17 Operation ................................................................................................. 17 Dimensions .............................................................................................. 17 Parameterisation
19 General ................................................................................................................. 19 Show actual values............................................................................................... 19 Select language .................................................................................................... 20 User settings ......................................................................................................... 20 Display ..................................................................................................... 20 Clock ........................................................................................................ 20 Switch clock ............................................................................................. 20 Ramp program (Software option) ............................................................ 21 Set-point .................................................................................................. 22 Evacuation time ....................................................................................... 22 Next Service ............................................................................................ 23 Pump regulation ...................................................................................... 23 USB Logging (Service Interface) ............................................................. 23 Monitoring ............................................................................................................. 23 Temperature deviation............................................................................. 23 Max. heat./cool. time ............................................................................... 24 Minimum flow rate ................................................................................... 24 Flow deviation (Software option) ............................................................. 24 Min. system pressure .............................................................................. 25 Interfaces .............................................................................................................. 25 Address ................................................................................................... 25 Temperature control ............................................................................................. 25 Temperature Regulation .......................................................................... 25 Control parameters outlet ........................................................................ 25 Control parameters cascade ................................................................... 26 Settings .................................................................................................... 26 Control system modes ............................................................................. 26 Fixed parameter sets ............................................................................... 26 Pressure control ................................................................................................... 27 Pump regulation (Software option) ....................................................................... 28 Unit configuration.................................................................................................. 28 Inputs .................................................................................................................... 30 Flow meter type F1000 (Software option, max. 300 lpm) ....................... 31 Outputs ................................................................................................................. 33 Relay..................................................................................................................... 34 Collective alarm .................................................................................................... 35 Save/Load ............................................................................................................ 37 Code ..................................................................................................................... 37 Options ................................................................................................................. 38 Current monitoring heating ................................................................................... 39 Service menu ........................................................................................................ 39 Multiflow ................................................................................................................ 39 Data Interfaces
41 Basic Concept ...................................................................................................... 41 Protocols ............................................................................................................... 41 Plug Nomenclature
43 RT100 Front panel................................................................................................ 43 RT100 Base Module ............................................................................................. 43 ii  Contents
RT100 Control System
V 01/2016
RT100 Digital Option ............................................................................................. 46 Digital Functions ...................................................................................... 46 Relay Functions ....................................................................................... 46 RT100 Analog Option ........................................................................................... 46 Digital Functions ...................................................................................... 46 Analog Functions ..................................................................................... 47 RT100 Option Reversal of Direction of Rotation >9A ........................................... 47 RT100 Option Current Monitoring Heating ........................................................... 47 Hardware
49 RT100 Front Panel - Layout.................................................................................. 49 RT100 Base Module - Layout ............................................................................... 50 Analog Option - Layout ......................................................................................... 51 Digital Option - Layout .......................................................................................... 52 Option Reversal of Direction of Rotation >9A - Layout ......................................... 53 Option Current Monitoring Heating - Layout ......................................................... 53 Option Profibus DP - Layout ................................................................................. 54 Option Euromap 66 - Layout ................................................................................. 55 Option Profinet-IO - Layout ................................................................................... 56 Fault Rectification
57 Alarm Messages ................................................................................................... 57 Alarm List .............................................................................................................. 57 Warnings .................................................................................................. 57 Alarms ...................................................................................................... 58 System Errors/System Notes ................................................................... 59 RT100 Control System - Maintenance/repair
61 Replacing the front panel ...................................................................................... 61 Removal ................................................................................................... 61 Installation ................................................................................................ 61 Loading the firmware ............................................................................... 61 Replacing the base module .................................................................................. 62 Removal ................................................................................................... 62 Installation ................................................................................................ 62 Hardware checklist................................................................................... 62 Loading the firmware ............................................................................... 62 Activating options ..................................................................................... 62 Loading the factory settings ..................................................................... 63 Configuration check ................................................................................. 63 Customer-specific settings ....................................................................... 63 CAN terminating resistors and address settings...................................... 64 Spare Parts
67 Ordering Spare Parts ............................................................................................ 67 RT100 Control System - Spare Parts ................................................................... 68 RT100 Control System
Contents  iii
V 01/2016
General Safety Information
Safety Symbols
DANGER
Denotes imminent danger.
Failure to heed the information can result in death or grave personal injury (disability)!
WARNING
Denotes a dangerous situation.
Failure to heed the information can result in death or grave personal injury (disability)!
CAUTION
Denotes a potentially dangerous situation.
Failure to heed the information can result in property damage as well as minor
or moderate personal injury!
NOTE
Denotes general information, useful advice to users and work recommendations, which, however, do not have any influence on the safety and health of
personnel.
RT100 Control System
General Safety Information  1
V 01/2016
Range of Application
This general safety information is generally valid for all temperature controllers and control systems from Regloplas.
Intended Use
The Regloplas control system is built according to the current state of the
art and the generally accepted principles of safety engineering. The control system is intended solely for the normal use for heating and/or cooling of injection and die casting moulds, extruders, calenders, mixers and
other consumers in areas in which there is no risk of explosion.
Any use beyond this shall be deemed to constitute improper use. The
manufacturer is not responsible for damage resulting from improper use;
the user is solely responsible for such risks. The control system may not
be used under other operating conditions and/or with other media, in deviation from our specifications, without the prior consent of Regloplas AG.
Use as intended also entails compliance with the operating, servicing and
maintenance conditions stipulated by the manufacturer. The control system may only be operated, serviced and maintained by personnel who
are familiar with these tasks and have been instructed as to the risks.
Safety Information
General Information
The Regloplas control system is safe to operate, but this device can pose
danger to life and limb if it is used incorrectly or for a purpose other than
that intended. It should be noted that this poses risks to the life and limb
of the user or third parties, adverse effects on the equipment and other
material assets belonging to the user, and risks to the efficient operation
of the equipment.
Start-up (i.e., commencement of intended use) is prohibited until it has
been determined that the control system has been set up and wired in
accordance with the Machinery Directive (2006/42/EC). EN 60204-1
(Safety of Machinery) must also be observed.
These operating instructions must be read carefully before turning on and
operating the temperature control unit. The information regarding the intended use and foreseeable misuse must be observed. Local safety
regulations must also be obeyed.
If the control system is used in combination with products by other manufacturers, their notices and safety regulations must also be obeyed.
Process Monitoring
In plants in which a temperature control system malfunction leads to endangerment of the operating personnel or destruction of the plant, an independent process monitor that shuts down the plant securely must be
used.
2  General Safety Information
RT100 Control System
V 01/2016
Information for Operators and Personnel
The operator and all persons who are tasked with working on the temperature control unit must obey the fundamental regulations regarding
work safety and accident prevention. The operator must ensure that only
persons who have read and understood these operating instructions, particularly the chapter on safety, work on the temperature control unit.
Any working methods that have a negative effect on the technical safety
of the temperature control unit must not be used. The operator must ensure that the temperature control unit is operated only in flawless condition. If necessary, the company using the equipment must obligate the
operating personnel to wear protective clothing.
For all tasks having to do with set-up, start-up, operating, modification of
operating conditions and operational modes, maintenance, inspection
and repair, any shut-down procedures stated to be necessary in the operating instructions must be followed.
Changing the Parameterisation
The parameterisation of the control system may only be carried out by
personnel trained by Regloplas. In particular, no parameters in the device
configuration may be changed without consulting Regloplas.
The relevant accident prevention regulations and the generally accepted
principles of safety engineering, occupational medicine and structural engineering must be observed. The national safety regulations must also be
obeyed.
Residual Risks
Any unauthorised modifications and changes to the temperature control
device as also unauthorised changes to the parameterisation of the control system are prohibited for reasons of safety.
If the temperature control unit is damaged, it must not remain in use; the
defective part must be replaced or repaired immediately. Only original
Regloplas replacement parts may be used. Damage due to use of thirdparty parts voids any and all warranty claims.
DANGER
The temperature control unit must be disconnected before it is opened (unplug
mains plug or, if present, turn the yellow/red main switch on the temperature
control unit)! Danger due to electrical shock!
Repair leaks in the temperature control circuit (device, connecting lines,
consumers, etc.) immediately.
In temperature control units that use oil as a heat transfer medium, it
should be noted that oil is flammable under certain conditions. For this
reason, the temperature control unit must not be located in the vicinity of
heat sources. The thermal insulation in the device must always be kept
clean. Insulation that is soaked with thermal oil poses an increased risk of
fire.
Burning thermal oil can be extinguished using a spray foam fire extinguisher, a powder fire extinguisher (avoid with dust-sensitive plants, control systems, EDP, etc.) or a CO2 fire extinguisher. The appropriate fire
RT100 Control System
General Safety Information  3
V 01/2016
extinguisher must be provided by the operator, taking into account the
equipment located in the room and the mandatory safety regulations.
The temperature control unit may only be operated when all safety systems are completely installed and intact.
The temperature control unit must be protected against sprays and cleaning agents.
Before detaching connecting lines in the temperature control circuit and
depending on the outlet temperature, allow the temperature control device to cool down first and then turn it off. Check that the pump is no
longer running.
WARNING
Important - danger of injury in the event of escaping water or oil!
Using this Documentation
This documentation contains important information for safe, economical
operation and for proper maintenance of the device.
Compliance with this documentation helps to avoid danger, minimise repair costs and downtime, and increase the dependability and service life
of the device/system.
NOTE
The operating instructions should be kept near the corresponding device/system and always be accessible to operating and maintenance personnel.
Additional Documentation
The included instructions are completely correct for the basic versions of
devices. Components that do not belong to the basic hardware are noted
in the instructions as extra equipment. The corresponding additional documents are included with special versions of devices. Any additional documents supplement and/or replace the descriptions contained in these
instructions, which are then either invalid or only conditionally valid.
4  General Safety Information
RT100 Control System
V 01/2016
Design and Function
Range of Application
The RT100 Control System has been developed for the control and operation of Regloplas temperature control units and in addition, facilitates
connection to a superordinate control system of a production plant.
Software Version
NOTE
The following description of the RT100 Control System and its parameterisation
is valid beginning with software version 1119.
RT100 Control System - Hardware
Construction
The microprocessor-controlled RT100 Control System from Regloplas
consists of a front panel (operation and display section) and a base module (power section).
CAUTION
No external, third-party devices may be connected to the 24 VDC supply and the
AC supply of the base module!
Operation Concept
The RT100 Control System is equipped with an RCD control knob. It can
be used for navigation in the user interface through simple rotating and
pressing.
Pressing once selects a value and turning the knob is used for configuration. Pressing again accepts the value.
RT100 Control System
Design and Function  5
V 01/2016
Operating Control and Display Elements
Display of actual
value
Display of Zone and temperature sensor Sn1/Sn2/Sn3
Additional
display
Display of set-point value
(SP1/SP2), interface (UI)
or external control (Ext.)
Interface
address
Status display
Selection of the
device functions
Symbol area
RCD control knob
(Regloplas Control Dial)
Status LEDs
RT100 Control System - front panel
Buttons
Setting the set-point value
Scrolling through pages
Setting the additional display
Setting the parameters
Selection of the device functions (toggling
SP1/SP2, drainage by suction, leak-stop)
Alarm reset and alarm history
Button ON/OFF
Status LEDs
Normal operation
Warning
Alarm
Device Functions
Set-point value toggling SP1/SP2
Draining (suction or blowing out)
Leak-stop operation
6  Design and Function
RT100 Control System
V 01/2016
Symbols
Interface operation
Level of the heat transfer medium (filled
quantity) low
Level of the heat transfer medium (filled
quantity) OK
Heating
Ramp program activated
Timer activated
Cooling
Feed pump, counter clockwise rotation
Feed pump, clockwise rotation
Alarm
Maintenance due (flashes if maintenance is
due)
RT100 Control System - Displays
Operation and Status Displays
In the off state of the RT100 Control System, the message OFF appears
in the display area. Upon switching on with the button ON/OFF, the additional display is shown. The top left part of the display shows the setpoint temperature SP1 or SP2 (SP = Set point). The top right part of the
display shows the current outlet temperature (actual value of temperature
sensor Sn1, Sn2 or Sn3).
Sn1 = Outlet temperature
Sn2 = Temperature, external
Sn3 = Inlet temperature
Three other selectable values are shown in the middle part of the display.
The additional display can be set by using the F2 key and by turning/pressing the RCD control knob (turning selects a value, pressing confirms it).
The symbols for set-point value display, suction operation (draining) and
leak-stop operation are shown in the lower left part of the display. The
various operational and status displays of the temperature control unit
are shown in the lower right part of the display.
Setting the Set-points
The set-point values SP1 and SP2 are set by pressing the key F1. The
set-point value is then coloured light blue and can be set with the RCD
control knob. This setting is also possible in the parameter positions. The
set-point values can be selected through an external digital signal.
Toggling of the set-point values SP1 and SP2 is achieved with the F3 key
and selection of the set-point toggling function. Set-point toggling is only
possible if there is no alarm pending.
RT100 Control System
Design and Function  7
V 01/2016
Parameter Menu
The parameter menu is activated by pressing the Parameter button in
this menu, all the parameters can be configured by turning/pressing the
RCD control knob.
RT100 Control System - Functions
Powering Up
Upon switching on the main switch, OFF appears in the display. The
RT100 Control System is now ready for operation and is switched on by
pressing the ON/OFF button, or by the timer, through a digital input or an
interface.
Depending on the programming, the set-point and actual values, as well
as information on the operational state of the control system or the temperature control unit are displayed.
Rotational field detection / Direction reversal
The rotary field detection of the RT100 Control System detects a wrong
phase sequence and reports this in the display or corrects the direction of
rotation automatically.
Power Down
The RT100 Control System is switched off by pressing the ON/OFF button, or by the timer, through a digital input or an interface.
Depending on the temperature of the heat transfer medium, the switching
off program runs as follows:

The pump and the control system are turned off. The RT100
Control System is in standby mode and the display is OFF

The pump continues to run. The device cools till the temperature
of the heat transfer medium has reached the programmed run-on
temperature then, the pump and the control system are turned
off. In the case of devices using pressurised water, the pump
runs for a few seconds in the opposite direction (pressure release). The RT100 Control System is in standby mode and the
display is OFF
Leak-stop operation
The leak-stop operation is activated by pressing the F3 key and selecting
the leak-stop symbol and is only possible if it is supported by the device
type.
The leak stop operation is only possible if water is used as the heat transfer medium and the set-point value is in the vicinity of the value run-on
temperature (0-80 °C). Pressurised water units do not have any leak-stop
operation.
When oil is used as a heat transfer medium, the set-point value must be
within the range 0-250 °C. The heating capacity is then max. 60 %, since
the thermal load of the oil must be kept low owing to the reduced pump
capacity.
8  Design and Function
RT100 Control System
V 01/2016
The leak-stop operation can be cancelled by pressing the ON/OFF button. When the ON/OFF button is pressed again (wait until the display
reads OFF), the unit switches back to normal operation.
Clearance for the Leak-Stop Function
The leak-stop function is not permitted with every device (e.g. if a change
in the direction of rotation of the delivery pump is not possible). The
clearance of the leak-stop function is set in the parameter menu.
DANGER
The leak-stop operation is an emergency operation and may only be switched on
or cleared for devices intended for the purpose. A leak-stop operation in the
case of devices not intended for the purpose can cause a fire.
Draining
The consumer device can be drained with the delivery pump (suction) or
with compressed air (blowing out); (setting in the parameter menu).
Drainage by Suction with Pump
The suction program allows the draining of the consumer connected at
the temperature control unit and is activated by pressing the F3 key and
selecting the suction symbol. The pump is switched off and when the
pump run-down time elapses, switched on again in the opposite direction.
The consumer is drained through suction during the defined period
(draining time).
Draining is only possible if the temperature of the heat transfer medium is
below the programmed run-on temperature value. If that is not the case,
the heat transfer medium is first cooled to this value.
Blowing out with Compressed Air
The blowing out program makes it possible to drain the consumer connected to the temperature control unit with compressed air. Blowing out is
activated after the pump run-down time has elapsed and directs compressed air through the consumer. The temperature control unit switches
off automatically after the set period (draining time) has elapsed.
The suction or blowing out program can be cancelled by pressing the
ON/OFF button. When the ON/OFF button is pressed again (wait until the
display reads OFF), the unit switches back to normal operation.
NOTE
In the case of pressurised water units, the pressure release valve closes 5 °C
above the run-on temperature value (max. 85 °C) and opens at the programmed
run-on temperature value during the cooling process.
RT100 Control System
Design and Function  9
V 01/2016
Operation with Code/Password
In order to prevent the values that have been set or programmed from
being set again unintentionally, the use of a code/password is earnestly
recommended.
The RT100 Control System has three password levels that are organised
hierarchically:

User password - Default 0000 (switched off)

Technician password - Default 0100

Service password - only for personnel trained by Regloplas
NOTE
It is earnestly recommended that an operator password should be set up when
commissioning the temperature control device.
Operation with Timer
The RT100 Control System has an integrated real-time clock. If the option Timer is present, the device can be switched on and off with this option.
Alarm Reset and Alarm History
Alarm Reset
If an alarm has been triggered, the signal horn can be switched off by
pressing the Alarm Reset button. After the malfunction has been rectified, the alarm can be reset by once again pressing the Alarm Reset button.
The Alarm Reset button also allows the manual acknowledgement of the
automatic toggling from control of the consumer temperature Sn2 to control of the outlet temperature Sn1 in case of a faulty or removed sensor
Sn2 in the consumer.
Alarm History
If there is no alarm pending, the Alarm Reset button can be used to view
the alarm history.
Save/Reset of the Setting Values
The RT100 Control System provides the facility to load the factory setting
values or the user settings at any time in a simple manner. Two different
customer-specific settings can be loaded afresh (user setting 1 and 2).
10  Design and Function
RT100 Control System
V 01/2016
RT100 Control System - Loading firmware/bootloader
USB flash drive
RT100 Control System

The empty USB flash drive must be formatted with FAT file system (see below)

The firmware must be extracted from the compressed file and
copied to the USB flash drive (see below)
Design and Function  11
V 01/2016
Loading the firmware/bootloader
CAUTION
The firmware must be loaded the first time that the device is switched on (main
switch), otherwise, the parameter settings will be incorrect!

Insert the USB flash drive containing the firmware into the USB
port on the front panel

Press and hold down front panel buttons F1 and F2 simultaneously

Switch on the RT100 control system

The RT100 control system will now load the bootloader

As soon as the bootloader has loaded, the message Update
successful will be displayed

Press the panel button F1

The RT100 control system will now load the new firmware

Attention - during the loading process, the device may not be
switched off under any circumstances!

As soon as the firmware has loaded, the message Update successful will be displayed

The device can now be started with button F1 on the front panel

The USB flash drive can be removed now
RT100 Control System - Activating Options
The RT100 control system can be equipped with different hardware and
software options.
The software options must be activated with a file loaded by USB stick.
This operation requires the serial number of the control system, which is
displayed in the Options parameter and can be found on the base module next to the barcode. The serial number consists of 6 letters (e.g.
AALASF).

In the Options parameter, select the Activate options menu

Now insert the USB stick with the options file (e.g. AALASF.opt The options file can be on the same USB stick as the firmware)
Software options
12  Design and Function

Universal interface

Switch clock

Ramp program

Cascade inlet (sensor Sn3)

Flow measuring F150

Flow measuring F351

Flow measuring F1000
RT100 Control System
V 01/2016
RT100 Control System

Reversal of rotation >9A/suction

Pump regulation

Flushing

Flow deviation

Set-point ramps
Design and Function  13
V 01/2016
Technical Data
RT100 Control System
General Data
RT100 Control System
Temperature range
Control response
Parameter input
Data memory
-25 - 450 °C
Outlet control:
PID-controller, with 10 hard-coded PID parameter sets or with a PID set
that can be set manually. Separate parameter sets for heating and cooling
Consumer control:
PID-controller, with 10 hard-coded PID parameter sets or with a PID set
that can be set manually
Input via keyboard and RCD control knob
Memory module with at least 10 years data retention time
Timer with Lithium battery and about 10 years data retention time
Adjustable maximum set-point value limit
Limit values
Programmable minimum and maximum deviation from the set-point value
of the heat transfer medium temperature and consumer temperature
Continuous self-monitoring of the regulation and control system
Probe breakage and sensor short-circuit (only in case of Pt100), probe
breakage
Monitoring equipment
Limit values for temperature, pump current (all 3 phases), level, function
of the heating and pump circuit breakers and the flow rate (option)
Monitoring the plausibility of the data in the memory, the maintenance interval, the flow monitor, the calibration values, the phase sequence of the
pump motor in compression or suction operation and of the external setpoint value signal (option)
Electrical Data
RT100 Control System
Input supply voltage
Power supply (85-265 VAC)
Degree of protection
Front panel with membrane keyboard (IP54)
Maintenance
Plug-in data memory, permanently connected to the temperature control
device, for fast and simple changing of the base module without loss of
data The user data are automatically read into the new base module
Integrated working-hour meter and maintenance interval display
RT100 Control System
Technical Data  15
V 01/2016
Inputs
RT100 Control System
Outlet:
Pt 100
External (consumer):
Optionally Pt100 (2- or 3-conductor), J (Fe-CuNi), K (NiCr-Ni), T (CuCuNi) or N (NiCrSi-NiSi) (Option), 20mA
Temperature sensor
Inlet:
Pt 100 (2- or 3-conductor)
External set-point value specification
Standardised and scalable, analog interface with 0/4-20 mA or 0-10 VDC
External heating-cooling command
Device On/Off
Program On/Off
Signal via potential-free contacts (option)
Set-point value toggling
Signal via keyboard (F3 key, standard) or via potential-free external contact (option)
Analog input
Electrically isolated analog set-point value input with scalable signal 0/420 mA or 0-10 VDC (option)
Outputs
RT100 Control System
Heating/cooling
Relay functions
Analog outputs
Triac outputs for circuit breakers or valves or solid-state relays (SSR)
1 relay (standard), programmable as common alarm or as individual functions (e.g. temperature switching point, deviation etc.)
3 relays (digital option), programmable as common alarm or as individual
functions (e.g. temperature switching point, deviation etc.)
Electrically isolated analog outputs with scalable signal 0/4-20 mA or 0-10
VDC. An actual or set-point value can be assigned to every output. A
thermal e.m.f. of a J-, K-, T- or N-element corresponding to the current
display-actual can be output as the actual value output (option)
Data Interfaces (Option)
RT100 Control System
Data transmission to control computer (hardware)
Various serial interfaces, Profibus DP, Euromap 66, Profinet-IO
Display
RT100 Control System
Construction, design
Black LCD display with white lettering. Simultaneous display of actual and
set-point values, three additional lines for important display values as well
as one status line
Fault Indications
Are shown in the display unit
16  Technical Data
RT100 Control System
V 01/2016
Precision
RT100 Control System
 0.3 % of the display value, min.  0.5 °C
Class accuracy / linearization
Deviation of the display
Pt100: 0,3 %
Thermocouples: 0,3 %
Pt100: 1 digit
Thermocouples: 2 digits
Operation
RT100 Control System
Operation
Operation using short-travel membrane key switch with pressure point in
the membrane keyboard and RCD control knob (Regloplas Control Dial).
Simple menu guidance in different languages. Set-point value and parameterisation protected through programmable codes
Dimensions
RT100 Control System
Front dimensions
130 x 140 mm
Base module
170 x 230 mm
RT100 Control System
Technical Data  17
V 01/2016
Parameterisation
General
The parameterisation of the RT100 Control System is carried out with the
Parameter button in the menu Parameters. The corresponding parameter is selected and set by turning/pressing the RCD control knob.
The parameters are described in the following chapters.
CAUTION
The RT100 Control System has a safety concept with different password levels.
Parameters with the password level "Service Engineer" may only be adjusted
by personnel trained by Regloplas. Regloplas AG is not liable for damage that
results from incorrect parameterisation!
Show actual values
(Password level - User password)
The respective current actual values are displayed in this menu:
Parameters
Remarks
Outlet temp.
Temperature of the heat transfer medium in the outlet - sensor Sn1 (in
°C/°F)
External temp.
Temperature of the consumer in - sensor Sn1 (in °C/°F)
Inlet temp.
Temperature of the heat transfer medium in the inlet - sensor Sn3 (in
°C/°F)
Heat./cool. power
Specification of the momentary output in % of the rated output
(a negative value means cooling capacity in %)
Flow rate
Flow rate of the heat transfer medium in l/min or GPM
Pump pressure
Differential pressure across the pump
Pressure set-point
Pressure set-point value of the heat transfer medium (bar)
System pressure
Pressure of the heat transfer medium in the system (bar)
Outlet pressure
Pressure of the heat transfer medium in the outlet (bar)
Pump current L1
Current drawn by the pump motor - Phase 1 (in A)
Pump current L2
Current drawn by the pump motor - Phase 2 (in A)
Pump current L3
Current drawn by the pump motor - Phase 3 (in A)
Operating hours
Number of operating hours of the temperature control unit
RT100 Control System
Parameterisation  19
V 01/2016
Parameters
Remarks
Next service
Display of the remaining operating hours up to the next maintenance
Interface
Display of the interface (with code)
Address
Display of the device address in case of operation via interface
Date
Display of the current date
Time
Display of the current time
Num. level 1 low
Display of the number of level undershoots
Control cabinet temp.
Current temperature in the control cabinet (in °C/°F)
Software Version
Display of the implemented software version (front panel/base module)
Corr. set-point
Set-point value for auxiliary controller of the cascade control
Flow deviation
Deviation of the flow rate in l/min or GPM
Select language
(Password level - Technician password)
One of the languages currently available is selected in this menu (second
line, German is in first line, English in second line).
The available languages are English, German, French, Italian, Spanish,
Dutch, Czech, Chinese, Russian, Slovenian, Polish, Danish, Hungarian,
Croatian, Romanian, Portuguese, Swedish and Japanese.
User settings
(Password level - Technician password)
Display
Parameters
Remarks
Contrast
Contrast of the display (in %)
Temperature display
Temperature display (in °C / 0.1 °C or °F)
Flow display
Flow display (in lpm or usGPM or ukGPM)
Zone display
Zone display (Manually or Auto)
Zone
Input of zone display if configuration is set on Manually
Clock
Parameter
Remarks
Time format
Selection of the time format (12/24-hour format)
Synchronize
Synchronisation of date and time
Switch clock
Parameter
Remarks
Programming the clock (10 steps)
Clock programming
(Software option)
20  Parameterisation
There are 10 steps (connections) available for programming the clock. A day-ofthe-week, a group of days of the week, a time and the type of time (on/off time)
must be programmed for every step. 2 steps are required so that the device is
switched on once and off thereafter. The steps that are not required are set to inactive. The active (On/Off) and inactive steps are visible in the second sub-level
RT100 Control System
V 01/2016
Parameter
Remarks
On/Off/Program 1-5 (Ramp program)/Inactive
Monday, Tuesday, Wednesday, Thursday, Friday, Saturday, Sunday, Mo-Th,
Mo-Fr, Mo-Sa, Mo-Su
Step 1-10
Time
Ramp program (Software option)
(Password level - Technician password)
Parameter
Range
Remarks
Program
Status
Loop
Status
Step
Display the status of the current ramp program
Actual value
Set-point value
End set-point value
Remaining step time
Program control
Program
Display ramp program
Status
Display status
START
Start ramp program
PAUSE
Pause ramp program
STOP + RESET
Stop/Reset Ramp program
No. of steps
Program steps (2-20)
Start step
Starting steps (1-20)
Start trigger
Start takes place manually/clock
Stop behaviour
Switching off/last set-point
value
No. of loops
Program passes (1-99)
Set-point (in °C/°F)
Program 1
Ramp time (in hrs./min.)
Step 1
Program administration
Start dwell time ("Directly" or
when "Set-point reached")
Steps
RT100 Control System
Dwell time (in hrs./min.)
Step 2
(Functions like Step 1)
Step 3
(Functions like Step 1)
Step 4
(Functions like Step 1)
Step 5
(Functions like Step 1)
Program 2
(Functions like Program 1)
Program 3
(Functions like Program 1)
Program 4
(Functions like Program 1)
Program 5
(Functions like Program 1)
Parameterisation  21
V 01/2016
Ramp program - Overview
Set-point
Parameter
Range
Remarks
Last set-point value
Set-point at startup
Always SP1
Upon switching on the temperature control unit, control
takes place on the selected set-point value
Always SP2
Set-point 1
Upon switching on, control is on the basis of the chosen
set-point value temperature 1 (SP1)
Set-point 2
Upon switching on, control is on the basis of the chosen
set-point value temperature 2 (SP2)
Selection of the set-point ramp heating (Gradient, Filter
or Inactive)
Set-point ramp heating
Set-point ramps (Software option)
Gradient heating
Setting in °C/min
Filter time constant heating
Setting in sec.
Selection of the set-point ramp heating (Gradient, Filter
or Inactive)
Set-point ramp cooling
Gradient cooling
Setting in °C/min
Filter time constant cooling
Setting in sec.
Set-point ramps
Evacuation time
Parameter
Remarks
Evacuation time
Evacuation time duration (0-500 sec.)
22  Parameterisation
RT100 Control System
V 01/2016
Next Service
Parameter
Remarks
Operating hours
Display of the operating hours
Next service
Setting the period up to the next maintenance (0 h = disabled)
Pump regulation
Parameter
Remarks
Pump pressure, Flow or
Delta T set-point
Set-point setting (in bar, lpm or °C)
Operating mode
Operating mode setting (Manually or Auto)
Hand-value
Setting in Hz
USB Logging (Service Interface)
Parameter
Remarks
Service Interface (USB
Logging)
Data-Logging on USB-Stick
"Active", "Inactive"
The USB Data logger is used for process-logging during production if no
superordinate control is present.
If the USB logging is set on "active" and an USB flash drive is plugged in,
every 10 seconds a record will be made. Per day (24 h) a file with the
date in the file name and with the suffix "lo1" will be created (e.g.
"20120825.lo1"). The records are provided with time and date.
In each case Set-point, Outlet temperature, External temperature, Inlet
temperature, Heating-/Cooling performance, Flow rate, Pump pressure,
System pressure and Pressure set-point will be stored. The csv file can
for example be imported into Excel. There is also a special import filter
for the Famos Reader software for quick overviews of data. Please use a
Regloplas USB flash drive for USB logging (part no. 176-100026).
Monitoring
(Password level - Technician password)
Temperature deviation
Parameter
Remarks
Set-point value/outlet LO
Monitoring of this parameter can be switched on/off (value adjustable in °C/°F)
Set-point value/outlet HI
Monitoring of this parameter can be switched on/off (value adjustable in °C/°F)
Set-point value/external
LO
Monitoring of this parameter can be switched on/off (value adjustable in °C/°F)
Set-point value/external
HI
Monitoring of this parameter can be switched on/off (value adjustable in °C/°F)
Set-point value/Inlet LO
Monitoring of this parameter can be switched on/off (value adjustable in °C/°F)
Set-point value/Inlet HI
Monitoring of this parameter can be switched on/off (value adjustable in °C/°F)
Outlet/Inlet LO
Monitoring of this parameter can be switched on/off (value adjustable in °C/°F)
Outlet/Inlet HI
Monitoring of this parameter can be switched on/off (value adjustable in °C/°F)
RT100 Control System
Parameterisation  23
V 01/2016
Max. heat./cool. time
Parameter
Remarks
Max. heating time
Input ON/OFF
Deviation
Input in °C
Time
Input in minutes
Max. cooling time
Input ON/OFF
Deviation
Input in °C
Time
Input in minutes
Minimum flow rate
Parameter
Remarks
Minimum flow rate
Input - monitoring of the minimum flow rate (Active/Inactive)
Minimum flow rate
Setting the minimum flow rate (l/min or GPM)
Active from temperature
Minimum flow rate active from adjustable temperature (in °C/°F)
Flow deviation (Software option)
Parameter
Remarks
Flow deviation
Input - deviation of the minimum flow rate (Active/Inactive)
Low pass actual value
Actual value setting - low pass (in seconds)
Low pass offset reference
Offset setting - low pass (in seconds)
Deviation
Deviation setting (-100-0%)
Alarm suppression
Setting of duration of the alarm suppression (in sec.)
Flow monitoring
24  Parameterisation
RT100 Control System
V 01/2016
Min. system pressure
Parameter
Remarks
Min. system pressure
Input - min. system pressure (Active/Inactive)
Min. system pressure
Input - min. system pressure (in bar)
Alarm suppression
Setting of duration of the alarm suppression (in sec.)
Interfaces
(Password level - User password)
The universal interface is available as a software option.
Address
Parameter
Remarks
Address
Address input (0-999)
Protocol
Display of the current protocol with baud rate
Change protocol
Selection/setting of the available protocols (see chapter Data Interfaces)
Temperature control
(Password level - Technician password)
Temperature Regulation
Parameter
Remarks
Contr. type
Ext./outlet casc., Inlet/Outlet casc. or Outlet type
Outlet control par.
Control type with sensor in the outlet
Cascade external/outlet
Control type with sensor in the consumer and in the outlet
Cascade inlet/outlet
Control type with sensor in the inlet and in the outlet
Control parameters outlet
Parameter
Range
Remarks
Control parameter set
Fixed/manual
Selection of control parameter set
Control parameter
outlet defined
Parameter set Heating
Selection of control parameter set Heating (1-10)
Parameter set Cooling
Selection of control parameter set Cooling (1-10)
P Heating
Setting control parameter P Heating (in °C/°F)
I Heating
Setting control parameter I Heating (in sec.)
D Heating
Setting control parameter D Heating (in sec.)
Capacity limitation
Heating
Capacity limitation Heating (0-100%)
Control parameter
outlet manual
RT100 Control System
P Cooling
Setting control parameter P Cooling (in °C/°F)
I Cooling
Setting control parameter I Cooling (in sec.)
D Cooling
Setting control parameter D Cooling (in sec.)
Power limit cooling
Capacity limitation Cooling (0-100%)
Neutral zone cooling
Setting of neutral zone cooling (0-10% of setpoint value)
Parameterisation  25
V 01/2016
Control parameters cascade
Parameter
Range
Remarks
Control parameter set
Input fixed/manual
Selection of the control parameter set
Input active/inactive
Setting of outlet limitation
Max. outlet limitation
Max. outlet limitation (in °C/°F, up to
max. set-point value)
Min. outlet limitation
Min. outlet limitation (in °C/°F)
Input active/inactive
Setting of outlet limitation
Max. Diff. Heating Int/Ext
Max. Diff. Heating Int/Ext (in °C/°F)
Max. Diff. Cooling Int/Ext
Max. Diff. Heating Int/Ext (in °C/°F)
Value 1-10
Selection of control parameter Cascade
fixed
Strengthening of cascade
Input value 0-99
Integral cascade
Input in sec.
Differential cascade
Input in sec.
P Heating auxiliary controller
Input in °C/°F
I Heating auxiliary controller
Input in sec.
D Heating auxiliary controller
Input in sec.
P Cooling auxiliary controller
Input in °C/°F
I Cooling auxiliary controller
Input in sec.
D Cooling auxiliary controller
Input in sec.
Neutral zone aux. controller
Input in %
Outlet limitation
Max. difference Int/Ext
Control parameter cascade
defined
Control parameter cascade
manually
Settings
Parameter
Remarks
Heating cycle time
Input of the pulse time heating (in seconds)
Min. heating control time
Input of the minimum actuation time heating (in milliseconds)
Cooling cycle time
Input of the pulse time cooling (in seconds)
Min. cooling control time
Input of the minimum actuation time, cooling (in milliseconds)
Control system modes
The RT100 Control System works with the following control algorithms:
-
PID control on outlet, inlet or external sensor - for this control type,
there are 10 fixed parameter sets each available for heating and
cooling, as well as one manual set
-
Cascade control with external sensor and outlet sensor as well as inlet sensor and outlet sensor
Fixed parameter sets
In order to save the operator the trouble of painstakingly defining the P, I,
and D control parameters for heating and cooling, it is possible to retrieve
fixed parameter sets adjusted to the applications.
Users can determine the best fixed set of parameters for their application
without any special knowledge of control technology by observing the following simple rules:
1. Basic setting - parameter set 5
26  Parameterisation
RT100 Control System
V 01/2016
2. If the programmed set/point value is not attained after some time,
then the next lower fixed parameter set (e.g. parameter set 4 instead
of 5) should be selected
3. If the actual value exceeds the set-point value (overshooting) or varies about the set-point value, the next higher fixed parameter set is
selected.
If none of these parameter sets lead to the desired stability of adjustment
because the controlled system deviates from the standard, it is possible
to create an individual parameter set.
Remark:
The set-point value is attained the fastest if the actual value overshoots
somewhat. If overshooting is not permissible, then one must reckon with
a somewhat longer heating-up time.
Pressure control
(Password level - Service password)
Parameter
Range
Pressure Control
Input pressure control active/inactive
Max. system pressure
Input max. system pressure (in bar)
Set-point
Pressure balance
Pressure increase
Pressure decrease
RT100 Control System
Remarks
Max. pressure set-point value
Input of the max. pressure (in bar)
Min. pressure set-point value
Input of the minimum pressure (in bar)
Set-point value, ramp
Input set-point value, ramp (in bar/second)
Constant pressure overlay
Input constant pressure overlay (in bar)
Percent pressure overlay
Input percent pressure overlay (in %)
Pressure compensation type
Input pressure compensation with solenoid
valve "Y2", "Y8.1" or "without"
Pressure switch point
Input of pressure switching point (in bar)
Pressure switching time
Input of pressure pulse time (in sec.)
Pressure increase type
Input of pressure increase with solenoid valve
"Y2", "Y2.1" or "Y2 always open"
Pulse time
Input of pulse time (in sec.)
Minimum actuation time
Input of the minimum actuation time (in milliseconds)
P Band
Input P Band (in bar)
Integral
Input integral (in sec.)
Capacity increase at 1 bar
Input of capacity increase (in %)
Capacity increase at 7 bar
Input of capacity increase (in %)
Capacity limitation
Input of capacity limitation (in %)
Hysteresis over set-point value
Input of hysteresis (in bar)
Cycle time
Input of pulse time (in sec.)
Min. actuation time
Input of the minimum actuation time (in milliseconds)
P band
Input P band (in bar)
Integral
Input integral (in sec.)
Power increase
Input power increase (in %)
Power limitation at 1 bar
Input limitation increase (in %)
Power limitation at 7 bar
Input limitation increase (in %)
Parameterisation  27
V 01/2016
Parameter
Range
Remarks
Neutral zone
Input neutral zone (in bar)
Min. system pressure
Input min. system pressure (in bar)
Vapour suppression
Input of steam suppression (in sec.)
Pump regulation (Software option)
(Password level - Service password)
Parameter
Remarks
Control type
Input of the control type (Pump pressure, Flow rate or Delta T - Outlet/Inlet)
Operating mode
Input of operating mode (Manually or Auto)
Pump pressure, Flow
rate or Delta T set-point
Input of set-point (in bar, lpm or °C)
Max. set-point
Input of set-point (in bar, lpm or °C)
Min. set-point
Input of set-point (in bar, lpm or °C)
Neutral zone
Input of neutral zone (in bar, lpm or °C)
Kp
Input of gain Kp
Reset time
Input of reset time (in sec.)
Derivative time
Input of derivative time (in sec.)
Max. output
Setting the output (in Hz)
Min. output
Setting the output (in Hz)
Hand-value
Input of hand-value (in Hz)
Unit configuration
(Password level - Service password)
Parameter
Remarks
Device type
Selection of heat transfer medium (Water/Oil)
Max. device temp.
Input of the maximum temperature of the temperature control unit (in °C/°F, normally 5-10 °C above the max. set-point value)
Max. set-point
Input of the maximum set-point value of the heat transfer medium temperature in
°C/°F)
Behaviour after power
failure
Input behaviour after power failure ("Remains switched off", "Remains switched off without error" or "Last status")
Closing temperature
Input of closing temperature (in °C/°F)
Pressure release
Switch off
Emptying (Software option)
28  Parameterisation
Pressure release type
Input pressure release type ("With pump",
"With Y8/Y8.1" or "Without")
Pressure release time
Input pressure release time (in sec.)
Behaviour
Input "Cool first" or "Immediately off"
Run-on temperature
Input run-on temperature when switching off
Run-on time
Input run-on time of pump after switching off
Cooling capacity
Input of cooling capacity for cooling process
Evacuation type
Input evacuation type ("Inactive", "With
pump" or "With pressure")
with pressure
with Y8/with Y18
RT100 Control System
V 01/2016
Parameter
Leak stop
Pump
Boost pump
Heating
Cooling
Remarks
Venting time
Venting time duration (in sec.)
Evacuation time
Evacuation time duration (in sec.)
Allow leak stop
Input allow leak stop (yes/no)
Nominal current, pump
Input nominal current pump (in A)
Monitor phase sequence
Input monitor phase sequence (yes/no)
Run-down time of pump
Input run-down time of pump (in sec.)
Automatic reversal of direction of
rotation >9A
Input automatic reversal of direction of rotation >9A (yes/no)
Monitoring
Input active/inactive
Maximum running time
Input in (in sec.)
Restart lockout
Input in (in sec.)
Active from set pressure
Input in (bar)
Output Heating
Input 'heating output' ("SSR AC", "SSR DC",
"SSR DC aux. cont." or "Contactor")
Heating 2
Input heating 2 (active/inactive)
Cooling principle
Input cooling type ("Direct", "Indirect" or "Indirect/direct")
Temperature switchpoint indirect/direct
Input of switching point (in °C/°F)
Cooling medium conveying
Input of cooling medium conveying ("With
SK-pump", "Without SK-pump" or "With 3way valve")
Antiblocking SK-pump
Active/Inactive if cooling medium conveying
is set "With SK-pump" (Activation of SKpump every 30 min. for 100 milliseconds)
Cooling valve reset time
Refilling after
Level
Run-on time, pump
Input run-on time of pump (in sec.)
Refilling time window
Input of refilling time window (in sec.)
Level counter
Input active/inactive
Number of level undershoots
Input possible number of level undershoots
Alarm suppression time
Input of alarm suppression time (in minutes)
Number of fluid reservoir
Number of heat transfer medium container
Monitoring Y2
Input Active/Inactive
Max. turn on time Y2
Input turn on time (in sec.)
Response delay
Input (in sec.)
Min. refill time
Input (in sec.)
Flushing
Input flushing time ("Off", "With Y19" or "With
Y2/Y8")
Flushing
Settings
RT100 Control System
Input of reset time, cooling valve (in sec.)
Input refilling after ("Power on" or "Control
on")
Start flushing
(Active/Inactive)
Start flushing time
(in sec.)
Max. flushing temperature
(in °C)
Interval flushing
(Active/Inactive)
Interval time
(in min.)
Interval flushing
time
(in sec.)
Parameterisation  29
V 01/2016
Inputs
(Password level - Technician password)
The parameters of the signal inputs are displayed in this menu.
Parameter
Range
Remarks
Temperature sensor Sn1
Offset
Input of offset (in °C/°F)
Temperature sensor Sn2
Temperature sensor Sn3
(Software option)
Pressure sensor 1, system
Pressure sensor 2, outlet
Flow rate (Software option)
Offset
Input of offset (in °C/°F)
Sensor type Sn2
Input of sensor type Sn2 ("No ext. Sensor",
"Pt 100 2-conductor", "Pt 100 3-conductor",
"TE Type K", "TE Type J", "TE Type T", "TE
Type N" or "4-20 mA", "Interface"
Offset
Input of offset (in °C/°F)
Sensor type Sn2
Input of sensor type Sn2 ("No ext. Sensor",
"Pt 100 2-conductor" or "Pt 100 3-conductor")
Pressure sensor 1
Input pressure sensor 1 (active/inactive)
Offset
Input of offset (in bar)
4 mA
Input 4 mA (in bar)
20 mA
Input 20 mA (in bar)
Pressure sensor 2
Input pressure sensor 2 (active/inactive)
Offset
Input of offset (in bar)
4 mA
Input 4 mA (in bar)
20 mA
Input 20 mA (in bar)
Flow meter
Input flow meter (active/inactive)
Flow meter type
Input flow meter type ("F150", "F160", "F181",
"F183", "F185", "F350", "F351", "scalable",
"F1000")
Input (X26-KEM, X27-F150)
Additional parameters in case of
flow meter type "Scalable"
Scaling 1 kHz (in lpm or GPM)
Filtering time constant (in sec.)
Additional parameters in case of
flow meter type "F1000"
(see the chapter "Flow meter type F1000")
Input "Inactive/Pressure switch/Pump pressure"
Flow monitor
Temp. monitor cooling
Analog input
Ext Start/Stop command
(digital or analog option)
30  Parameterisation
When selecting "Pump pressure"
Min. pump pressure (in bar)
Alarm suppression time
Input in (in sec.)
Input "Active/Inactive"
Analog input
Input "Pump current" or "Set-point"
Analog input
Input "0-10 V", "0-20 mA", "4-20 mA" or "Inactive"
Code 0
When the external contact closes, the unit is
turned off and the ON/OFF button is blocked
Code 1
When the external contact opens, the unit is
turned off and the ON/OFF button is blocked
Code 2
The unit can be switched on and off via the
external contact (closing of the external contact - unit switches off / opening of the external contact - device switches on)
Code 3
The unit can be switched on and off via the
external contact (closing of the external contact - unit switches on / opening of the external contact - device switches off)
RT100 Control System
V 01/2016
Parameter
Range
Remarks
Code 4
The unit can be switched on and off as follows (closing of the external contact - unit
switches on / opening of the external contact
- unit switches off, the ON/OFF buttons, leak
stop and discharge as well as start/stop by
serial interface are inactive)
Code 5
Code 6
The unit will be switched off immediately by
closing of the external contact - Warning Device external switched off immediately will
be shown.
The unit can not be switched on until the contact will be opened. There will be no cooling
or pressure relief, so the device may still be
very hot and under pressure!
The unit will be switched off immediately by
closing of the external contact - Warning Device external switched off immediately will
be shown.
The unit can not be switched on until the contact will be closed. There will be no cooling or
pressure relief, so the device may still be very
hot and under pressure!
For code 2 and 3, the following applies:
Switching on and off with the button ON/OFF is possible at any time
Differential pressure filter
(digital or analog option)
Input "Opening/Closing"
Flow meter type F1000 (Software option, max.
300 lpm)
Parameters
Remarks
Flow meter
Active/inactive
Flow meter type
F1000
Pump type
Display of the pump type
Settings
(see the following chapter "Settings")
Settings
Parameters
Remarks
Pump tolerance
Deviation in % of the expected max. pump pressure. If this value is not reached,
an error message will be shown ("Pump power too low")
Pump calibration value
Correction value of the pump calibration (can also be input manually)
Pump pressure
ON - Differential pressure outlet/system
OFF - only outlet pressure
Filtering time constant
Averaging time of the flow
Automatic calibration
Switching automatic pump calibration on or off
Manual calibration
Start manual calibration
Pump pressure
Display of the pump pressure during calibration
Manual calibration
Manual calibration starts when, in the menu, the parameter Manual calibration is set to ON. The user is thereupon prompted to close the ball
valve in the outlet (flow = 0 l/min). When the ball valve is closed, the pa-
RT100 Control System
Parameterisation  31
V 01/2016
rameter Manual calibration is set to OFF and then the ball valve is
opened again. Calibration is now complete.
The parameter Manual calibration only appears in the menu when Automatic calibration is set to OFF.
Automatic calibration
If the parameter Automatic calibration is set to ON, then every time the
pump starts, the time-controlled automatic pump calibration will be executed (there must be a solenoid valve present in the outlet for this purpose). The following parameters can be defined for the automatic calibration:
Parameters
Remarks
Time till calibration
Time till switching on the solenoid valve in seconds
Calibration time
Switching time of the solenoid valve in seconds
Time till re-calibration
Time till repetition of the calibration in seconds.
With 0 seconds, the calibration is not repeated
Time till
calibration
Calibration
time
Time till re-calibration
Calibration
time
Starting the
pump
Importing the characteristic curve
The characteristic curve must be saved in the csv format and is divided
into a header area and a data area. The existing characteristic curve can
be overwritten by a new characteristic curve at any time. In the menu
item Save/Load / Load characteristic curve F1000, a characteristic
curve can be loaded from the USB stick.
32  Parameterisation
RT100 Control System
V 01/2016
Outputs
(Password level - Technician password)
The parameters of the signal outputs are displayed in this menu.
Parameter
Range
Remarks
Continuously inactive
Continuously active
Common alarm (see the parameter "Common alarm")
Heating 1
Heating 2
Minimum flow rate
Flow monitor
Level
Pump current
Alarm
Deviation Set-point value/Outlet
HI
Deviation Set-point value/Outlet
LO
Deviation Set-point/External HI
Deviation Set-point/External LO
Deviation Set-point/Inlet HI
Deviation Set-point/Inlet LO
O1
Deviation Outlet/Inlet HI
Deviation Outlet/Inlet LO
Deviation Flow rate
24 VDC outputs
Temp. switching point (in °C/°F)
Flow switching point (in lpm or GPM)
Band deviation (in °C/°F)
Control on
Clock active
Pump is running
Level 1 reached
Level 2 reached
Heating 1 on
Heating 2 on
Cooling on
Pressure increase
Pressure decrease
Maintenance
Pump regulation Start/Stop
O2
Data input output O2 (for functions, see output O1)
Pump regulation Right/Left
O3
RT100 Control System
Data input: output O3 (for functions, see output O1)
Parameterisation  33
V 01/2016
Parameter
Analog output 1
(analog option)
Analog output 2
(analog option)
Range
Remarks
Analog output 1
Inactive, 4-20 mA, 0-20 mA, 10 V, TE Type J,
TE Type N, TE Type T, TE Type K
Layout
Outlet temperature, External temperature,
Inlet temperature, Set-point value 1, Set-point
value 2, Flow, Set-point, Pump regulation
Lower end of scale
in corresponding dimension unit
Upper end of scale
in corresponding dimension unit
Offset
in corresponding dimension unit
Analog output 2
Inactive, 4-20 mA, 0-20 mA, 10 V, TE Type J,
TE Type N, TE Type T, TE Type K
Layout
Outlet temperature, External temperature,
Inlet temperature, Set-point value 1, Set-point
value 2, Flow, Set-point
Lower end of scale
in corresponding dimension unit
Upper end of scale
in corresponding dimension unit
Offset
in corresponding dimension unit
Relay
(Password level - Technician password)
The parameters of the relay functions are displayed in this menu:
Parameter
Range
Remarks
Function
Input "Opening/Closing/Single shot lead.
edge"
Control unit ON
Clock activated
Pump running
Level 1 reached
Level 2 reached
Heating 1 ON
Heating 2 ON
Cooling ON
Pressure increase
Pressure decrease
Relay K1
Relay
Service
Max heat./cool. time
Power ON
Common alarm (see the parameter " Common alarm")
Heating 1
Heating 2
Alarm
Minimum flow rate
Flow monitor
Level
Pump current
Deviation Set-point/Outlet HI
34  Parameterisation
RT100 Control System
V 01/2016
Parameter
Range
Remarks
Deviation Set-point/Outlet LO
Deviation Set-point/External HI
Deviation Set-point/External LO
Deviation Set-point/Inlet HI
Deviation Set-point/Inlet LO
Deviation Outlet/Inlet HI
Deviation Outlet/Inlet LO
Deviation Flow rate
Temp. switch point (actual value in °C/°F)
Flow switch point (in lpm or GPM)
Band deviation (actual value in °C/°F)
Relay K2
(digital option)
Relay K3
(digital option)
Relay K4
(digital option)
Function
Input "Normally open/Normally closed"
Relay
(for functions, see relay K1)
Function
Input "Normally open/Normally closed"
Relay
(for functions, see relay K1)
Function
Input "Normally open/Normally closed"
Relay
(for functions, see relay K1)
Collective alarm
(Password level - Technician password)
The common alarm is configured in this menu. The common alarm can
be assigned to a relay or to a 24 VDC output.
Parameter
Remarks
Alarm repeat time
Input alarm repeat time (in sec.)
Heating 1
Input alarm heating 1 (On/Off)
Heating 2
Input alarm heating 2 (On/Off)
Min. flow rate
Input alarm min. flow rate (On/Off)
Flow deviation
Input alarm deviation of flow rate (On/Off)
Flow monitor
Input alarm flow monitor (On/Off)
Level
Input alarm level (On/Off)
Pump current
Input alarm pump current (On/Off)
Temp. monitor cooling
Input alarm cooling temperature monitor (On/Off)
Current monitor heating
Input alarm Current monitor heating (On/Off)
SSR DC aux. contact
Input SSR DC aux. contact (On/Off)
from SOF V1102:
In the case of the following alarms, the common alarm relay is always activated:
RT100 Control System

Switch over heat carrier - reboot of the machine required

RTC Error or empty battery - Time and date settings lost

External set-point signal disconnected or not available

Direction of rotation cannot be changed
Parameterisation  35
V 01/2016
36  Parameterisation

Software version incompatible:
Analog Option, Digital Option, Heating current monitoring, Reversal of direction of rotation, Profibus, Profinet, Ethernet/IP,
CAN Demag, CANopen

Option missing or faulty:
Analog Option, Digital Option, Heating current monitoring, Reversal of direction of rotation, Profibus, Profinet, Ethernet/IP,
CAN Demag, CANopen

AD converter failure

Attention - temperature control cabinet too high

Turn on time refill exceeded

Maximal operating time boost pump exceeded

Min. pump pressure underrun

Max. temperature exceeded Sn3

Max. temperature exceeded Sn2

Max. temperature exceeded

Heating thermostat is activated

Frequency converter alarm

Motor current underrun

Phase sequence failure

Phase sequence unidentified

Phase missing

Motor contactor malfunction

Temperature sensor Sn1 failure

Temperature sensor Sn2 failure - switched to outlet control

Temperature sensor Sn3 failure

System pressure sensor inactive

System pressure sensor failure

Power failure

Safety thermostat is activated

Deviation set-point value/outlet exceeded
Deviation set-point value/outlet underrun
Deviation set-point value/external exceeded
Deviation set-point value/external underrun
Deviation set-point value/inlet exceeded
Deviation set-point value/inlet underrun
Deviation outlet/inlet underrun
Deviation outlet/inlet underrun
RT100 Control System
V 01/2016
Save/Load
Parameter
Remarks
Load user setting 1
Loading the user settings 1
Save user setting 1
Saving the user settings 1
Load AIC factory settings
Loading the user settings AIC
Save AIC factory settings
Saving the user settings AIC
Loading the factory settings
Loading the factory settings
Save the factory settings
Saving the factory settings (Regloplas password required)
Load settings from USB stick
Loading the settings from the USB stick
Save settings to USB stick
Saving the settings to the USB stick
Load characteristic curve F1000
Loading the characteristic curve F1000 (pump characteristic) from the
USB stick
Code
The password parameters are displayed in this menu:
Parameter
User password
Technician password
Service password
Reset passwords
RT100 Control System
Range
Remarks
New password
Input new password
Repeat
Repetition of password input
Set
Activation of the password
New password
Input new password
Repeat
Repetition of password input
Set
Activation of the password
New password
Input new password
Repeat
Repetition of password input
Set
Activation of the password
Reset code (if the password has
been forgotten, a corresponding
reset code is required)
Input of the reset code (four-digit)
Reset
Resetting to default passwords (ex-factory)
Parameterisation  37
V 01/2016
Options
The RT100 Control System options are displayed in this menu.
The RT100 Control System offers a releasing facility of software and
hardware options for function enhancement. The software options are released through a USB stick.
Parameter
Range
Remarks
Analog option
Digital option
Option current monit. heating
Option reversal of rotation
Hardware options
Option Profibus
Option CANOpen
Installed hardware options are displayed. To
remove an option, it should be manually set
to OFF
Option CAN Demag
Option Profinet
Option Ethernet/IP
Option Flow
Universal interface
Switch clock
Ramp program
Cascade inlet
Flow rate measurement F150
Flow rate measurement F351
Software options
Flow rate measurement F1000
Reversal of direction of rotation/suction
Activated software options are displayed. For
releasing a software option, a code is required (file on USB stick). The serial number
of the control system is required for this purpose
Pump regulation
Flushing
Flow deviation
Set-point ramps
USB Logging
Detection of the USB stick, load software options from the USB stick. The serial number
of the control system is required for this purpose
Activate options
Wait for USB stick
Serial number
Display of the base module serial number of the RT100 Control System
(8 letters, e.g. AALARP)
38  Parameterisation
RT100 Control System
V 01/2016
Current monitoring heating
(Password level - Technician password)
Parameter
Range
Remarks
Input active/inactive
Current converter ratio
Max. current Heating 1 (in A)
Settings
Current monitoring
Min. current Heating 1 (in A)
Max. current Heating 2 (in A)
Min. current Heating 2 (in A)
Heating current L1
(display in A)
Heating current L2
(display in A)
Heating current L3
(display in A)
Service menu
(Password level - Service password)
Parameter
Range
Remarks
Software version
Display of the current software version
Compatibility
Analog option
Digital option
Current monitoring option
Software versions
Option reversal of direction of rotation
Compatibility
Display of the current software version,
the corresponding options and the system
Option Profibus
Option CANOpen
Option CAN Demag
Option Profinet
Delete alarm list
Input of the Regloplas-AIC password required
Output
"None", "X40-M1", "X41-Y2", "X42-Y8",
"X43-Y16, Y13", "X45-Y19", "X46-M2",
"X47-Y6" or "X48-Y8.1"
"Active", "Inactive"
IO Test
Output
"None", "X40-M1", "X41-Y2", "X42-Y8",
"X43-Y16, Y13", "X45-Y19", "X46-M2",
"X47-Y6" or "X48-Y8.1"
"Active", "Inactive"
Multiflow
(Password level - Service password)
See therefore the corresponding Multiflow user manual.
RT100 Control System
Parameterisation  39
V 01/2016
Data Interfaces
Basic Concept
The operation with data interfaces makes possible an external, superordinate control system of the temperature control unit. The choice of the
protocol and the address of the data interface is described in the Parameterisation chapter.
Protocols
Designation
Baud rate
Interface
4800 Bd
20 mA-CL
Address
Inactive
1
2
5
6
7
8
9
10
15
16
18
19
20
21
22
23
24
25
26
27
28
29
30
Aarburg
Engel CL
4800 Bd
20 mA-CL
Stork
1200 Bd
20 mA-CL
Ferromatik Milacron
4800 Bd
20 mA-CL
Klöckner Desma
4800 Bd
20 mA-CL
Demag Ergotech
4800 Bd
20 mA-CL
Krauss Maffei
4800 Bd
20 mA-CL
Dr. Boy
4800 Bd
RS 232
Sächsische Kunststofftechnik
4800 Bd
RS 485
CAN Demag Ergocontrol
615 kBd
Engel RS232
4800 Bd
RS 232
SPI
19.2 kBd
RS 485
A32-255
SPI
9600 Bd
RS 485
A32-255
SPI
4800 Bd
RS 485
A32-255
SPI
2400 Bd
RS 485
A32-255
A32-255
A13-17
SPI
1200 Bd
RS 485
Bühler Dataspeed
4800 Bd
RS 485
Frech Datacontrol
9600 Bd
A11-18
Frech Datacontrol
4800 Bd
A11-18
Frech Datacontrol
2400 Bd
A11-18
Frech Datacontrol
1200 Bd
A11-18
CAN Demag Ergocontrol
500 kBd
A13-17
CAN Demag Ergocontrol
250 kBd
A13-17
RT100 Control System
Data Interfaces  41
V 01/2016
Designation
31
33
34
35
36
37
CAN Demag Ergocontrol
38
Euromap 66
39
40
41
42
43
44
Profibus DP
Baud rate
Interface
125 kBd
A13-17
max. 12 MBd
RS 485
Ferromatik Milacron RS485
4800 Bd
RS 485
Bühler Dataspeed
9600 Bd
RS 485
Ethernet/IP
Address
A0-124
Ethernet
IP Address
max. 12 MBd
RS 485
A0-124
250 kBit/s
CANOpen
(Euromap 66)
Netstal from 31
Profibus DP (Pump regulation)
max. 12 MBd
RS 485
A0-124
Profibus DP (Protocol V2)
max. 12 MBd
RS 485
A0-124
Profinet IO
100 MBd
Profinet IO
Profinet IO
100 MBd
Profinet IO
Engel
4800 Bd
RS 485
Ethernet/IP
100 MBd
Ethernet
Profibus DP (Alarm Reset)
42  Data Interfaces
IP Address
RT100 Control System
V 01/2016
Plug Nomenclature
RT100 Front panel
Plug
Designation
X2
Options
X3
Base module
X4
Interfaces Universal RP or 20 mA CL
X5
USB Host
X6
USB Device
RT100 Base Module
Plug
RT100 Control System
Designation
X1
Display and operations module (front panel)
X2
Base module
X3
Options
X4
Options
X5
Options
X6
Power supply
X7
EEprom (Memory)
X10:1
Flow monitor F3/B42
X10:2
Flow monitor F3/B42
X11:1
Level switch S3
X11:2
Level switch S3
X12:1
Level switch S1
X12:2
Level switch S1
X13:1
Digi In (Feedback frequency converter)
X13:2
Digi In (Feedback frequency converter)
X14:1
Digi In (Monitoring SK pump)
X14:2
Digi In (Monitoring SK pump)
X15:1
Sensor, internal (Pt100) B1
X15:2
Sensor, internal (Pt100) B1
X16:1
Sensor, external (Pt100 / TC+) B3
Plug Nomenclature  43
V 01/2016
Plug
Designation
X16:2
Sensor, external (Pt100 / TC-) B3
X16:3
Sensor, external (Pt100) B3
X17:1
Sensor, inlet (Pt100) B14
X17:2
Sensor, inlet (Pt100) B14
X17:3
Sensor, inlet (Pt100) B14
X18:1
Sensor, external (4-20mA) B3
X18:2
Sensor, external (4-20mA) B3
X20:1
Digi In
X20:2
Digi In
X21:1
+
Heating 1 24VDC
X21:2
-
Heating 1 24VDC
X22:1
+
Heating 2 24VDC
X22:2
-
Heating 2 24VDC
X23:1
+
Digi Out (Frequency converter Start/Stop)
X23:2
-
Digi Out (Frequency converter Start/Stop)
X24:1
+
Digi Out (Frequency converter Right/Left)
X24:2
-
Digi Out (Frequency converter Right/Left)
X25:1
+
Digi Out
X25:2
-
Digi Out
X26:1
COM flow rate measurement F18x, F35x
X26:2
Signal flow rate measurement F18x, F35x
X26:3
Shield flow rate measurement F18x, F35x
X27:1
BN flow rate measurement F150
X27:2
GN flow rate measurement F150
X27:3
WH flow rate measurement F150
X28:1
+
Pressure sensor 1, system B8
X28:2
-
Pressure sensor 1, system B8
X29:1
+
Pressure sensor 2, outlet B8.1
X29:2
-
Relay K1 NO
X30:2
Relay K1 COM
X30:3
Relay K1 NC
X31:1
L
X31:2
X32:1
X33:1
L
Feedback Heating 1
L
Feedback Heating 2
Feedback Heating 1
X33:2
X34:1
Feedback Heating 2
L
X34:2
X35:1
L
AC In
AC In
L
X36:2
X37:1
Thermostat F7
Thermostat F7
X35:2
X36:1
Feedback Delivery
Feedback Delivery
X32:2
44  Plug Nomenclature
Pressure sensor 2, outlet B8.1
X30:1
AC In
AC In
L
AC In
RT100 Control System
V 01/2016
Plug
Designation
X37:2
RT100 Control System
AC In
X38:1
COM
Safety thermostat F5
X38:2
NO
Safety thermostat F5
X38:3
NC
Safety thermostat F5
X40:1
N
Cooling pump SK M1 / Compressed air Y16.1
X40:2
L
Cooling pump SK M1 / Compressed air Y16.1
X40:3
PE
Cooling pump SK M1 / Compressed air Y16.1
X41:1
N
Valve refill Y2 / Additional lower level lamp H3
X41:2
L
Valve refill Y2 / Additional lower level lamp H3
X41:3
PE
X42:1
N
Valve refill Y2
Valve pressure release Y8
X42:2
L
Valve pressure release Y8
X42:3
PE
Valve pressure release Y8
X43:1
N
Compressed air Y16 / Air inlet Y13
X43:2
L
Compressed air Y16 / Air inlet Y13
X43:3
PE
Compressed air Y16 / Air inlet Y13
X44:1
N
Delivery, Heating 1+2
X44:2
L
Heating 1 K21-23
X44:3
L
Heating 2 K24-26
X44:4
L
Delivery, K10
X45:1
N
Valve flushing Y19 / Blow out OFF Y18
X45:2
L
Valve flushing Y19 / Blow out OFF Y18
X45:3
PE
Valve flushing Y19 / Blow out OFF Y18
X46:1
N
Filling pump M2
X46:2
L
Filling pump M2
X46:3
PE
Filling pump M2
X47:1
N
Valve, Cooling Y6
X47:2
L
Valve, Cooling Y6
X47:3
PE
Valve, Cooling Y6
X48:1
N
Valve Additional pressure release Y8.1
X48:2
L
Valve Additional pressure release Y8.1
X48:3
PE
Valve Additional pressure release Y8.1
X49:1
L
Valve Outlet (Flow rate F1000 NO)
X49:2
L
AC Out
X49:3
L
AC Out
X50:1
T1
Delivery pump M10
X50:2
T2
Delivery pump M10
X50:3
T3
Delivery pump M10
X50:4
PE
Delivery pump M10
X51:1
L1
Mains input 200-600V
X51:2
L2
Mains input 200-600V
X51:3
L3
Mains input 200-600V
X51:4
L
Mains input 115/230V
X51:5
N
Mains input 115/230V
X51:6
PE
Mains input
Plug Nomenclature  45
V 01/2016
RT100 Digital Option
The digital functions of the RT100 Digital Option are mirrored identically
on the RT100 Analog Option.
Digital Functions
Plug
Designation
X80:1
External heating
X80:2
External cooling
X80:3
External heating/cooling active
X80:4
External On/Off
X80:5
External toggling SP1-SP2
X80:6
Differential pressure, filter
X80:7
External Start program
X80:8
External Stop program
X80:9
GND X80: 1-8
Relay Functions
Plug
Designation
X81:1
Relay K2 NO
X81:2
Relay K2 COM
X81:3
Relay K2 NC
X81:4
Relay K3 NO
X81:5
Relay K3 COM
X81:6
Relay K3 NC
X81:7
Relay K4 NO
X81:8
Relay K4 COM
X81:9
Relay K4 NC
RT100 Analog Option
Digital Functions
Plug
46  Plug Nomenclature
Designation
X100:1
External heating
X100:2
External cooling
X100:3
External heating/cooling active
X100:4
External On/Off
X100:5
External toggling SP1-SP2
X100:6
Differential pressure, filter
X100:7
External Start program
X100:8
External Stop program
X100:9
GND X100: 1-8
RT100 Control System
V 01/2016
Analog Functions
Plug
Designation
X101:1
Analog input set-point value
X101:2
+ 15 VDC
X101:3
Analog output 1 V
X101:4
Analog output 1 mA
X101:5
Analog output 1 TC
X101:6
Analog output 2 V
X101:7
Analog output 2 mA
X101:8
Analog output 2 TC
X101:9
GND outputs X101: 1, 3-8
RT100 Option Reversal of Direction of Rotation >9A
The RT100 option for reversal of the direction of rotation >9A is intended
for motor currents >9 A.
Plug
Designation
X120:1
Pump motor T1
X120:2
Pump motor T2
X120:3
Pump motor T3
X120:4
Pump motor PE
X121:1
Mains supply L1
X121:2
Mains supply L2
X121:3
Mains supply L3
X121:4
Mains supply PE
RT100 Option Current Monitoring Heating
Plug
RT100 Control System
Designation
X150:1
Current converter 1
X150:2
Current converter 1
X150:3
Current converter 2
X150:4
Current converter 2
Plug Nomenclature  47
V 01/2016
Hardware
RT100 Front Panel - Layout
RT100 Front Panel Print - Layout
CAUTION
Electronic parts can be damaged by electrostatic charges. For this reason,
proper grounding must be ensured during installation!
Fasten an antistatic wristband to your wrist before installing electronic components!
RT100 Control System
Hardware  49
V 01/2016
RT100 Base Module - Layout
RT100 Base Module - Layout
50  Hardware
RT100 Control System
V 01/2016
Analog Option - Layout
The digital functions of the RT100 Analog Option are mirrored identically
on the RT100 Digital Option.
Analog function
Digital function
Analog Option - Layout
CAUTION
If both a digital option and an analog option are installed, the digital functions
of the digital option must be used!
The digital functions of the analog option are not activated in this case!
RT100 Control System
Hardware  51
V 01/2016
Digital Option - Layout
The digital functions of the RT100 Digital Option are mirrored identically
on the RT100 Analog Option.
Relay function
Digital function
Digital Option - Layout
CAUTION
If both a digital option and an analog option are installed, the digital functions
of the digital option must be used!
The digital functions of the analog option are not activated in this case!
52  Hardware
RT100 Control System
V 01/2016
Option Reversal of Direction of Rotation >9A - Layout
Option Reversal of Direction of Rotation >9A - Layout
Option Current Monitoring Heating - Layout
Option Current Monitoring Heating - Layout
RT100 Control System
Hardware  53
V 01/2016
Option Profibus DP - Layout
Option Profibus DP - Layout
S3 Address
0=Zone 1
1=Zone 2
Board for Mainboard-Options - Layout
54  Hardware
RT100 Control System
V 01/2016
Option Euromap 66 - Layout
Option Euromap 66 - Layout
S3 Address
0=Zone 1
1=Zone 2
Board for Mainboard-Options - Layout
RT100 Control System
Hardware  55
V 01/2016
Option Profinet-IO - Layout
Option Profinet-IO - Layout
S3 Address
0=Zone 1
1=Zone 2
Board for Mainboard-Options - Layout
56  Hardware
RT100 Control System
V 01/2016
Fault Rectification
Alarm Messages
The RT100 Control System can display various error messages (warnings and alarms). Attention must be paid to these error messages without
fail, otherwise, malfunctions of / damage to the temperature control unit
and production downtimes may result.
Pressing the Alarm Reset button allows you to acknowledge/reset an
alarm (e.g. switching off the horn). Only after the malfunction has been
rectified can the alarm display be deleted by once again pressing the
Alarm Reset button.
The Alarm Reset button also allows the manual acknowledgement of the
automatic toggling from control of the consumer temperature (or cascade
control) Sn2 to control of the outlet temperature Sn1 in case of a faulty or
removed sensor Sn2 in the consumer.
Alarm List
Pressing the Alarm Reset button opens the alarm list as long as there is
no alarm queued. The last ten alarm messages with date and time are
displayed here.
Warnings
Error message
Rectification
Service is due
Carry out maintenance procedure according to the
operating manual. Increment the parameter Next
Maintenance by 1000 hours
Clean filter
Clean the corresponding filter or if required, replace it
Current data lost, load factory settings
The RT100 Control System has lost the parameters
and had to load the factory settings
Outlet pressure sensor faulty
Replace outlet pressure sensor
Heating contactor 1 failure
The contactor Heating 1 does not get actuated correctly any more - replace
Heating contactor 2 failure
The contactor Heating 2 does not get actuated correctly any more - replace
Illegal or broken characteristic curve F1000
Switch the main switch off and on again. If the fault is
still present, re-load characteristic curve F1000
Pump power too low
Check/inspect the pump or in the menu F1000 reduce
the parameter pump tolerance (default 50%)
RT100 Control System
Fault Rectification  57
V 01/2016
Error message
Rectification
Deviation set-point value/outlet underrun
Adjust the outlet temperature and acknowledge the
fault
Deviation set-point value/outlet exceeded
Adjust the outlet temperature and acknowledge the
fault
Deviation set-point value/external underrun
Adjust the external temperature and acknowledge the
fault or error
Deviation set-point value/external exceeded
Adjust the external temperature and acknowledge the
fault or error
Deviation set-point value/inlet underrun
Adjust the inlet temperature and acknowledge the
fault
Deviation set-point value/inlet exceeded
Adjust the inlet temperature and acknowledge the
fault
Deviation outlet/inlet underrun
Adjust the inlet temperature and acknowledge the
fault
Deviation outlet/inlet exceeded
Adjust the inlet temperature and acknowledge the
fault
Level 2 underrun
Refill heat transfer medium
Pressure balance not possible
Check water inflow pipe and water pressure (min. 2
bar)
Leak stop not possible
Reduce the temperature
Leak stop not allowed
Unit is not allowed for leak stop
Suction not possible
Switch the unit to normal operation mode
SSR error
SSR DC with auxiliary contact has activated. Check
SSR
Alarms
Error message
Rectification
External set-point signal disconnected or not available
Connect the external set-point value signal (optionally
check control system)
Maximal operating time boost pump exceeded
Check hose connections to the consumer, fix the
leakages
Flow monitor is activated
Check outlet pressure (min. 0,7 bar must be available)
Min. pump pressure underrun
Check outlet pressure
Min. flow rate underrun
Check min. flow rate (the specified min. flow rate must
be available)
Flow rate deviation too high
Large variation in the flow (there may be a leak in the
circuit)
Max. temperature exceeded
Max. temperature Sn2 exceeded
Max. temperature Sn3 exceeded
Max. heat transfer medium temperature may not exceed the die max. device temperature (optionally
check the consumer temperature)
Heating thermostat is activated
Temperature control unit has become too hot - let it
cool down and determine the cause
Heating current monitoring is activated
Check heating element(s) and replace, if necessary
Direction of rotation cannot be changed
---
Motor current underrun
Check pump/pump motor (with ohmmeter) and replace, if necessary
Motor current exceeded
Check pump/pump motor (with ohmmeter) and replace, if necessary
Phase sequence failure
Correct the phase sequence (interchange 2 phases)
Phase sequence unidentified
Switch off phase sequence monitoring
58  Fault Rectification
RT100 Control System
V 01/2016
Error message
Rectification
Phase missing
Check the mains, input conductor and pump motor
Motor contactor malfunction
Check motor contactor and if required, replace it
Temperature sensor Sn1 failure
Replace temperature sensor Sn1
Temperature sensor Sn2 failure - switched to outlet
control
Replace temperature sensor Sn2
Temperature sensor Sn3 failure
Replace temperature sensor Sn3
System pressure sensor failure
Replace the system pressure sensor
System pressure sensor inactive
Activate the system pressure sensor
Power failure
Failure of the power supply or temperature control
unit not switched off properly
Safety thermostat is activated
Temperature control unit has become too hot - determine the cause and reset the thermostat
Temp. monitor cooling act, cooling disabled
Check the cooling and cooling water flow
Frequency converter alarm
Remedy the frequency converter fault
Turn on time refill exceeded
Check the cooling water circuit and the cooling circuit
for leaks
Level 1 underrun
Refill heat transfer medium
System Errors/System Notes
Error message
Rectification
Memory stick missing
Insert memory stick
AD converter failure
Replace the base module
Attention - temperature control cabinet too high
Place the temperature control unit in a place with low
ambient temperature
Incompatible data on stick
Load current software version
Communication failure
Check the connection between the front panel and the
base module
Software version error
Re-load software (applies to front panel and base
module)
Data corrupt on stick
Insert new memory stick and re-load device parameters
Current settings lost / factory settings loaded
Carry out a new client-specific settings parameterise
Settings defect / data not loaded
Replace the memory stick
No data on USB stick or wrong file extension
Load the correct data on USB stick
More than 1 file on USB stick
Load the correct data on USB stick
Data failure - no data loaded from USB stick
Load the correct data on USB stick
Option not activated
Activate the option
DEMO MODE / Pump current measurement inactive
System message without remedial action
Saving data
Data saving in progress
Data saved
Data saving finished
Data error - no data saved to USB stick
Replace the USB stick
Pump is off or has wrong direction
Adjust the pump rotating field
Please close tap
Close the tap on the outlet
Calibration done - please open tap
Open the tap on the outlet
Clean the filter
Clean the external filter
External set-point signal disconnected or not available
Connect the external set-point signal
RTC Error or empty battery - Time and date settings
Set the correct date/time and/or replace the battery on
RT100 Control System
Fault Rectification  59
V 01/2016
Error message
Rectification
lost
the front panel
USB Slave mode operation not possible
Switch on the temperature control unit again
Save/Load not possible in USB Slave Mode
Switch on the temperature control unit again
Save/Load not possible during device is on
Switch the temperature control unit to OFF
Switch over heat carrier - reboot of the machine required
Switch on the temperature control unit again with the
main switch
Error, password not reset
Enter the reset code correctly
Password reset
Passwort was reset
Illegal operation
Observe the operating sequence
Zone 1 missing
Connect Zone 1, check address of Zone 1
Zone 2 missing
Connect Zone 2, check address of Zone 2
Software version option incompatible:
Analog Option, Digital Option, Heating current monitoring, Reversal of direction of rotation, Profibus, Profinet,
Ethernet/IP, CAN Demag, CANopen
Update the software
Option missing or faulty:
Analog Option, Digital Option, Heating current monitoring, Reversal of direction of rotation, Profibus, Profinet,
Ethernet/IP, CAN Demag, CANopen
Connect the corresponding option or switch off in the
parameter Hardware Options
60  Fault Rectification
RT100 Control System
V 01/2016
RT100 Control System - Maintenance/repair
Replacing the front panel
Removal
CAUTION
The exact sequence of operations described below must be strictly followed.
Otherwise, parameterization errors are possible!
The address of the base module must be correct before the control system is
powered up for the first time. Otherwise, the base module boot loader will have
to be reloaded by the manufacturer!

Disconnect all plug-in connections

The front panel is fixed with 6 screws on the device door. Loosen
all the screws and remove the defective front panel

Send the defective front panel to Regloplas AG (Switzerland) in
ESD protective packaging, complete with a description of the
fault
Installation

Fasten the front panel with 6 screws on the device door

Reconnect all plug-in connectors
Loading the firmware
See the section "RT100 Control System - Loading the firmware".
RT100 Control System
RT100 Control System - Maintenance/repair  61
V 01/2016
Replacing the base module
Removal
CAUTION
The exact sequence of operations described below must be strictly followed.
Otherwise, parameterization errors are possible!
The address of the base module must be correct before the control system is
powered up for the first time. Otherwise, the base module boot loader will have
to be reloaded by the manufacturer!

Disconnect all plug-in connections

Carefully unplug the memory card

The base card is fixed inside the device with 6 screws. Loosen all
the screws in alternation so that the plastic spacer bolts do not
fall out

Send the defective base module card to Regloplas AG (Switzerland) in ESD protective packaging, complete with a description of
the fault
Installation

Fasten the base card inside the device with 6 screws. Tighten
the screws in alternation to avoid twisting the base card

Reconnect all plug-in connectors

Carefully reinsert the memory card
Hardware checklist

Is the CAN connecting cable correctly plugged in?

Are the CAN terminating resistors set to the correct ON/OFF position?

Are the addresses of the base module (main units) correctly set?
(zone 1 = address 0, zone 2 = address 1 - very important for dual
devices with a single display)

Is the motor fuse F10 (10 A aM/Class CC) fitted?

Is the relay plug K1 connected?
Loading the firmware
See the section "RT100 Control System - Loading the firmware".
Activating options
See the section "RT100 Control System - Activating options".
62  RT100 Control System - Maintenance/repair
RT100 Control System
V 01/2016
Loading the factory settings
The factory settings are restored in the Save/Load parameter in the
Load factory settings menu. This returns the RT100 to the manufacturer's default settings.
Configuration check
The unit configuration must be checked to determine whether everything
has functioned correctly. Important points to check in the Unit configuration parameter:

Unit type (oil, water)

Maximum temperature in device

Emptying - Evacuation type

Pump - Nominal pump current in the Unit configuration parameter

Pump - Automatic reversal of direction of rotation
Customer-specific settings
The corresponding customer-specific parameter settings must be reentered (e.g. interface addresses etc.)
RT100 Control System
RT100 Control System - Maintenance/repair  63
V 01/2016
CAN terminating resistors and address settings
On delivery of the assembly, the CAN terminating resistors on the base
module (switch S1) and on the front panel (switch S2) are set to ON.
On delivery, the address of the base module is 0 (rotary switch S2).
In the case of dual units, address 1 is set for zone 2 (rotary switch S2).
No.
Connection combination
1
Front panel with one
base module
Description
Both terminating resistors are switched on (checked by Regloplas)
2
Front panel with two
base modules
3
One option
4
Several options
64  RT100 Control System - Maintenance/repair
RT100 Control System
V 01/2016
No.
Connection combination
5
Front panel with option
6
Front panel with option
RT100 Control System
Description
RT100 Control System - Maintenance/repair  65
Address
Change protocol
Interfaces
66  RT100 Control System - Maintenance/repair
Display
Clock
Switch clock
Ramp program
Set-point
Evacuation time
Next service
Pump regulation
USB Logging
User settings
Temperature deviation
Max. heat./cool. time
Minimum flow rate
Flow deviation
Min. system pressure
Monitoring
Pressure control
Max. system pressure
Set-point
Pressure balance
Pressure increase
Pressure decrease
German
English
French
Italian
Spanish
Dutch
Czech
Chinese
Russian
Slovenian
Polish
Danish
Hungarian
Croatian
Romanian
Portuguese
Swedish
Japanese
Outlet temperature
External temperature
Inlet temperature
Heat./cool. power
Flow rate
Pump pressure
Pressure set-point
System pressure
Outlet pressure
Pump current L1
Pump current L2
Pump current L3
Operating hours
Next service
Interface
Address
Date
Time
Num. level 1 low
Control cabinet temp.
Software version
Corr. set-point
Flow deviation
Software versions
Delete alarm list
IO Test
Service menu
Control type
Operating mode
Pump pressure set-point
Max. set-point
Min. set-point
Neutral zone
Kp
Reset time
Derivative time
Max. output
Min. output
Hand-value
Pump regulation
Pressure control
Select language
Show actual values
RT100 Control System
Parameter Menu Structure
V 01/2016
Relay K1
Relay K2
Relay K3
Relay K4
Relay
24 VDC outputs
Analog output 1
Analog output 2
Outputs
Device type
Max. device temp.
Max. set-point
Behaviour after power failure
Closing temperature
Pressure release
Switch off
Emptying
Leak stop
Pump
Boost pump
Heating
Cooling
Level
Flushing
Unit configuration
User password
Technician password
Service password
Reset passwords
Code
Load user setting 1
Save user setting 1
Load AIC factory settings
Save AIC factory settings
Load factory settings
Save factory settings
Load settings from USB stick
Save settings to USB stick
Load characterist. curve F1000
Save/Load
Alarm repeating time
Heating 1
Heating 2
Min. flow rate
Flow deviation
Flow monitor
Level
Pump current
Temp. monitor cooling
Current monit. Heating
SSR DC aux. cont.
Collective alarm
Show actual values
Select language
User settings
Monitoring
Interfaces
Temperature control
Pressure control
Pump regulation
Unit configuration
Inputs
Outputs
Relay
Collective alarm
Save/Load
Code
Options
Current monitoring heating
Service menu
Multiflow
RT100 Control System
Control type
Outlet control parameter
Control parameter cascade
Settings
Temperature control
Temperature sensor Sn1
Temperature sensor Sn2
Temperature sensor Sn3
Pressure sensor 1, system
Pressure sensor 2, outlet
Flow rate
Flow monitor
Temp. monitor cooling
Analog input
Ext. Start/Stop command
Diff. pressure filter
Inputs
Current monitoring
Settings
Heating current L1
Heating current L2
Heating current L3
Current monit. heating
Hardware options
Software options
Activate options
Serial number
Options
V 01/2016
Spare Parts
Ordering Spare Parts
For fast, error-free supply of spares, we need the following data without
fail:
-
Device type
-
Device number
-
Voltage
-
Frequency
This information is given on the rating plate on the device.
-
Position number of the component
This information is given in the corresponding figures in this operating
manual (also see the service section) and in the electrical circuit diagram
of the device.
CAUTION
Only original Regloplas spare parts may be used!
In case of damage from the use of non-original parts, the warranty will be rendered null and void!
RT100 Control System
Spare Parts  67
V 01/2016
RT100 Control System - Spare Parts
RT Display unit - complete
176-100028
RT100 Base module - 115/230 VAC
176-100001
RT100 Memory print
176-100002
RT100 Digital Option
176-100003
RT100 Analog Option
176-100004
RT100 cable, Universal, L=300 mm, X61 X62
176-100005
RT100 Front panel
176-100006
RT 100 cover for control knob
176-100007
RT100 control knob
176-100008
RT100 Option Reversal of Direction of Rotation >9A
176-100009
RT100 Option Current Monitoring Heating
176-100010
RT100 cable 20 mA CL Aarburg, L=300 mm, X51 X52
176-100011
RT100 Profibus DP
176-100012
RT100 Profinet-IO
176-100040
RT100 Euromap 66
176-100013
Battery for display unit
177-100002
RT100 Protective cover, lockable, for Display RT100
176-100024
Fuse - F100 - 2,5 AF fast-acting
143-042283
Socket, push-in, 2-pin, black, marking 1|2, sensor inputs 24 VDC, 0.5 A
203-100000
Socket, push-in, 3-pin, black, marking 1|2|3, sensor inputs 24 VDC, 0.5 A
203-100001
Socket, push-in, 3-pin, orange, marking NO|C|NC, AC In/Out, relay 250 VAC, 3 A
203-100002
Terminal strip, tension spring, 2-pin, orange, marking 1|2, AC In/Out, relay 250
VAC, 3 A
203-100003
Terminal strip, tension spring, 3-pin, orange, marking 1|2|3, AC In/Out, relay 250
VAC, 3 A
203-100004
Terminal strip, tension spring, 3-pin, orange, marking 1|2|ground symbol, AC
In/Out, relay 250 VAC, 3 A
203-100005
Terminal strip, tension spring, 4-pin, orange, marking 1|2|3|4, AC In/Out, relay
250 VAC, 3 A
203-100006
Socket, push-in, 4-pin, black, marking T1|T2|T3|ground symbol, AC In/Out, motor
600 VAC, 12 A
203-100007
Socket, push-in, 6-pin, black, marking L1|L2|L3|L|N| ground symbol, AC In/Out,
motor 600VAC, 12 A
203-100008
Terminal strip, tension spring, 9-pin, orange
203-100017
68  Spare Parts
RT100 Control System
V 01/2016
RT100 Control System
Spare Parts  69
Download PDF
Similar pages