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.