REGLOPLAS 300L User manual

En
Operating Instructions
Temperature Control Unit
300L(D)/350L(D)

V 09/2011
Documentation Temperature Control Unit 300L(D)/350L(D)
This documentation is copyrighted. Unauthorised duplication is prohibited
by law. To the best of our knowledge and belief, the information con-
tained in this documentation is true and correct as of the date of publica-
tion. The contents, however, do not constitute a binding obligation on the
part of Regloplas AG and are subject to change without notice.
© Copyright 2011 Regloplas AG
All rights reserved
Printed in Switzerland
Regloplas AG
Flurhofstrasse 158
9006 St. Gallen
Switzerland
Tel.: [phone]
Fax.: [phone]
e-mail: [email protected]
Website: www.regloplas.com

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Temperature Control Unit 300L(D)/350L(D) 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 Parameter Settings..............................................................3
Residual Risks ...........................................................................................3
Using This Documentation......................................................................................4
Additional Documentation..........................................................................4
Operating Instructions 5
General ...................................................................................................................5
Introduction ................................................................................................5
Operating Range........................................................................................5
Start-up ...................................................................................................................6
Setting up the Temperature Control Unit...................................................6
Safekeeping of the operating instructions..................................................7
Inspection of Consumers...........................................................................7
Water Quality .............................................................................................7
Thermal Oil.................................................................................................7
Connecting Lines.......................................................................................8
Electrical Connections ...............................................................................8
Operation of the Temperature Control Unit ............................................................9
RT100 Control System...............................................................................9
Buttons.......................................................................................................9
Status LEDs...............................................................................................9
Device Functions .....................................................................................10
Symbols ...................................................................................................10
RT100 Operation and Status Displays ....................................................10
Setting the Set-point values.....................................................................10
Parameter Menu......................................................................................11
RT100 Control System - Functions.......................................................................11
Switching on the Temperature Control Unit.............................................11
Starting up for the first time / Commissioning..........................................11
Operating Modes .....................................................................................13
Draining the Consumer............................................................................13
Operation with Code/Password ...............................................................13
Operation with Timer................................................................................14
Alarm Reset and Alarm History................................................................14
Save/Reset of the Setting Values............................................................14
RT100 Control System - Unlocking Options............................................14
Switching off the Temperature Control Unit.............................................15
Changing Consumers/Decommissioning..............................................................15
Alarm Messages ...................................................................................................15
Alarm list ...............................................................................................................16

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ii •Contents Temperature Control Unit 300L(D)/350L(D)
Warnings..................................................................................................16
Alarms...................................................................................................... 16
System Errors.......................................................................................... 18
Maintenance.........................................................................................................18
Periodic Inspections and Maintenance Procedures................................18
Cleaning...................................................................................................20
Repairs .................................................................................................... 20
Transport .............................................................................................................. 21
Disposal................................................................................................................21
Maintenance 23
Guidelines for Connecting Hoses......................................................................... 23
Technical Data 300L(D)........................................................................................ 24
Technical Data 350L(D)........................................................................................ 25
Block Diagram300L(D)/350L(D)........................................................................... 26
Diagram (Pump capacity)..................................................................................... 27
Diagram (Cooling capacity).................................................................................. 28
Components/Spare parts 300L(D)/350L(D) .........................................................29
Dimension sheet 300L.......................................................................................... 32
Dimension sheet 300LD.......................................................................................33
Dimension sheet 350LD.......................................................................................34
Level Switch.......................................................................................................... 35
300L(D)....................................................................................................35
Dismantling/Replacement........................................................................35
350L(D)....................................................................................................36
Dismantling/Replacement........................................................................36
Solenoid valves ....................................................................................................37
Overview.................................................................................................. 37
Safety thermal cut-out .......................................................................................... 37
Overview and operating principle............................................................ 37

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Temperature Control Unit 300L(D)/350L(D) 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 Temperature Control Unit 300L(D)/350L(D)
Range of Application
This general safety information is generally valid for all temperature con-
trollers and control systems from Regloplas.
Intended Use
The Regloplas temperature control unit is built according to the current
state of the art and the generally accepted principles of safety engineer-
ing. The temperature control unit is intended solely for the normal use for
heating and/or cooling of injection moulds and die casting dies, extruders,
calenders, mixers and other consumers in areas where 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 temperature control unit
may not be used under other operating conditions and/or with other me-
dia, in deviation from our specifications, without the prior consent of Re-
gloplas AG.
The intended use also entails compliance with the operating, servicing
and maintenance conditions stipulated by the manufacturer. The tem-
perature control unit 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 temperature control unit is safe to operate but can cause
danger if it is used incorrectly or for a purpose other than its intended
use. It should be noted that any such incorrect use or non-compliance
with the intended use can cause 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 equip-
ment.
Start-up (i.e., commencement of intended use) is prohibited until it has
been determined that the temperature control unit 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 switching on
and operating the temperature control unit. The information regarding the
intended use and foreseeable misuse must be observed. Local safety re-
gulations must also be obeyed.
If the temperature control unit is used in combination with products made
by other manufacturers, the notices and safety regulations of these ma-
nufacturers must also be obeyed.
Process Monitoring
In plants in which a malfunction of the temperature control system leads
to endangerment of the operating personnel or destruction of the plant,

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Temperature Control Unit 300L(D)/350L(D) General Safety Information •3
an independent process monitor that reliably shuts down the plant must
be used.
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, in
particular the chapter on safety, may 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 relating to set-up, start-up, operating, modification of operat-
ing conditions and operational methods, maintenance, inspection and re-
pair, any shut-down procedures stated to be necessary in the operating
instructions must be followed.
Changing the Parameter Settings
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
unit as well as 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 from the electrical power
supply before it is opened (unplug the mains plug and, if fitted, press the main
switch on the temperature control unit). Danger of electric shock!
Any leaks in the temperature control circuit (device, connecting lines,
consumers, etc.) must be repaired immediately.
In the case of temperature control units that use oil as the heat transfer
medium, please remember that oil is flammable under certain conditions.
For this reason, the temperature control unit must not be located close to
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.

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4 •General Safety Information Temperature Control Unit 300L(D)/350L(D)
Burning thermal oil can be extinguished using an AFFF spray foam fire
extinguisher, a powder fire extinguisher (to be avoided in the case of
dust-sensitive plants, control systems, EDP, etc.) or a CO2fire extin-
guisher. The appropriate fire extinguisher must be provided by the opera-
tor, taking into account the equipment located in the room and the man-
datory 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 from the temperature control circuit
and depending on the outlet temperature, allow the temperature control
unit to cool down first and then switch 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 documentation is completely correct for the basic versions
of devices. Components that do not belong to the basic hardware are no-
ted as extra equipment. The corresponding additional documents are in-
cluded with special versions of devices. Any additional documents sup-
plement and/or replace the descriptions contained in this documentation,
which are then either invalid or only conditionally valid.

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Temperature Control Unit 300L(D)/350L(D) Operating Instructions •5
Operating Instructions
General
Introduction
These operating instructions contain a detailed description of the
Temperature Control Unit 300L(D)/350L(D) as well as important informa-
tion for safe operation and optimal maintenance.
The operating instructions must be kept near the temperature control unit
and always be accessible to operating and maintenance personnel.
Operating Range
The operating range and medium of the Temperature Control Unit
300L(D)/350L(D) are shown in the following table (in this regard, see also
the chapter "Technical Data" in the service section).
Temperature Control
Unit Type 300L(D) 350L(D)
Temperature range up to 300 °C up to 350 °C
Heat transfer medium Oil Oil
NOTE
The technical data and information for installation, start-up and maintenance of
the temperature control unit can be found in the maintenance section of these
operating instructions. The operating instructions should be kept near the de-
vice/system and always be accessible to operating and maintenance personnel!

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6 •Operating Instructions Temperature Control Unit 300L(D)/350L(D)
Start-up
Setting up the Temperature Control Unit
The temperature control unit is designed for an ambient temperature ran-
ge of 10-40 °C. Sufficient ventilation must be ensured during set-up. The
distance between the devices and/or between the temperature control
unit and a wall must be at least 10 cm. The ventilation slits must not be
covered.
•Check the temperature control unit to ensure that it is undam-
aged and complete
•Do not tip the temperature control unit! Heat transfer medium
remaining in the unit from the test run could spill, and there is a
risk that the thermal insulation could become soaked with the flu-
id (medium)
•Position the temperature control unit on a horizontal surface and
engage the wheel brake
WARNING
Never start up the temperature control unit without the side panels and housing!
Never use the temperature control unit in potentially explosive environments and
protect it against sprays and cleaning agents that contain solvents!
Do not place the temperature control unit close to sources of heat (e.g. furnaces
in die-casting plants)!
Any leaks in the temperature control circuit (temperature control unit, connecting
lines, consumers, etc.) must be repaired immediately!
The thermal insulation in the temperature control unit must be kept clean at all
times (thermal insulation soaked with thermal oil is a fire risk)!
Observe local laws during set-up!
CAUTION
Danger of injury due to release of hot thermal oil!
Before detaching connecting lines in the temperature control circuit, the tem-
perature control unit must first be allowed to cool down. The cooling time will
depend on the outlet temperature. The shutdown procedure is initiated by press-
ing the ON/OFF button. The pump continues to run. The temperature control unit
cools down until the temperature of the heat transfer medium has reached the
programmed coastdown temperature (factory default 60 °C). The pump and the
control system are then switched off!
Check that the pump is no longer running (indicator in the display = OFF)!
NOTE
Burning thermal oil can be extinguished using an AFFF spray foam fire extin-
guisher, a powder fire extinguisher (to be avoided in the case of dust-sensitive
plants, control systems, EDP, etc.) or a CO2 fire extinguisher (danger of reigni-
tion, limited suitability).
The appropriate fire extinguisher must be provided by the operator, taking into
account the equipment located in the room and the mandatory safety regula-
tions.

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Temperature Control Unit 300L(D)/350L(D) Operating Instructions •7
Safekeeping of the operating instructions
The operating instructions for the temperature control unit belong in the
hands of the personnel responsible for start-up and operation. Please
ensure that the operating instructions are read. By doing so, you will
avoid unnecessary expense and problems during start-up as well as pro-
duction downtime.
Inspection of Consumers
Before installing the connecting lines between consumer and tempera-
ture control unit, the consumer must be subjected to the following inspec-
tions:
•Verify that channels are unobstructed
•Remove residual fluid and fouling with compressed air (foreign
objects such as shavings etc. can damage the pump)
•Rust and scale deposits and oil residue must be removed be-
cause they greatly interfere with the heat exchange between con-
sumer and heat transfer medium and increase the pressure drop
in the consumer. Descaling can be carried out using the Re-
gloplas REG descaling unit (see the "Regloplas Temperature
Control Technology" brochure, REG data sheet)
•Oil deposits can be removed with the SR80 system cleaner (see
the "Regloplas Temperature Control Technology" brochure,
SR80 data sheet)
When converting the consumer from operation with water to thermal oil,
all residual water in the consumer and in the connecting lines must be ful-
ly removed (danger of accident due to vapour pressure when heating) -
see chapter on "Converting the consumer from water to thermal oil"
Water Quality
The water used must meet the following requirements to avoid damage
to the cooler of the temperature control unit:
Criterion Requirement
Appearance clear/without sediment
Cloud < 0.5 NTU (very light cloud)
Total hardness < 10 °dH
pH-value 6.5-8.5
Conductivity max. 500 µS/cm
Carbonate hardness < 5 °dH
Addition of RK93 corrosion inhibitor is urgently recommended (see the
"Regloplas Temperature Control Technology" brochure, RK93 data
sheet).
Thermal Oil
Regloplas recommends the thermal oils Regloplas RO300 or Thermi-
nol 66. The film temperature of the thermal oil must be 40 °C above the
outlet temperature of the temperature control unit.

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8 •Operating Instructions Temperature Control Unit 300L(D)/350L(D)
Connecting Lines
The connecting lines must consist only of pressure-resistant and tem-
perature-resistant hoses and screw fittings. The cross-section of the con-
necting lines may not be reduced (see maintenance section).
•Outlet and inlet - use only pressure-resistant and temperature-
resistant hoses and screw fittings. The connecting lines must be
routed so that they are protected against unintentional contact.
Thermal expansion must be taken into account in pipe joints
•Cooling water supply - when connecting to public water mains,
the applicable laws and safety regulations must be observed
(e.g., connection of the unit via circuit separator). The water
mains pressure must be within the range of 2-6 bar Use only
pressure-resistant and temperature-resistant hoses and screw fit-
tings
•Cooling water outlet - must be free of back-flow and always
open. The hose must be fastened so that any escaping steam at
the start of the cooling procedure does not pose a hazard
•Overflow - must always be open
CAUTION
If the cooler is leaky, thermal oil can enter the wastewater!
For reasons of safety, the cooling system must always be connected!
Electrical Connections
The temperature control unit may only be connected by a qualified elec-
trician.
•Compare supply voltage and frequency with the information on
the rating plate of the temperature control unit
•Verify the rating of the preliminary fuse according to the informa-
tion in the electrical diagram, and check that the power consump-
tion conforms to the value on the rating plate of the temperature
control unit
•Observe the applicable local laws and safety regulations when
connecting to the mains

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Temperature Control Unit 300L(D)/350L(D) Operating Instructions •9
Operation of the Temperature Control Unit
The temperature control unit must only be switched on after inspecting
the consumer, connecting the connecting lines and electrical connec-
tions, and opening the outlet/inlet shut-off valves. The vent valves on the
consumer and the shut-off valves (if present) must be open.
RT100 Control System
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 mode Warning Alarm
Status display
Display of set-point
value SP1/SP2 or ex-
ternal operation
RCD control knob
(Regloplas Control Dial)
Symbol area
Display of zone and tem-
perature probe
Sn1/Sn2/Sn3
Status LEDs
Selection of the device
functions
Display of actual
value
Additional display
Interface address

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10 •Operating Instructions Temperature Control Unit 300L(D)/350L(D)
Device Functions
Set-point value toggling SP1/SP2 Draining (suction or blowing out)
Leak-stop mode
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, counterclockwise rotation
Feed pump, clockwise rotation Alarm
Maintenance due (flashes if maintenance is
due)
RT100 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 ON/OFF button, 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 va-
rious operational and status displays of the temperature control unit are
shown in the lower right part of the display.
Setting the Set-point values
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.

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Temperature Control Unit 300L(D)/350L(D) Operating Instructions •11
To toggle between set-point values SP1 and SP2, press the F3 button
and select of the set-point toggling function. Set-point toggling is only
possible if there is no alarm pending.
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
Switching on the Temperature Control Unit
Upon switching on the main switch, the message 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.
Starting up for the first time / Commissioning
Filling with the heat transfer medium
After carrying out the checks on the consumer, connecting the hoses and
electrical connections, proceed as follows:
•Switch on the main switch on the temperature control unit
•Open the vent valve on the consumer, and also the shut-off valve
(if fitted)
•Using a funnel, pour thermal oil slowly into the filling port, until
the red indicator lamp of the level control is switched off. After the
pump starts up, top up again with oil until the pressure displayed
on the pressure gauge stabilizes at a constant level. This proce-
dure ensures that all lines (both inside and outside the unit) are
filled with thermal oil (for the minimum oil level, see the "Techni-
cal Data" chapter in the Maintenance section). Regloplas rec-
ommends thermal oils Regloplas RO300 or Therminol 66 (see
"Accessories for Temperature Control Units" brochure). As a pre-
ventive precaution, Regloplas recommends the addition of sys-
tem cleaner SR80 (see "Regloplas Temperature Control Units"
brochure, SR80 data sheet)
•Do not close the vent valve on the consumer until thermal oil is
flowing out of the consumer at a regular rate
•Since fresh thermal oil for filling/topping up the system generally
contains moisture, action must be taken to remove this moisture
as an essential precaution (see chapter on "Procedure in the
event of water condensation")
•Check the temperature control circuit for leaks

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12 •Operating Instructions Temperature Control Unit 300L(D)/350L(D)
Operating principle of the two level switches in the
300L(D)
The two level switches in the tank of the 300L(D) each have a specific
switching point. The level switch with the blue marking (S1, NC, upper
switch-point) controls the level control warning lamp and indicates when
the thermal oil must be topped up. The second level switch (S3, NO, lo-
wer switch-point) switches off the feed pump if the oil level is too low, in
order to prevent the pump running dry (see also the Maintenance sec-
tion).
When filling with thermal oil, the feed pump starts up at the lower switch-
point, and the level control warning lamp is switched off at the upper
switch-point.
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.
Venting the Temperature Control Unit
Each time the unit is filled or refilled with thermal oil, the unit and the
temperature control circuit must be vented. To prevent overheating of the
heating elements due to incipient air bubbles in the temperature circuit,
the inlet pressure in the temperature control unit is monitored by a mini-
mum pressure switch. This switch cuts off the heating if the pressure is
too low (0.7 bar) and also activates an alarm. To prevent the heating be-
ing switched on by the control system, a set-point value of approximately
10 °C must be set, and the temperature control unit must be vented at
this value for about 10 minutes.
Re-starting
•Switch on the main switch on the unit
•Open the vent valve on the consumer, and also the shut-off valve
(if fitted)
•Check the temperature control circuit for leaks
•Do not close the vent valve on the consumer until oil is flowing
out of the consumer at a regular rate
WARNING
Risk of burns on touching any parts in contact with the thermal oil!

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Temperature Control Unit 300L(D)/350L(D) Operating Instructions •13
Operating Modes
Normal mode
The heat transfer medium is pumped through the temperature circuit and
consumer by pump pressure.
Leak-Stop Mode (Emergency Mode)
Leak-stop mode is activated by pressing button F3 and selecting the
Leak-Stop symbol. The heat transfer medium is drained from the con-
sumer by reversing the direction of rotation of the pump. Leak-stop op-
eration is only possible at temperatures below 250 °C.
CAUTION
During leak-stop operation, if heating is on, the thermal oil is under high ther-
mal stress, because the pump power is reduced!
Draining the Consumer
The heat transfer medium is drained out of the consumer by suction by
means of the feed pump. During this process, the maximum expansion
volume must be taken into account (see also "Technical Data" chapter).
CAUTION
During drainage by suction, the volume of heat transfer medium in the con-
sumer must be less than the expansion volume in the temperature control unit:
otherwise the temperature control unit will overflow!
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 after the
pump run-down time has elapsed the pump is switched on again in the
opposite direction. The consumer is drained by suction during the defined
period (draining time).
Draining is only possible if the temperature of the heat transfer medium is
below the programmed coastdown temperature value. If that is not the
case, the heat transfer medium is first cooled to this value.
The suction program can be aborted 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.
Operation with Code/Password
In order to prevent the values that have already been set or programmed
from being unintentionally reset/adjusted, the use of a code/password is
urgently recommended. The code is defined in the parameter Code.
The RT100 control system has three password levels that are organised
hierarchically:

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14 •Operating Instructions Temperature Control Unit 300L(D)/350L(D)
•User password - Default 0000 (switched off)
•Technician password - Default 0100
•Service password - only for personnel trained by Regloplas
NOTE
It is strongly recommended that an operator password should be set up when
commissioning the temperature control unit.
Operation with Timer
The RT100 control system has an integrated real-time clock. If the Timer
option is available, 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 reme-
died, the alarm can be reset by once again pressing the Alarm Reset
button.
The Alarm Reset button also allows manual acknowledgement of the au-
tomatic switchover (toggling) from consumer temperature control Sn2 to
outlet temperature control Sn1 if sensor Sn2 is defective or removed
from 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 settings
or user settings at any time in a simple manner. Two different customer-
specific settings can be loaded afresh (user setting 1 and 2).
RT100 Control System - Unlocking Options
The RT100 control system can be equipped with different hardware and
software options.
The software options must be activated with a file via USB stick. This re-
quires the serial number of the control system, which is displayed in the
parameter Options and can be seen on the power section by the bar-
code.
The serial number consists of 6 letters (e.g. AALASF).

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Temperature Control Unit 300L(D)/350L(D) Operating Instructions •15
Switching off the Temperature Control Unit
The temperature control unit is switched off by pressing the ON/OFF but-
ton on the RT100 control system or by the timer, through a digital input or
an interface.
Depending on the temperature of the heat transfer medium, the shut-
down program runs as follows:
•The pump and the control system are switched off. The RT100
control system will then be in standby mode and the message
OFF appears on the display.
•The pump continues to run. The unit cools down until the tem-
perature of the heat transfer medium has reached the pro-
grammed coastdown temperature. On reaching this temperature,
the pump and the control system are effectively switched off. In
the case of pressurised water units, the pump then continues
running for a further few seconds in the opposite direction (pres-
sure release). The RT100 control system will then be in standby
mode and the message OFF appears on the display.
Changing Consumers/Decommissioning
Before detaching the connecting lines, it is necessary to verify that the
temperature control unit is switched off and that all circuits are depressur-
ized (see the chapter "Switching off the Temperature Control Unit"). The
temperature control unit must be drained completely and stored in a dry
place at 10-40 °C when not in use. To restart the unit, proceed as in-
structed in the "Start-up" chapter.
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 cleared by once again pressing the
Alarm Reset button.
The Alarm Reset button also allows manual acknowledgement of the au-
tomatic switchover (toggling) from consumer temperature control (or cas-
cade control) Sn2 to outlet temperature control Sn1 in the event that
sensor Sn2 is defective or removed from the consumer.

V 09/2011
16 •Operating Instructions Temperature Control Unit 300L(D)/350L(D)
Alarm list
Pressing the Alarm Reset button opens the alarm list, as long as there is
no active alarm. The last ten alarm messages are displayed in this list,
complete with date and time.
Warnings
Error message Remedy
Service is due Carry out maintenance procedure according to the
operating manual. Increment the parameter Next ser-
vice by 2000 hours
Clean the filter Clean the corresponding filter or if required, replace it
Current settings lost
factory settings loaded The RT100 control system has lost the parameters and had to load the factory settings
Outlet pressure sensor failure Replace outlet pressure sensor
Heating contactor 1 failure The Heating 1 contactor is no longer switching cor-
rectly - replace
Heating contactor 2 failure The Heating 2 contactor is no longer switching cor-
rectly - 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 pump tolerance parameter (default 50%)
Deviation set-point/outlet underrun Adjust the outlet temperature and acknowledge the
fault
Deviation set-point/outlet exceeded Adjust the outlet temperature and acknowledge the
fault
Deviation set-point/external underrun Adjust the external temperature and acknowledge the
fault or error
Deviation set-point/external exceeded Adjust the external temperature and acknowledge the
fault or error
Deviation set-point/inlet underrun Adjust the inlet temperature and acknowledge the
fault
Deviation set-point/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 Top up heat transfer fluid
Pressure compensation not possible Check water inflow pipe and water pressure (min. 2
bar)
Alarms
Error message Remedy
Switch over heat carrier - reboot of the machine re-
quired
The device type was changed in the configuration
(water/oil as heat transfer medium); the unit must be
switched off and then on again using the main switch
External set-point signal disconnected or not available External set-point signal must be present (if required,
check external control system)
Analog option missing or defective Connect analogue option or switch it off in the Hard-
ware Options parameter