Thermal Care Aquatherm RQT Standard Instruction Manual

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you received it in the User Guide. Our service department uses this information, along
with the manual number, to provide help for the specic equipment you installed.
Please keep this User Guide and all manuals, engineering prints, and parts lists together
for documentation of your equipment.
Date:
Serial Number(s):
Model Number(s):
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for incidental, consequential damages in connection with the furnishing, performance or use of this information.
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implied warranties of merchantability and tness for a particular purpose.
Please record your equipment’s
model and serial number(s) and
the date you received it in the
spaces provided.
Copyright 2022 l Thermal Care l All rights reserved

I iii
Table of Contents
1-1 Introduction
Purpose of the User Guide .............................................................................................. 1-2
How the Guide is Organized ........................................................................................... 1-2
Your Responsibility as a User.......................................................................................... 1-2
ATTENTION: Read This So No One Gets Hurt................................................................. 1-3
Zero Energy State (ZES)................................................................................................... 1-4
2-1 Description
What is the Aquatherm RQT Standard ........................................................................... 2-2
Typical Applications ....................................................................................................... 2-2
How the RQT Standard Direct Injection Works.............................................................. 2-3
RQT Standard Control Features vs RQT Premium and RQT Advanced.......................... 2-4
Specications: RQT Standard ........................................................................................ 2-5
3-1 Installation
Unpacking the Boxes...................................................................................................... 3-2
Preparing for Installation................................................................................................ 3-3
Installation - Electrical ................................................................................................... 3-6
Connecting Process and Water Supply Lines Without Purge ....................................... 3-7
Connecting Process and Water Supply Lines With Purge............................................. 3-8
Connecting the Main Power Source............................................................................... 3-9
Testing the Installation .................................................................................................3-10
Initial Setup...................................................................................................................3-11
RQT Standard Control Setup ........................................................................................3-11
Changing Temperature Units .......................................................................................3-12
Additional RQT Standard Control Setup......................................................................3-12
4-1 Operation
The RQT Standard Control.............................................................................................. 4-2
Home Screen Display...................................................................................................... 4-3
User Parameters.............................................................................................................. 4-3
Starting the RQT Standard temperature control unit .................................................... 4-4
Stopping the RQT Standard temperature control unit .................................................. 4-5
Using the Mold Purge Option ......................................................................................... 4-6
Selecting Tuning Parameters ......................................................................................... 4-7
RQT Standard Control Vent Timer Adjustment .............................................................. 4-8

iv I
5-1 Maintenance
Maintenance of Your RQT Standard temperature control unit...................................... 5-2
Preventive Maintenance Schedule................................................................................. 5-2
Accessing the RQT Standard temperature control unit Enclosure................................ 5-3
Removing the Pump Motor and Seal ............................................................................. 5-4
Reassembling the Pump Motor and Seal ...................................................................... 5-7
Resetting Pump Overload............................................................................................... 5-9
Replacing Pump Overload.............................................................................................. 5-9
Replacing the PLC.........................................................................................................5-10
Replacing the Heater Contactor...................................................................................5-11
Replacing the RTD ........................................................................................................5-12
Repairing Cooling Valves.............................................................................................. 5-13
Disassembly of Optional Direct Acting Solenoid Valves .............................................5-14
Disassembly of Optional Pilot Operated Solenoid Valves ...........................................5-15
Replacing Immersion Heaters ......................................................................................5-16
Removing the Pump......................................................................................................5-18
6-1 Troubleshooting
Before Beginning ............................................................................................................ 6-2
A Few Words of Caution.................................................................................................. 6-2
Identifying the Cause of a Problem................................................................................ 6-3
Controller Warnings and Alarms .................................................................................... 6-4
RQT Standard Control Alarms ........................................................................................ 6-4
RQT Standard Control Alarm/Warnings....................................................................... 6-15
RQT Standard Control Warnings..................................................................................6-24
Checking the RTD .........................................................................................................6-26
Appendix A
We’re Here to Help........................................................................................................... A-1
How to Contact Customer Service ................................................................................. A-1
Before You Call... ............................................................................................................. A-1

I v
Appendix B
User Parameters.............................................................................................................. B-1
Factory Parameters......................................................................................................... B-5
Diagnostics ..................................................................................................................... B-7
PID Parameters .............................................................................................................B-11
Appendix C
Plumbing Diagrams ........................................................................................................C-1

vi I
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1
SECTION
Introduction I 1-1
Purpose of the User Guide........................................1-2
How the Guide is Organized .....................................1-2
Your Responsibility as a User ...................................1-2
ATTENTION: Read This So No One Gets Hurt...............1-3
Zero Energy State (ZES) ...........................................1-4
Introduction
1
Introduction

1-2 I Introduction
Purpose of the User Guide
This User Guide describes the Thermal Care RQT Standard temperature control unit and
explains step-by-step how to install and operate this equipment.
Before installing this product, please take a few moments to read the User Guide and
review the diagrams and safety information in the instruction packet. You also should
review manuals covering associated equipment in your system. This review won’t take
long, and it could save you valuable installation and operating time later.
How the Guide is Organized
Symbols have been used to help organize the User Guide and call your attention to im-
portant information regarding safe installation and operation.
Symbols within triangles warn of conditions that could be hazardous to users or could
damage equipment. Read and take precautions before proceeding.
Numbers indicate tasks or steps to be performed by the user.
A diamond indicates the equipment’s response to an action performed by the user or a
situation.
An open box marks items in a checklist.
A circle marks items in a list.
Indicates a tip. A tip is used to provide you with a suggestion that will help you with the
maintenance and the operation of this equipment.
Indicates a note. A note is used to provide additional information about the steps you are
following throughout the manual.
Your Responsibility as a User
You must be familiar with all safety procedures concerning installation, operation, and
maintenance of this equipment. Responsible safety procedures include:
•Thorough view of this User Guide, paying particular attention to hazard warnings,
appendices, and related diagrams.
•Thorough review of the equipment itself, with careful attention to voltage sources,
intended use, and warning labels.
•Thorough review of instruction manuals for associated equipment.
•Step-by-step adherence to instructions outlined in this User Guide.
1
u
r
•
2
0

Introduction I 1-3
1
Introduction
ATTENTION:
Read This So No One Gets Hurt
We design equipment with the user’s safety in mind. You can avoid the potential hazards
identied on this machine by following the procedures outlined below and elsewhere in
the User Guide.
WARNING: Improper installation, operation, or servicing may result in equipment
damage or personal injury.
This equipment should be installed, adjusted, and serviced by qualied technical
personnel who are familiar with the construction, operation, and potential hazards of
this type of machine.
All wiring, disconnects, and fuses should be installed by qualied electrical technicians
in accordance with electrical codes in your region. Always maintain a safe ground. Do
not operate the equipment at power levels other than what is specied on the machine
serial tag and data plate.
WARNING: Voltage Hazard
This equipment is powered by three-phase alternating current, as specied on the
machine serial tag and data plate.
A properly sized conductive ground wire from the incoming power supply must be
connected to the chassis ground terminal inside the electrical enclosure. Improper
grounding can result in severe personal injury and erratic machine operation.
Always disconnect and lock out the incoming main power source before opening the
electrical enclosure or performing non-standard operating procedures, such as routine
maintenance. Only qualied personnel should perform troubleshooting procedures that
require access to the electrical enclosure while power is on.
WARNING: Compressed Air Hazard
If you use compressed air, you must wear eye protection and observe all OSHA and other
safety regulations pertaining to the use of compressed air. Bleed o pressure before
servicing equipment.
CAUTION: Hot Surfaces
Surface temperatures inside the RQT Standard temperature control unit can exceed
250°F {121°C}.Always allow the unit to cool below 100°F {38ºC} before opening,
servicing, or disassembling the unit.

1-4 I Introduction
Zero Energy State (ZES)
CAUTION: Before performing maintenance or repairs on this product, you should
disconnect and lockout electrical power sources to prevent injury from unexpected
energizing or start-up.
During maintenance, it is essential that the system be put into a state which eliminates
the possibility of components making an unexpected and dangerous movement.
This procedure is typically referred to as lockout. After all energy sources have been
neutralized, the system is in the zero mechanical state (ZMS). This provides maximum
protection against unexpected mechanical movement.
The lockout procedure must include all energy sources:
•Electrical power supply
•Compressed air supply
•Potential energy from suspended parts
•Pressurized process uid loop
•Cooling uid supply
•Cooling uid return
•Stored thermal energy
•Any other source that might cause unexpected mechanical movement or energy
release
The following is a recommended Zero Energy State procedure which must be followed
prior to any inspection, or maintenance of the TCU.
1 Turn o the all devices attached to the RQT Standard temperature control unit.
2 Perform the proper shutdown sequence to the connected equipment and allow
all components (internally and externally) to adequately cool.
3 Disconnect and lock out the primary electrical supply feeding all attached com-
ponents.
WARNING: Before removing lockout devices and returning switches to the ON position,
make sure that all personnel are clear of the machine, tools have been removed and all
safety guards reinstalled.
4 Disconnect and lock out the compressed air supply (if equipped).
5 Isolate the RQT Standard temperature control unit from other uids in the
system, such as the main process loop and the cooling uid supply and return.
6 Bleed o uid pressure that may be present in the various uid containing por-
tions of the RQT Standard temperature control unit, keeping in mind that pres-
sure can be the result of increased temperatures.

2
SECTION
Description I 2-1
2
Description
What is the RQT Standard ........................................2-2
Typical Applications................................................2-2
How the RQT Standard Direct Injection Works ............2-5
RQT Standard Control Features vs RQT Advanced & RQT
Premium.............................................................2-6
Specifications: RQT Standard...................................2-7
Description

2-2 I Description
What is the RQT Standard
The RQT Standard circulates water at a temperature higher than the available water
supply, to add or remove heat as needed to maintain a uniform temperature setpoint in the
process.
The RQT Standard is available in single zone conguration for process heating and cool-
ing.
Typical Applications
The best model for your application depends on the process temperature you need to
maintain and the quality of the cooling water supply.
RQT direct injection (DI) models control the temperature by discharging heated process
water or adding cooling water directly from the water supply. DI models are designed for:
•Process temperatures up to 250°F {121°C}.
•Use with chiller water or properly treated and ltered tower or city water.
Check to make sure all piping connections are secure and that all lines are suitable for
water or the coolant in the system at the maximum setpoint temperature and cumulative
pressure rating of the maximum pump pressure and the unit ll uid pressure
Make sure that the cooling source is the appropriate temperature and pressure for your
application. In most cases, the cooling source is between 40°F and 85°F. The cooling
source uid pressure must be above the setpoint of the pressure switch in order for the
unit to start. For most applications, the design cooling source supply pressure is between
25 psi and 50 psi and must not exceed 90 psi for the 2HP module (95 psi for the 3/4 HP
model). If the total pressure in the unit exceeds 135 psi, the pressure relief valve in the
unit will open. If this becomes an issue, install a pressure-regulating valve (available from
our Parts Department) on the supply line to help regulate the pressure to ensure it does
not exceed the pressure rating of the pressure relief valve. For further assistance in install-
ing a pressure-regulating valve, please contact our Customer Service Department.

Description I 2-3
2
Description
How the RQT Standard Direct Injection Works
Direct injection models maintain the process temperature by electrically heating and/
or injecting cool water supplied to the RQT Standard by a chiller, tower, or other water
source.
1 The temperature of the process uid is measured as it leaves the unit’s primary
heater tank. The uid then ows through the “To Process” line to the mold or pro-
cess. The uid returns to the unit through the “From Process” line for reheating or
cooling.
2 The temperature of the process uid may be measured as it ows into the mixing
tank through the “From Process” line.
3 If the “To Process” temperature is above the setpoint value, the cooling valve opens.
Cool water enters the bottom of the mixing tank via the “Cooling In” line. Warm
water ows out of the top of the tank via the “Cooling Out” line.
NOTE: The “From Process” can also be congured as a controlling source.
If the “To Process” temperature is below the setpoint, the heater elements inside the
heater tank are energized.
4 The pump moves water from the mixing tank into the heater tank. Pressure is mea-
sured before and after the pump with pressure gauges.
See Appendix C for plumbing diagrams.

2-4 I Description
RQT Standard Control Features vs
RQT Advanced and RQT Premium Units
Control features on the RQT Standard Control features on the RQT Advanced and RQT Premium
Standard
Optional


Use the charts below to compare RQT control options and chose the one perfect for your application.
Model RQT Standard
Direct Injection 
Closed Circuit - Common Source
Closed Circuit - Separate Source
Construction
Standard Pump Range 3/4 or 2 Hp
Standard Heater Range 12 kW
Cast Heater / Pump 
Incoloy Heaters 
Silicon Carbide Seals 
Pressure Gauges 
Pressure Transducer
Solid State Heater Relays (SSRS)
Controls
PID Control 
Setpoint / Actual Display 
Password Protection
Modbus-RTU via RS-485
Modbus-TCP via Ethernet
SPI RS-485 Interface
OPC-UA via Ethernet
Retransmit Process Temp
Auto Restart Capability
Mold Purge (Factory Installed) 
Phase Detection Circuit
Choice of Control Points 
Seal Saver/Auto Cool Stop
Status / Alarm Lights
Audible Alarm
Strobe Light
Alarm Dry Contacts
Remote RTD Support
Trending
Model RQT Advanced RQT Premium
Direct Injection  
Closed Circuit - Common Source  
Closed Circuit - Separate Source 
Construction
Standard Pump Range 3/4 to 10 Hp 3/4 to 10 Hp
Standard Heater Range 0 to 48 kW 0 to 48 kW
Cast Heater / Pump  
Incoloy Heaters  
Silicon Carbide Seals  
Pressure Gauges
Pressure Transducer 
Solid State Heater Relays (SSRS) 
Controls
PID Control  
Setpoint / Actual Display  
Password Protection 
Modbus-RTU via RS-485 
Modbus-TCP via Ethernet  
SPI RS-485 Interface 
OPC-UA 
Retransmit Process Temp  (0-10 VDC) 
Auto Restart Capability  
Mold Purge (Factory Installed)  
Phase Detection Circuit  
Choice of Control Points  
Seal Saver/Auto Cool Stop  
Status / Alarm Lights
Audible Alarm  
Strobe Light  
Alarm Dry Contacts  
Remote RTD Support  
Trending 
Control temperature
based on temperature at
process supply or return
points, or an average of
the two points.
Purge On/Off button
included on control.
Phase detection
indicates incorrect
pump rotation or an
open electrical leg.


Description I 2-5
2
Description
Specifications: RQT Standard
Specication Notes
Models RQT Standard
Performance characteristics
Minimum setpoint temperature °F {°C} 40 {4}
Maximum setpoint temperature °F {°C} 250 {121}
Minimum operating temperature °F {°C} Approximately 20° {11°} above the cooling water inlet temperature
Standard cooling valve size inches {mm} Cvsolenoid valve-3/8 {9.5} (Cv=2.5)
Available pump sizes 0.75, 2 {0.56, 1.49 kW}
Available heater sizes 12 kW
Pump performance - Consult factory for pump performance characteristics at other operating points.
Pump 3/4 Hp {0.56 kW} 2 Hp {1.49 kW}
Nominal ow gpm {lpm} 50 {189} 75 {284}
Pressure @ nominal ow psi {kg/cm2} 20 {1.4} 30 {2.1}
Dimensions inches {mm}
Standard cabinet, not including any connections
A - Height 24.98 {634}
B - Width 14.09 {358}
C - Depth 24.09 {612}
Water connections
All models NPT inches (female)
To/From process 1.50
Cooling water in/out 1.00
Shipping weight ranges lb {kg} Weights vary depending on selected options, voltage and pump HP
Single Zone
Pump Minimum Maximum
0.75 Hp {0.56 kW} estimated 240 {109} estimated 325 {147}
2 Hp {1.49 kW} estimated 250 {113} estimated 338 {153}
Total full load amps per zone* Standard voltage is 460 volts, 3 phase, 60 Hz.
Heater
Voltage 208-230/3/60 400/3/50 460/3/60 575/3/60
208 230
Pump size
0.75 Hp {0.56 kW} 30.3 33.2 19.2 16.6 13.4
2.0 Hp {1.49 kW} 33.3 36.1 21.4 18.1 14.5
* FLA data for reference purposes only. Does not include any options or accessories on equipment. For full FLA detail for power circuit design of specic machines and systems, refer to the electrical
diagrams of the equipment order and the nameplate applied to the machine.
Consult factory about your application prior to using a check valve on the Cooling Water Inlet of your RQT Standard controlled unit.
Specifications may change without notice. Consult factory for the most current information.
A
B C

2-6 I Description
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3
SECTION
Installation I 3-1
3
Installation
Installation
Unpacking the Boxes ...............................................3-2
Preparing for Installation ........................................3-3
Installation - Electrical ...........................................3-6
Connecting Process and Water Supply Lines Without
Purge.................................................................3-7
Connecting Process and Water Supply Lines With
Purge.................................................................3-8
Connecting the Main Power Source...........................3-9
Testing the Installation ......................................... 3-10
Initial Setup .........................................................3-11
RQT Standard Control Setup...................................3-11
Changing Temperature Units ..................................3-12
Additional RQT Standard Control Setup...................3-12

3-2 I Installation
Unpacking the Boxes
RQT Standard models come fully assembled. If it was specied at the time of the order,
the optional purge valve is factory-installed.
CAUTION: Lifting
To avoid personal injury or damage to the RQT Standard, lift the unit using a forklift or
hoist with straps that have been positioned at the center of gravity.
WARNING: If using straps, be sure to use a spreader bar or equivalent so the top sheet
metal of the RQT Standard isn’t inadvertently pinched due to the lifting action.
NOTE: If the temperature control unit is stored prior to installation, it is important to protect it from
damage. Blow out any water from the unit to protect it from damage from freezing. Cover the equipment to
keep dirt and debris from accumulating on it. Units should not be stored in areas warmer than 145°F {63°C}.
1 Carefully remove the RQT Standard and components from its shipping containers.
2 Remove all packing material, protective paper, tape, and plastic. Compare contents
to the shipping papers to ensure that you have all the parts.
3 Carefully inspect all components to make sure no damage occurred during ship-
ping. Check all wire terminal connections, bolts, and any other electrical connec-
tions, which may have loosened during shipping.
4 Record serial numbers and specications in the blanks provided on the back of the
User Guide’s title page. This information will be helpful if you ever need service or
parts.
5 You are now ready to begin installation. See Installation Section entitled,
Preparing for Installation.
NOTE: Beware that the room-temperature water frequently contains a surprisingly large quantity of
dissolved air within it and this air will separate from the water once heated to an elevated temperature. Ad-
ditional provisions may have to be made to remove this air from the uid loop, as it will inhibit heat transfer,
and damage the pump and heater if it comes out of the uid.

Installation I 3-3
3
Installation
Preparing for Installation
The RQT Standard is easy to install, if you plan the location and prepare the area
properly.
WARNING: Improper installation, operation, or servicing may result in equipment
damage or personal injury.
This equipment should only be installed, adjusted, and serviced by qualied technical
personnel who are familiar with the construction, operation, and potential hazards of
this type of machine.
All wiring, disconnects, and fuses should be installed by qualied electrical technicians
in accordance with electrical codes in your region. Always maintain a safe ground. Do
not operate the equipment at power levels other than what is specied on the machine
serial tag and data plate.
1 Position the RQT Standard as close to the process machine as possible.
2 Make sure the installation area provides:
UA three-phase power source supplying the correct cur-
rent for your RQT Standard model. Check the serial tag
on the unit for required voltage, phase, frequency, and full
load amps. Check the electrical prints for the disconnect
fuse size and minimum wire connection size. All wiring
should be completed by qualied personnel and should
comply with your region’s electrical codes.
UCompressed, dry air (<100psi) if your RQT Standard is equipped with the Mold
Purge option.
UA clean, well-ventilated environment. The room temperature should not exceed
104° F {40° C} with 95% non-condensing humidity and should not fall below
32° F {0° C}.
UMinimum clearance for safe operation and maintenance. The diagram at
the right shows minimum clearance for operation. You also need enough
clearance in rear for water hookups. For maintenance, you should move
the RQT Standard to provide at least 36 inches {91 cm} on any side of the
RQT Standard. Additionally, your required electrical codes may require a larger
service area in front of the electrical panel.
UA source of water for cooling. City, tower or chiller water may be used, as long
as the supply pressure is at least 25 psi and not more than 90 psi for 2 HP models
(95 psi for 3/4 HP models).
UCheck to make sure all piping connections are secure and that all lines are
suitable for water or the coolant in the system at the maximum setpoint tem-
perature and cumulative pressure rating of the maximum pump pressure and the
cooling water supply pressure, or the nameplate rating of the pressure relief valve
(150psi), whichever is greater.
UA location to mount an external three-phased, fused, and grounded electrical
disconnect.
ULockable isolation devices for all utilities, including electrical disconnect, cool-
ing water line valves, and compressed air supply disconnect and bleed-o.
RQT
Process
Machine
Alternate
locations
LowProcess
STOPPED
Setpoint
200°F
InletPres
To
Process
198°F
RUN MP
12 inches
{305 mm}
12 inches
{305 mm}
20 inches
{508 mm}
Pump HP Max Cooling
(PSI)
3/4 95
1 90
2 90
3 85
5 75
7.5 65
10 50
NOTE: If your cooling water
pressure exceeds the cooling water
pressure chart referenced previously,
install a pressure-regulating valve
before the cooling inlet.

3-4 I Installation
Preparing for Installation (Continued)
UMake sure that the cooling source is the appropriate temperature and pres-
sure for your application. In most cases, the cooling source is between 40°F
{4°C} and 85°F {29°C}. The cooling source uid pressure must be above the
setpoint of the pressure switch in order for the unit to start. For most applications,
the design cooling source supply pressure is betweeen 25 psi and 50 psi, not to
exceed 90 psi for 2 HP models (95 psi for 3/4 HP models). The pressure relief
valve is located on the “From Process” side of the pump and will start to dis-
charge if the pressure exceeds 135 psi. If this becomes an issue, install a pres-
sure-regulating valve (available from our Parts Department) on the supply line
to help regulate the pressure to ensure it does not exceed the pressure rating of
the pressure relief valve. For further assistance in installing a pressure-regulating
valve, please contact our Customer Service Department.
System Fill Water Chemistry Requirements
The properties of water make it ideal for heat transfer applications. It is safe, non-am-
mable, non-poisonous, easy to handle, widely available, and inexpensive in most industri-
alized areas.
When using water as a heat transfer uid it is important to keep it within certain chemis-
try limits to avoid unwanted side eects. Water is a “universal solvent” because it can dis-
solve many solid substances and absorb gases. As a result, water can cause the corrosion
of metals used in a cooling system. Additionally, dissolved minerals naturally present in
tap water will precipitate out onto the system plumbing at elevated uid temperatures,
forming scale. The life giving properties of water can also encourage biological growth
that can foul heat transfer surfaces.
To avoid the unwanted side eects associated with water cooling, proper chemical treat-
ment and preventive maintenance is required for continuous plant productivity.
Unwanted Side Eects of Improper Water Quality
•Corrosion
•Scale
•Fouling
•Biological Contamination
Cooling Water Chemistry Properties
•Electrical Conductivity
•pH
•Alkalinity
•Total Hardness
•Dissolved gases