REGLOPLAS RT100 Owner's manual

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.: [phone]
Fax: [phone]
E-mail: [email protected]
Homepage: www.regloplas.com

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RT100 Control System Contents i
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

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ii Contents RT100 Control System
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

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RT100 Control System Contents iii
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

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RT100 Control System General Safety Information 1
General Safety Information
Safety Symbols
DANGER
Denotes imminent danger.
Failure to heed the information can result in death or grave personal injury (dis-
ability)!
WARNING
Denotes a dangerous situation.
Failure to heed the information can result in death or grave personal injury (dis-
ability)!
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 recommenda-
tions, which, however, do not have any influence on the safety and health of
personnel.

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2 General Safety Information RT100 Control System
Range of Application
This general safety information is generally valid for all temperature con-
trollers 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 con-
trol system is intended solely for the normal use for heating and/or cool-
ing 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 de-
viation 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 sys-
tem 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 in-
tended 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 manu-
facturers, their notices and safety regulations must also be obeyed.
Process Monitoring
In plants in which a temperature control system malfunction leads to en-
dangerment of the operating personnel or destruction of the plant, an in-
dependent process monitor that shuts down the plant securely must be
used.

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RT100 Control System General Safety Information 3
Information for Operators and Personnel
The operator and all persons who are tasked with working on the tem-
perature 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, par-
ticularly 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 en-
sure that the temperature control unit is operated only in flawless condi-
tion. 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 op-
erating 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 en-
gineering 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 con-
trol 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 third-
party 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 extin-
guisher, a powder fire extinguisher (avoid with dust-sensitive plants, con-
trol systems, EDP, etc.) or a CO2fire extinguisher. The appropriate fire

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4 General Safety Information RT100 Control System
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 sys-
tems are completely installed and intact.
The temperature control unit must be protected against sprays and clean-
ing agents.
Before detaching connecting lines in the temperature control circuit and
depending on the outlet temperature, allow the temperature control de-
vice 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 re-
pair costs and downtime, and increase the dependability and service life
of the device/system.
NOTE
The operating instructions should be kept near the corresponding de-
vice/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 doc-
uments are included with special versions of devices. Any additional doc-
uments supplement and/or replace the descriptions contained in these
instructions, which are then either invalid or only conditionally valid.

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RT100 Control System Design and Function 5
Design and Function
Range of Application
The RT100 Control System has been developed for the control and op-
eration 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 mod-
ule (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 configura-
tion. Pressing again accepts the value.

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6 Design and Function RT100 Control System
Operating Control and Display Elements
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
Status display
Display of set-point value
(SP1/SP2), interface (UI)
or external control (Ext.)
RCD control knob
(Regloplas Control Dial)
Additional
display
Symbol area
Display of Zone and tempera-
ture sensor Sn1/Sn2/Sn3
Interface
address
Status LEDs
Selection of the
device functions
Display of actual
value

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RT100 Control System Design and Function 7
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 addi-
tional display is shown. The top left part of the display shows the set-
point 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 turn-
ing/pressing the RCD control knob (turning selects a value, pressing con-
firms 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.

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8 Design and Function RT100 Control System
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 tem-
perature 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 but-
ton, 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 re-
lease). 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 trans-
fer 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.

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RT100 Control System Design and Function 9
The leak-stop operation can be cancelled by pressing the ON/OFF but-
ton. 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 con-
nected to the temperature control unit with compressed air. Blowing out is
activated after the pump run-down time has elapsed and directs com-
pressed 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.

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10 Design and Function RT100 Control System
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 op-
tion Timer is present, the device can be switched on and off with this op-
tion.
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 recti-
fied, the alarm can be reset by once again pressing the Alarm Reset but-
ton.
The Alarm Reset button also allows the manual acknowledgement of the
automatic toggling from control of the consumer temperature Sn2 to con-
trol 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).

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RT100 Control System Design and Function 11
RT100 Control System - Loading firmware/bootloader
USB flash drive
The empty USB flash drive must be formatted with FAT file sys-
tem (see below)
The firmware must be extracted from the compressed file and
copied to the USB flash drive (see below)

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12 Design and Function RT100 Control System
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 simultane-
ously
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 suc-
cessful 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 mod-
ule 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
Universal interface
Switch clock
Ramp program
Cascade inlet (sensor Sn3)
Flow measuring F150
Flow measuring F351
Flow measuring F1000

V 01/2016
RT100 Control System Design and Function 13
Reversal of rotation >9A/suction
Pump regulation
Flushing
Flow deviation
Set-point ramps