350L

Operating Instructions
Operating Instructions
Temperature Control Units
150S • 300S • 300(DG) • 301(DG) • 350L
Contents

1. Notes on safety 27
2. Range of application 28
3. Setting up 28
4. Switching the unit on 30
5. Switching the unit off 32
6. Changing the consumer. Shutting the unit down for more than one month. Switching the unit back on 32
7. Maintenance 32
8. Ordering replacement parts 34
9. Shipping the unit 34
10. Optional equipment 34
11. Troubleshooting 35
12. Technical data 36

Guidelines for connecting hoses 39

Service 41

1. Notes on safety

• Emergency off: Press the yellow/red main switch on the temperature control unit (when present) or
pull out the plug.
• Thermal oil is combustible under certain conditions, therefore:
– Do not place the unit in the vicinity of heat sources (e.g. oven in die-casting plants).
– Keep thermal insulation clean at all times. Insulation soaked in thermal oil is a fire hazard.
– Repair leaks in the temperature control circuit (unit, connection lines, consumer, etc.) immediately.
• Burning thermal oil can be extinguished with:
– AFFF spray foam fire extinguisher.
– Powder fire extinguisher (avoid using near dust-sensitive equipment, e.g. process controllers, com-
puters, etc.)
– CO2 fire extinguisher (Backflash hazard, suitable only under certain conditions).
The suitable fire extinguisher shall be provided by the operator under consideration of the equipment
found in the room and all applicable safety regulations.
• Never operate the unit without the side panels in place.
• Protect the unit from sprays and cleansers containing solvents.
• Injury hazard from leaking hot thermal oil.
– Before detaching connecting hoses in the temperature control circuit, cool the unit down and then
switch it off, depending on the magnitude of the outlet temperature.
– Check if the pump has stopped.
• In equipment in which a malfunction of the temperature control system can be hazardous to operating
personnel or lead to destruction of the equipment, independent monitoring equipment to monitor the
process and switch the equipment off safely.
• The unit shall not be placed in areas subject to explosion.

BA 150S-350L/0703/d/f/e 27
• These Operating Instructions belong in the hands of the set-up and operating personnel.
Please ensure that the Operating Instructions are read. You will thereby save yourself unnecessary
costs and problems during the set-up as well as prevent downtime.

2. Range of application

The temperature control unit serves to heat or cool injection moulds and diecasting dies, extruders, calenders,
mixers and other consumers in areas not subject to explosion.
The units are designed for use with thermal oil up to the following maximum outlet temperatures: Model 150S:
150 °C (special version to 180 °C), Model 300S, 300(DG), 301(DG): 300 °C. Model 350L: 350 °C. For technical data,
see Section 12.

3. Set-up

3.1 Unpacking
Do not tip the unit. The heat transfer fluid remaining from the test run could run out, which could soak the insula-
tion.

3.2 Placing the unit

The unit is designed for an ambient temperature of 10 to 40 °C. When placing the unit, ensure that there is suffi-
cient ventilation. The distance between units or between a unit and the wall must be at least 4 cm
Place the unit on a level base and engage the wheel brakes.
The unit shall not be placed in the vicinity of heat sources, e.g. ovens in diecasting plants, as thermal oil is com-
bustible under certain conditions.

3.3 Consumer checks

Before connecting the hoses between the consumer and the temperature control unit, the following checks shall
be performed on the consumer:
1 Check conduits for blockage.
2 Remove fluid and dirt residue using compressed air. Foreign bodies such as splinters can damage the pump.
3 Remove rust, scaling and oil residue, as these strongly restrict heat transfer between the consumer and the
heat transfer fluid and increase the pressure drop in the consumer. The Regloplas descaling unit, REG, can be
used to descale (→”Regloplas Temperature Control Units” brochure, “REG” Data sheet). The Regloplas Sys-
tem Cleaner, SR80, can be used to remove oil deposits (→ ”Regloplas Temperature Control Units” brochure,
“SR80” Data sheet).
4 When switching between water or steam to thermal oil, all water residue in the consumer and in the
connection hoses must be removed completely: Accident hazard during heat-up due to the pressure of
the steam thus created.
Proceed as described in Section 7.3.

3.4 Water quality

To prevent damage to the temperature control unit cooler, the water used must meet the following requirements:
Total hardness 4–18 °d
Ph value 7–9 KKG*
Conductance max.1000 µS/cm
*KKG = Lime/carbon dioxide balance

3.5 Connection hoses

See also page 39.
– Outlet and inlet: Use only pressure and temperature resistant hoses (→ ”Accessories for temperature control
units” brochure).
For pipes, the thermal expansion must be taken into account.
The connection hoses shall be laid out such that they are protected from accidental contact.

28 BA 150S-350L/0703/d/f/e
– Cooling water inlet: The pressure must be at least 3 bar. Use only pressure-resistant hoses. (→ ”Accessories
for Temperature Control Units” brochure). For the connection to the public mains, follow applicable guidelines
and safety regulations (e.g. connecting the unit via a system separator).
– Cooling water outlet: Must be free of backflow and always open. The hose shall be fastened such that any
vapour escaping at the beginning of the cooling process do not present a hazard.
Unsealed coolers can release thermal oil into the wastewater.
– Overflow of the expansion vessel: Must always be open.
For safety reasons, the cooler must always be connected.

3.6 Electrical connections

1 Mains voltage and frequency must match the information found on the rating plate.
2 Check the back-up fuse value according to the information in the electrical schematic in the electrical part of
the unit.
3 All applicable guidelines and safety regulations shall be followed when connecting the unit to the mains.
4 Markings of the connection cable strands in accordance with IEC standards:
3P E yellow/green
black-brown/blue

3.7 Filling the heat transfer fluid

After checking the consumer, and connecting the hoses and electrical cables, proceed as follows:
1 Switch on the main switch on the unit (when present).
2 Open the vent and shutoff valves (when present).
3 Using a funnel, pour the thermal oil into the filling port slowly, until the level control’s red indicator lamp (when
present) of the level control at the top of the unit to the rear near the filling port extinguishes. Minimum filling
quantity in accordance with Section 12 of the Technical Data.
Warning: Every time the unit is filled with thermal oil, the unit and the temperature control circuit must be
vented as follows:
Switch the unit on. To prevent overheating of the heating elements due to initial trapped air in the temperature
control circuit, the outlet pressure in the unit is monitored by a minimum pressure switch. It will interrupt
heating when the pressure is too low (0.7 bar) and the flow alarm will be activated. To prevent the heater from
being switched on before the controller is switched on, a set-point value of approximately 10 °C is set and the
unit is vented at this value for approximately 10 minutes.
Recommended thermal oil: Regloplas RO150 (only for model 150S), RO300 or Therminol 66 (→ ”Accessories
for temperature control units” brochure).
As a preventative measure, we recommend the addition of the SR80 system cleaner (→ ”Regloplas tempera-
ture control units”, ”SR80” data sheet).
4 Do not close the vent valve at the consumer until thermal oil flows from it regularly.
5 As newly filled thermal oil usually contains moisture, the moisture must be removed as described in Section
7.3, Operations 4 and 5.

BA 150S-350L/0703/d/f/e 29
4. Switching on

4.1 Switching on with the RT30 controller (Fig. 1, Table 1)

1 Switch the unit/pump on using the corresponding switch.
After it is switched on, the RT30 runs a functional test for approximately 5 sec-
onds. During this test, all displayed values will blink.
Once the test has been successfully completed, the actual value will appear in
the upper display and the set-point value in the lower.
2 Check the pump’s direction of rotation using the direction of rotation arrows.
If the direction of rotation is incorrect, switch the two phases in the unit’s plug.
Important: The rotary switch (when present) on the front plate must be in the
”+” position, i.e. pumping mode.
3 Continue filling the thermal oil only as long as the pump runs without interrup-
tion and the red display lamp of the level controller goes out, that is, sufficient
thermal oil is circulating in the temperature control circuit (unit, connecting
hoses, consumer, etc.).
4 Check the temperature control circuit (unit, connecting hoses, consumer, etc.)
for leaks.
Fig. 1: Controller RT30
5 Close the vent valve only when water runs out of it regularly.

Element
MAIN AL 1

Meaning Pump, Heating Cooling Level Motor Safety

Control control contactor thermostat

Lamp –– In operation In operation Insufficient Thermal relay Temperature

lights heat transfer has released too high
fluid in circuit

Table 1: Control and display elements with RT30 controller

4.1.1 Setting elements

– Set the set-point value using the ”∆“ and “∇“ keys.
– Neutral zone: This is set at the factory to +2 °C. Between the set-point value and the selected value of +2 °C,
the unit will neither heat nor cool.

4.1.2 Malfunction indicator

In the event of a sensor break, the message “Sbr” will be displayed. In the event of a sensor short circuit, the
message “Err” will be displayed.
In both cases, cooling is switched on, to ensure that the consumer is protected against overheating (display lamp
“Al 1”).

4.2 Switching on with the RT50 control system (Fig. 2)

1 Once the main switch on the unit has been turned on, “OFF” will appear in the display. The RT50 is now ready
for operation.
2 Switch on by pressing the “ON/OFF“ key. Depending on the programming, the set-point and actual values as
well as information on the operational state of the control system and unit will appear on the display.

30 BA 150S-350L/0703/d/f/e
4.3 Operating and display elements (Fig. 2)
1 LCD display.
2 Keys for programming and selecting the display.
3 Alarm reset key. 1
4 On/Off key.
5 Key for leak-stop mode. 10
6 Key for suction and blow-out. 2
7 Key for switching between set-point values SP1 and SP2.
8 Key for operation with timer. 3 9
9 Keys for entering set-point value and programming. 8
4
10 Status line. 7
5
6

Fig. 2: Eléments de commande et d’affichage

Set-point and actual value displays

Once the control system has been switched on using the “ON/OFF“ key, the set-point temperature SP1 or SP2
(SP = Set-point) will appear in the lower part of the display, and in the upper part the actual value of the outlet
temperature S1 of the internal sensor in the heat transfer fluid or S2, the temperature of the external sensor in
the consumer (S = Sensor).
Keys for entering the set-point value and programming
Increasing or decreasing the set-point value, selecting the program position, changing the programmed values.
Timer key
If the RT50 is equipped with a timer, it is activated by this key. The unit is switched on and off via the timer.
Leak-stop key
Pressing this key puts the unit into leak-stop mode. Leak-stop mode is possible only when the set-point value is
between 0 and 250 °C max.
In leak-stop mode, the heating capacity is at a maximum of 60% to keep the thermal load on the oil due to the
reduced pumping capacity low.
The leak-stop function can be stopped by pressing the “ON/OFF“ key (wait until “OFF“ appears on the display).
The unit will then switch over to normal mode.
Suction key (evacuation).
Pressing this key initiates the evacuation sequence. The consumer connected to the unit is evacuated by the
pump.
Evacuation is possible only when the temperature of the heat transfer fluid is below the value programmed for
the run-out temperature “RT50 Operating Instructions“, Section 7.2, P 4.3). If this is not the case, the unit will
first cool the heat transfer fluid to this value.
The pump is switched off. Once the pump run-out time (“RT50 Operating Instructions“, Section 7.2, P 4.9), has
elapsed the pump is switched on again in the opposite direction of rotation. The pump then evacuates the con-
sumer during the programmed evacuation time (“RT50 Operating Instructions“, Section 7.2, P, P 4.6).
After the programmed evacuation time, the unit switches off automatically. The suction process can be inter-
rupted by pressing the “ON/OFF“ key. Pressing the “ON/OFF“ key again.
Alarm Reset key
Function:
– Manual reset of the alarm relay (e.g. switching off a horn). Once the malfunction has been corrected, the alarm
display can be erased by pressing the key once more.
– Manual acknowledgment of the automatic switch from control of the consumer temperature or cascade con-
trol to control of the outlet temperature in the event of a defective or missing S2 sensor in the consumer.
SP key
Switchover between set-point value 1 (SP1) and set-point value 2 (SP2).
Note: Set-point value switchover is possible only when no alarm is active.
Operation with code
To prevent the set/programmed values from being inadvertently changed, we strongly recommend the use of a
code. There are 4 possibilities:
– Entered value code

BA 150S-350L/0703/d/f/e 31
– Set-point value code
– User setting 1 code
– User setting 2 code
Programming these codes is described in the “RT50 Operating Instructions”, Section 7.2, item 15.
Save/Reset to Factory or user setting
The RT50 control system offers the possibility to reload the factory settings easily and at any time.
In the same way, two different, customer-specific settings can be reloaded (user settings 1 and 2).
Programming these codes is described in the “RT50 Operating Instructions”, Section 7.2, item 14.

5. Switching off

5.1 Switching off with the RT30 controller

1 Cool the unit and the temperature control circuit to 80 °C or below.
2 Switch off the pump using the switch (→ Table 1).

5.2 Switching off with the RT50 control system

5.2.1 Using the On/Off key

The switching off process is initiated by pressing the “ON/OFF” key or via the timer. The switching off process
runs automatically depending upon the temperature of the heat transfer fluid as follows:
– Pump and control are switched off. The RT50 is still under power (stand-by mode). The display indicates
“OFF”.

5.2.2 By previous evacuation of the consumer

See Optional equipment, Section 10.

6. Changing the consumer. Shutting the unit down for more than one month. Switching the
unit back on

Before removing connection hoses, ensure that the unit is switched off and that all circuits are free of pressure.
The unit must be evacuated completely and stored in a dry location between 10 und 40 °C when not used.
Depending on the storage location, condensed water can develop, so the procedure described in Section 7.3, 2–5,
must be performed.

7. Maintenance

7.1 Periodic checks and maintenance procedures

To make the maintenance procedures easier, the RT50 control system is equipped with a service-interval display.
We recommend entering the corresponding service interval (e.g. 2000 hours). For programming, see “RT50 Ope-
rating Instructions”, Section 3.9.
We recommend that the following cleaning procedures are performed every time heat transfer fluid is added or
replaced. Please note that the following information is for 8 hours of operation daily. For operations with more
than one shift, these checks and maintenance procedures shall be performed in correspondingly shorter intervals.
Defective components shall be repaired or replaced immediately.
• Checks and maintenance procedures shall be performed by qualified personnel.
• Maintenance procedures on the electrical equipment shall be performed by a qualified electrician.
• Main plug shall not be pulled out until the unit is switched off.
• When working with pumps with magnetic couplings, be aware of danger from magnetic fields:
– People with pacemakers and/or implanted metal components must maintain sufficient distance
from the unit or should not perform maintenance operations on the pump.
– When pushing the magnetic coupling together, hold the motor such that no fingers could be
trapped as a result of magnetic strength.
– Maintain the necessary distance from computers, diskettes, credit cards, electrical watches, etc.

32 BA 150S-350L/0703/d/f/e
7.1.1 Daily checks/maintenance
Check the temperature control circuit (unit, connecting hoses, consumer, etc.) for leaks. Fix any leaks immedi-
ately. Replace oily insulation immediately and remove any oil spills.

7.1.2 Monthly checks/maintenance

1 Check the inlet opening for the pump cooling for blockage. Clean unit from the inside to the outside using
compressed air.

7.1.3 Semi-annual checks and maintenance

1 Remove level switch and clean (→ Service).
2 Check the function of the safety thermostat.
Attention: The temperature control circuit (unit, connecting hoses, consumer, etc.) must be suitable for the
check temperature.
Enter the set-point value at the controller as follows: Model 150S: 160 °C (Version to 180 °C: set value to 190 °C).
Models 300S, 300(DG), Model 301(DG): 320 °C. Model 350L: 370 °C.
Heat the unit (temperature control circuit) to this temperature. With the RT30 controller, the “Safety thermo-
stat” lamp will light up. The heat must switch off.
With the RT50 system, the outlet limit (“RT50 Operating Instructions”, Section 7.2, P 3.2) or maximum set-
point value (P 4.4) may need to be entered correspondingly. The alarm “Safety thermostat triggered” will ap-
pear on the display. The unit must now cool.
Attention: After these checks have been completed, reset to the original set-point value.
3 Check the electrical equipment such as grounding wires, contactors, firm positioning of the connection cables,
etc.
4 Check the oil after approximately 1000 hours of operation (corresponds to approximately half a year under 1
shift operation). The only way to tell if the oil can continue to be used is by analysing it, preferably performed
by the heat transfer fluid manufacturer. The dark colour is not indicative of the condition of the oil.
Approximately 1 litre of used oil is needed for the analysis. For safety reasons (escaping oil vapour is a fire
hazard), the oil must be removed at a low temperature (approximately 30 °C). The sample should be marked
with: address, date of removal, outlet temperature and type of heat transfer fluid.
The analysis is generally provided by the manufacturer at the actual cost.
5 Dismantle the solenoid valve for the cooler in accordance with the drawing (→ Service): Check the membrane
for scaling and damage. Ensure that the core and spring bolts move smoothly. Clean or replace components as
necessary.

7.1.4 Annual checks/maintenance

Always change the oil after approximately 2000 hours of operation (corresponds to about 1 year in 1 shift opera-
tion). This value is a guideline. Depending on operating conditions (temperature, narrow consumer cross-section,
primarily heating, etc.), the oil may need to be changed more frequently (→ 7.2).

7.2 Changing the thermal fluid

Change the thermal fluid as follows:
1 Evacuate the unit and consumer completely through their corresponding draining port.
2 Depending on the number of operating hours, clean the unit and consumer as described in Sections 7.3 and
7.4.
3 Refill as described in Section 3.7.

7.3 Switching the consumer from water to thermal oil

Procedure when condensation forms
1 Check the consumer for scaling and clean with the REG descaling unit (→ ”Regloplas Temperature Control
Units”, “REG” data sheet).
2 Attention: All water residues in the temperature control circuit (connection hoses, unit, consumer, etc.) must
be removed completely. Any vapour pressure presents a hazard during the heat-up phase. Procedure:
3 Fill thermal oil as described in Section 3.7.
4 Allow the unit to run at a temperature of 100 °C for at least 30 minutes.

BA 150S-350L/0703/d/f/e 33
5 When no more boiling sounds can be heard, increase the temperature to the desired operating temperature in
10 °C increments.
If boiling sounds continue, allow the unit to run at the same temperature unit no more boiling sounds can be
heard.
The unit is now ready for operation with thermal oil.

7.4 Cleaning
Please note when using solvents for cleaning: Due to danger of explosion, do not blow out the unit. It
must be rinsed thoroughly. When using a solvent, the manufacturer’s regulations on usage must be fol-
lowed.
Thermal oil and solvents are combustible under certain conditions. Cleaning must not be performed in the
vicinity of heat sources.

We recommend that the following cleaning procedure be performed every time the heat transfer fluid is added or
changed. Conditions which are less than optimal will require that these procedures be made with greater fre-
quency. This is particularly true for points 5 and 6.
1 Evacuate the unit through the draining port.
2 Clean the filter in the temperature control circuit.
3 Check the cooler for scaling; clean with the REG descaling unit if necessary.
4 Remove and clean the heating elements if the oil was very dirty or if the manometer pressure was high.
6 Dismantle the solenoid valve for the cooler in accordance with the sketch (→ Service): Check the membrane
for scaling and damage. Ensure that the core and spring bolts move smoothly. Clean or replace components as
necessary.

8. Ordering spare parts

Use only original spare parts.

To ensure quick and accurate delivery of spare parts, we need the following information
1 Type of temperature control unit
2 Model number
3 Voltage
4 Frequency
You will find this data on the unit’s rating plate.
5 Part number of the component. You will find this information on the corresponding drawing in these Operating
Instructions (→ Service) as well as on the schematic in the electrical section of the unit.

9. Shipping

Before shipping the unit, evacuate it completely through its draining port. Due to danger of freezing (collapse if
the cooling hoses), blow the cooler out at a low temperature as follows:
1 Enter a set-point value of 0 °C at the controller.
2 Ensure that the cooler’s solenoid valve is open.
3 Blow out the cooler with compressed air at a maximum pressure of 6 bar.
Do not tip the unit. Heat transfer fluid remaining in the unit could run out, presenting the danger of saturate the
insulation, the electrical components and thus danger of fire.
Use the original packing material.
Mark the “Top” clearly.

10. Optional equipment

10.1 Leak-stop mode and evacuation of the consumer through suction

By reversing the pump’s direction of rotation, the heat transfer fluid can be removed through the consumer by
means of vacuum.

34 BA 150S-350L/0703/d/f/e
To note
– In leak-stop mode, the oil is subject to high thermal loading due to the greatly reduced pump capacity. For this
reason, the oil must be checked and changed, if necessary, more frequently. For the procedure, see Section
7.1.3, item 4, and Section 7.1.4.
– When suctioning, the volume of heat transfer fluid must be less than the volume of the expansion vessel (see
“Technical data”, Section 12). Otherwise, the unit will overflow.
Leak-stop mode with the RT30 controller
1 Switch the unit off as described in Section 5.1.
2 Set the rotary switch to”–“.
3 Switch the pump on.
Do not set the set-point value higher than 250 °C.
Leak-stop mode with the RT50 controller
Pressing the “Leak Stop” key switches the unit to leak-stop mode. Leak-stop mode is possible only when the set-
point value is between 0 and 250 °C (see “RT50 Operating Instructions”, Section 7.2, item 4.4).
Suction with the RT30 controller
1 Switch the unit off as described in Section 5.1.
2 Set the rotary switch to ”–“.
3 Switch the pump on.
4 Keep the rotary switch in the “A” position to evacuate the consumer.
Suction with the RT50 control system
Pressing the “Suction” key initiates the suction program. The consumer connected to the unit will be evacuated.
Suction is possible only when the medium temperature S1 lies below the programmed pump run-out temperature
(see “RT50 Operating Instructions”, Section 7.2, item 4.3). If this is not the case, the unit will cool to this tem-
perature before initiating the program.
The suction procedure and the leak-stop function can be interrupted by pressing the “ON/OFF” key.
Pressing the “ON/OFF” key again will return the unit to normal mode.
During leak-stop mode, the set-point value shall not exceed the run-out temperature (“RT50 Operating Instruc-
tions”, Section 7.2, item 4.3).

10.2 Flow measurement (RT50 only)

Using the 䉴 key, move to “Display actual value”. Press the same key again to read the flow rate. To return to
the operating level, press the same key once more.

11. Troubleshooting

For RT30 controller malfunction messages, see Section 4.1.2.

For RT50 control system malfunction messages, see the “RT50 Operating Instructions”, Section 6. 3.

BA 150S-350L/0703/d/f/e 35
Temperiergerät
Régulateur de température
Temperature Control Unit
350L
Gerätenummer / Numéro d'appareil / Serial number 1260’0018’0001 – 1260-0018’0002

Technische Daten
Caractéristiques
Technical data
Max. Vorlauftemperatur Anschlüsse
Température max. de sortie 350 °C Kühlwassernetz 3/4"
Max. outlet temperature Vor-Rücklauf Flansch DN 20/PN 40
Raccordements
Réseau d'eau de refroid. 3/4"
Wärmeträger Oel Sortie-retour Flasque DN 20/PN 40
Fluide Huile Connections
Fluid Oil Cooling water mains 3/4"
Outlet/inlet Flange DN 20/PN 40

Füllmenge
Filling quantity 32 l Betriebsspannung
Volume de remplissage Tension d'alimentation 3x400 V/50 Hz
Operating voltage

Regler
Régulateur RT50 Leistungsaufnahme
Controller Puissance consommée 26.8 kW/41 A
Power consumption

Messart
Principe de mesure Pt100 Abmessungen B/H/T
Measuring mode Dimensions L/H/P 470/1467/1491 mm
Dimensions W/H/D

Heizleistung
Puissance de chauffage 24kW Farbe
Heating capacity Couleur RAL 5013
Colour finish

Kühlleistung
bei Vorlauftemperatur
bei Kühlwassertemperaur
Puissance de refroid. 110kW
à la temp. de sortie 340°C
à la temp. de l'eau de refroid. 20°C
Cooling capacity
at outlet temperature
at cooling water temp.

Pumpenleistung/Typ
Fördermenge
Druck
Capacité de pompe/type FM 65
Débit max. 90 l/min
Pression max. 10bar
Pump capacity/type
Flow rate
Pressure
 REGLOPLAS
Temperiergerät
Régulateur de température Type 350 L
Temperature control unit
Gerätenummer Numéro de l’appareil Number of unit 1260-0018

69

72
P1
73
61
2
64

E21-23

41
Y16 56
Y6

78 66
60
67
68a 68
Y13 46
S3
Q1
37

F3 58

B1 F5

84
40

35
M10

9 75
24.08.07
 REGLOPLAS
Stückliste Liste de pièces Parts list
Pos./It. Artikel Article Item
2 Schloss Serrure Lock
35 Pumpe Pompe Pump
37 Ausdehnungsgefäss Vase d’expansion Expansion vessel
40 System mit Isolation Système avec isolation System with insulation
41 Kühler Refroidisseur Cooler
46 Schwimmer Flotteur Float
56 Rückschlagventil Soupape de retenue Check-valve
58 By-Pass By-pass By-pass
60 Filter Wassernetz Filtre réseau d’eau Filter water mains
61 Manometer Manomètre Pressure gauge
64 Oelstandsanzeige Indicateur de niveau d’huile Oil level gauge
66 Wassernetz Réseau d’eau Cooling water mains
67 Wasserablauf Sortie d’eau Water drain
68 Ablass-Stutzen Bouchon de vidange Drain plug
68a Ablass-Stutzen Pumpe Bouchon de vidange pompe Drain plug pump
69 Einfüllstutzen Tube de remplissage Filler pipe
70 Ueberlauf Trop-plein Overflow
72 Vorlauf Sortie Outlet
73 Rücklauf Entrée Inlet
78 Pressluftanschluss Connexion air comprimé Conntction for compressed air
82 Strömungswächter Surveillance de flux Flow monitor
84 Dreiwegventil Vanne à 3 voies Three-way valve

B1 Temperaturfühler intern Sonde de température interne Temperature sensor internal

E21-23 Heizung Chauffage Heater

F3 Minimaldruckschalter Pressostat de pression min. Min pressure switch

F5 Sicherheitsthermostat Thermostat de sécurité Safety thermostat

M10 Motor Moteur Motor

P1 Regler Régulateur Controller

Q1 Hauptschalter Interrupteur principal Main switch

S3 Schwimmerschalter Interrupteur flotteur Level switch

Y6 Magnetventil Kühlung Electro-vanne refriodissement Solenoid valve, cooling

Y13 Magnetventil Absaugung Electro-vanne aspiration Solenoid valve, suction
Y16 Magnetventil Pressluft Electro-vanne air comprimé Solenoid valve, compressed air

24.08.07
Pumpe / Pompe / Pump FM 65

601.107

1 2

Ersatzteile
1 Pumpenkopf mit Magnetkupplung
2 Motor mit Magnetkupplung

Pièces de rechange
1 Tête de pompe avec accouplement magnétique
2 Moteur avec accouplement magnétique

Replacement parts
1 Pump head with magnetic drive
2 Motor with magnetic drive motor

36 BA 300L(D) 0601/dfe
 RT50

Programming
Instructions

65
Outlet ºC
S1
Set value
SP1 80ºC
Programming instructions control system RT50
Valid from software version 345
1. General comments 1
2. Range of application 1
3. Operating elements and displays 1
4. Switching on 2
5. Switching off 3
6. Displays 3
7. Programming 18
8. Programming example 18
9. Control options 18
10. Operation with interface 18
11. Appendix 19

Subject to change without notice

1. General comments

The Regloplas RT50 microprocessor control system consists of a control component with operating and display elements,
as well as a performance component with several inserts for accessories such as interfaces etc.

2. Range of application

The RT50 control system was developed for use in temperature control unit (hereafter referred to as “units“). It enables
dialog between one or more units and the production facility computer as well as operation independent of the computer.

3. Control and indicating elements (Fig. 1)

1 LCD display.
2 Keys for programming and selection of displayed value.
3 Alarm reset key.
4 On/off key.
5 Key for leak-stop mode. 1
6 Key for drainage and blowing out modes.
7 Key for switching between SP1 and SP2. 10
8 Key for operation with timer. 2
9 Keys for setting the set-point value and programming.
10 Status line. 3 9
4 8
5 7
6
Fig. 1: Operating elements and displays

Set-point and actual value display

When the unit is turned on via the ON/OFF key, the set temperature
SP1 or SP2 (SP= set-point value) appears in the lower part of the
display while the upper part of the display indicates the outlet
temperature (actual value) S1 of the sensor in the heat transfer fluid
or S2 of the external sensor in the consumer (S=sensor).
Key for setting the set-point value and programming
Increase and decrease the set-point value and change programmed values.
Timer key
Activates the timer, when present. The timer turns the controller on and off.

PA RT50 0309/e 1
Leak-stop key
Pressing this key will switch the unit over to leak-stop mode. Leak-stop mode is possible only when:
- If water is the heat transfer fluid, the set-point value should lie in the runout temperature range
(Section 7.2, P 4.3) of 0 to 80 °C max.
- If oil is the heat transfer fluid, the set-point value should be in the range of 0 to 250 °C.
With leak-stop mode and oil, the max. heating capacity is 60 %, to keep the oil’s thermal load due to reduced pump
capacity low.
Leak-stop mode can be interrupted by pressing the ON/OFF key. Pressing the ON/OFF key again (after waiting for OFF to
appear on the display) will return the unit to its normal mode.
Suction key
Pressing this key initiates the evacuation program. The consumer connected to the unit is evacuated either by the pump
via suction or by blowing out with compressed air.
Evacuation is only possible when the temperature of the heat transfer fluid is below the programmed runout temperature
(Section 7.2, P 4.3). If this is not the case, the unit will cool the heat transfer fluid to this level.
The pump is switched off. Once the pump’s run-down time (Section 4.9) has elapsed, the pump is switched on again in
the opposite direction of rotation. It then empties the consumer during the programmed value for evacuation time
(Section 7.2, P 4.6).
The blow-out program using compressed air is activated once the pump’s run-down time has elapsed.
After the programmed evacuation time, the unit will switch itself off automatically. The suction and blow-out programs
can be interrupted by pressing the ON/OFF key.
Pressing the ON/Off key again (after waiting for OFF to appear on the display) will return the unit to its normal mode.
Note: In pressurised water units, the pressure relief valve closes 5 °C above the value runout temperature,
i.e. at max. 85 °C, and opens at the programmed runout temperature during the cooling process.
Alarm reset key
Functions:
- Manual resetting of the alarm relay (e.g. horn switched off). As soon as the malfunction has been corrected, the
alarm display can be switched off by pressing this key once more.
- Manual acknowledgment of the automatic switch-over from consumer temperature control or cascade control to
outlet temperature for defective or missing sensor S2.
SP key
Switch-over from set-point value 1 (SP1) to set-point value 2 (SP2) and vice versa.
The set-point values can also be activated by an external digital signal.
A switch-over can only take place if no alarm is active.

Operation with code

To prevent the set or programmed values from being changed inadvertently, we strongly recommend the use of a code.
There are four possibilities:
- Code input value
- Code set-point value
- Code user setting 1
- Code user setting 2
They can be programmed as described in Section 7.2, P 15.
The input value code for the RT50 is set to 50 at the factory.

Save/Reset for factory and user settings

The RT50 control system offers the possibility to change the factory setting simply and at any time.
In the same way, two different customer-specific settings can be reloaded (user settings 1 and 2).
Programming is described in Section 7.2, P 14.

4. Switching on
Once the main switch has been turned on, OFF will appear on the display. The RT50 is now ready for operation.
Switch the unit on by pressing the ON/OFF key.
Depending on the programming, the set-point and actual values as well as information on the operating condition of the
control system and unit.
See also Section 6.
If the unit is equipped with the suction equipment and the phase sequence is wrong, two phases are switched
automatically, so that the pump operates in positive pressure mode.

2 PA RT50 0309/e
5. Switching off
The switching off procedure is initiated by pressing the ON/OFF key or by the timer.
The switching off program runs automatically as follows, depending on the temperature of the heat transfer fluid:
- Pump and control system are switched off. The RT50 is still powered (stand-by mode).
The display shows OFF.
- The pump continues to run. The unit cools until the temperature of the heat transfer fluid reaches the programmed run
temperature (Section 7.2, P 4.3). The pump and controller are then switched off. The RT50 stays in stand-by mode.
The display indicates OFF.

6. Displays
The following boxed text can appear on the display:

6.1 Operating displays

Outlet (upper value) as actual value: S1, internal sensor. S2, external sensor. Inlet sensor
S3.
Set-point value: SP1, SP2 or Extern.
External control via external set-point value entry.
External set-point Cascade control with external sensor S2.
Suction The unit will cool to the programmed runout temperature and then switch itself off automatically.
Service due This message indicates that the unit is due for maintenance. However, the unit can still be operated normally.
Programming: Section 7.2, P 3.8.

6.2 Status displays

Unit On, Off.
1 hour Timer operation.
Leak-stop
Leak-stop clock
Suction
Ser_A3 Interface and unit address (e.g. 3).

6.3 Alarm displays

The alarm display blinks every second. Malfunctions must always be corrected by qualified personnel.

For control Outlet sensor, Inlet or External.

If a sensor becomes defective, the will switch automatically to cooling.

During cascade control, a defective external sensor (S2, consumer) will cause the unit to control to the internal sensor S1.
The actual value of the internal sensor temperature at the time of sensor malfunction will be used as the new set-point
value. The alarm must be acknowledged.

Level too low

Wrong phase sequence
The pump will switch off a few seconds after it is switched on. Pump and control system remain switched off.

Motor current exceeded

Malfunction of motor contactor One or more phases is missing or no response was received from the motor contactor via
the auxiliary contact.
Safety therm. triggered The unit cools automatically.
Heater thermostat triggered (Model P140S). The unit cools automatically.
Maximum set-point exceeded The unit cools automatically.
Flow monitor triggered The heat switches off automatically.
Flow rate too low The heat switches off automatically.

PA RT50 0309/e 3
Dev. set-point/Actual, Set-point/External actual Set-point/Inlet have been exceeded or fallen short of. Unit and control
system continue to run normally.

Heating contact malfunction Cause: Despite command, the contact did not pick up.

Set-point or actual value is too high for leak-stop mode

External set-point signal interrupted or not present The unit cools automatically.
Analog/Digital transformer defective Unit and control system are switched off.
Program memory defective Unit and control system are switched off.
Microprocessor malfunction Unit and control system are switched off.
Calibrated values changed or wrong Unit and control system run normally.
Unit data in memory wrong or lost Unit and control system are switched off.
Press the alarm reset key twice: The initialisation data are imported anew.
If the initialisation data can be imported successfully, the normal display appears. If not, the alarm appears again.

Timer battery defective or dead Unit and control system continue to run normally.
Unit mains voltage too low Unit and control system are switched off.
Two flow monitors are connected at the same time
The message goes away as soon as only one flow monitor is connected.

No data available The factory or user settings contain no data.

Memory not present or defective e.g. memory not inserted.

6.4 Additional messages

In addition to the messages listed under 6.1. through 6.3, one of eight possible additional messages may be overlaid. See
Section 7.2, item 16.

7. Programming

7.1 Programming keys

See also Fig. 1.
Functions
S - Change the set-point value.
T - Change the line within the corresponding programming level.
- Change the value of the corresponding input line.

X - Switch from the operating level to the program overview.

- Switch from one programming level to another.

W - Back to the operating level.

- Back to the program overview.

7.2 Programming process

- The sheet, “Menu RT50” in the Appendix is critical to understanding the following:
- Numbering refers to the sheet, “Menu RT50”.
- The following text contains a “P” before the section number to differentiate the programming section from the rest of
the sections.
- Display depends on special equipment.
- Programming can be done with the control system switched on or off.

4 PA RT50 0309/e
P1 Show actual value
On this level, the following actual values are shown:

P 1.1 Outlet
Outlet temperature. Temperature S1 of the heat transfer fluid (Sensor Sn1).

P 1.2 External
Consumer temperature. External sensor Sn2 in consumer.

P 1.3 Inlet
Inlet temperature S3 at unit entrance.

P 1.4 Heating/cooling cap.

Shows the current power as a percentage of the nominal power.
Example: Nominal power of the unit 9 kW. Value shown 33 %, i.e. the currently required power for the control
system is 3 kW.
A negative number indicates cooling.

P 1.5 Flow rate

Flow rate in l/min or GPM.

P 1.6 Pump current L1

Current, phase 1 of the pump motor in A.

P 1.7 Pump current L2

Current, phase 2 of the pump motor in A.

P 1.8 Pump current L3

Current, phase 3 of the pump motor in A.

P 1.9 Operating hours

Number of the unit’s operating hours.

P 1.10 Service after

Hours remaining until next maintenance service.

P 1.11 Software version

Software version being used.

P 1.12 Interface
Built-in interface (hardware), e.g. RS 485.

P 1.13 Protocol
Protocol installed (software), e.g. Profibus.

P 1.14 Address
Unit address when operating with an interface.

P 1.15 Day/time
Programmed day of the week and time

P2 Select language

P 2.1 Sprache Deutsch

P 2.2 Language English

P 2.3 Langue Française

PA RT50 0309/e 5
P3 User configuration
For P 3.1 and 3.2 see also Section 11, Abb. 2.

P 3.1 Deviation Set/Actual

Values for deviation above (…) or below (†), with respect to
Set-point/outlet
Set-point/external
Set-point/inlet

Entry xx °C
Setting range 0 to 99 °C

P 3.2 Outlet limit

Limitation of the maximum and minimum outlet temperatures, i.e.
Outlet limit, max
Outlet limit, min

Entry xx °C
Setting range 0 to 99 °C

P 3.3 Minimum flow rate

Entry xx l/min
Setting range 2 to 50 l/min

P 3.4 Interface

Address
Protocol
Number entry as described in Section 10.

P 3.5 Temperature display

Display in °C
Display in °F

P 3.6 Flow rate display

Display in l/min
Display in GPM

P 3.7 Set-point at start

Last active set-point

When switched on, the unit will control to the last active set-point.
Always SP1will control to the last set-point 1 (SP1) entered.
Always SP2
When switched on, the unit will control to set-point 2 (SP2).

P 3.8 Next service

P 3.9 The number of elapsed operating hours shows on the display.
Enter the number of operating hours until the next service procedure.
The value entered must be higher than the number of Operating hours shown.
Setting range: 0 to 99999 (value in hours).

6 PA RT50 0309/e
P4 Unit configuration

P 4.1 Heat transfer fluid

The type of heat transfer fluid is entered at the factory, depending on the type of unit.
Heat transfer fluid Water
Oil

P 4.2 External sensor type

Type pf external sensor Sn 2.
Resist. Therm. Pt 100
Thermocoup. K NiCr-Ni
Thermocoup. J Fe-CuNi
Thermocoup. T Cu-CuNi

P 4.3 Run-out temperature

See also Section 11, Fig. 2.
Before the unit is switched off by the OFF key or when suction is activated, the unit will first cool to the
temperature set in the next step.
Units with direct cooling: Value must be 0. This initiates automatic pressure release for 30 seconds after the unit is
switched off by the OFF key.
First cool to
Entry xx °C
(then autom. off)
Setting range 0 to 80 °C. 0 = Function off. Leak-stop and suction modes not possible.

P 4.4 Maximum set-point

See also Section 11, Fig. 2.
The maximum set-point value can be set in this position. The value will vary with the type of unit. The value set
must not exceed the value Tmax. on the rating plate.
Max. setting
Set-point
Entry xxx °C
See rating plate
on unit
Setting range 0 to 420 °C.

P 4.5 Evacuation options

Evacuation with pump

Evac. w/comp. air

P 4.6 Evacuation time

The suction or blow out time will vary with the type of heat transfer fluid used.
Evacuation time
Entry xxx s
Setting range 0 to 500 s. Only displayed when accessory present.

P 4.7 Pump current

Pump current on
Rating plate x.x A
Entered at the factory in accordance with the information provided on the rating plate.
Can be changed by ±10 % as needed.

PA RT50 0309/e 7
P 4.8 Pump dir. of rotation
The pump’s direction of rotation will be corrected automatically upon incorrect phase sequence.
(Possible only when the Suction option is present).
Dir.of rot. will be
corrected yes
no

P 4.9 Pump run-out time

Maximum possible run-out time of the pump in s before the change in direction of rotation for evacuation by
means of suction or leak-stop mode.
Pump run-out time
before change in dir. of rot. xx s
Setting range: 3 to 30 s.

P 4.10 Power failure behav.

Last state
After a power outage, the unit will operate as it did before the power outage.
Stays off
After a power outage, the unit remains switched off.

P 4.11 Heating 2

Heating 2 inactive
Heating 2 active Only possible in units with 2 heating levels.

P 4.12 Heating cycle time

Heating cycle time

Entry xx s
Setting range 1 to 30 s

P 4.13 Cooling cycle time

Cooling cycle time

Entry xx s
Setting range 1 to 30 s

P 4.14 Suppress heating

Suppression of the heating command. The heating command will be suppressed during the period of time set.
Heating command
Suppress xxx ms
Setting range 0 to 200 ms

P 4.15 Suppress cooling

Suppression of the cooling command. The cooling command will be suppressed during the period of time set.
Cooling command
Suppress xxx ms
Setting range 0 to 200 ms

P 4.16 Pump. cooling medium

Activation of the extra pump in the cooling circuit (cooling system "SK").
Extra pump no
Extra pump yes

8 PA RT50 0309/e
P 4.17 Func. of ext. contact
Switch on/off via external contact:
Ext. contact Code 0
When the external contact is closed, the unit is switched off and the ON/OFF key blocked.
Ext. contact Code 1
When the external contact is opened, the unit is switched off and the ON/OFF switch blocked.
Ext. contact Code 2
The unit can be switched on and off via the external contact as follows:
Closing the external contact: Unit switches off.
Opening the external contact: Unit switches on.
Ext. contact Code 3
The unit can be switched on and off via the external contact as follows:
Closing the external contact: Unit switches on.
Opening the external contact: Unit switches off.
For codes 2 and 3: Switching on and off via the ON/OFF key is always possible.

P 4.18 Level alarm

Pump run-out time

Entry xx s
After the level monitor has been triggered due to insufficient level of heat transfer fluid, the pump will continue
to run after its set run-out time to prevent the unit from being switched off suddenly.
Setting range 3 to 60 s

Refill time window

Entry xx s
The refill time window is the maximum time the refill valve can be open. If the level is still insufficient after this
time has elapsed, the alarm message Level too low remains.
Setting range 3 to 60 s

No. of insufficient
Levels before
Alarm
Entry xx
The number of level insufficiencies before the alarm is triggered. It is set to 1 for approximately 30 minutes after
the last level insufficiency. Valid only for units using water as the heat transfer fluid (Section 4.1).
0 = Alarm counter off
Setting range 1 to 40

Alarm suppression
time after switch on
Entry xx min
Once the power has been switched on (main switch) the heat transfer fluid can be refilled as often as desired
during the time period set.
0 = Function off.
Setting range 0 to 15 min

P 4.19 Pressure relief valve

Time delay
Valve xx s
Time delay until the pressurised water unit’s pressure relief valve Y 8 opens.
0 = No delay. The set value may not be 0 for P 140S units.
Valid only when using water as the heat transfer fluid (Section 4.1).
Setting range 1 to 9 s

PA RT50 0309/e 9
P 4.20 Viscosity
When flow measurement available, enter the kinematic viscosity in mm2/s at 20 °C.
When water is used as the heat transfer fluid (Section 4.1) the value 1.0 is entered automatically.
Kinematic
viscosity of medium
at 20 °C / 68 °F
Entry xx.x mm2/s

P5 Control

P 5.1 Type of control

Select the desired type of control:
PID Outlet With sensor in outlet
PID External With sensor in consumer
PID Inlet With sensor in inlet
Casc. External/outlet With sensor in consumer and in outlet
Casc. Inlet/outlet With sensor in inlet and in outlet
Casc. Cavity control With sensor in outlet and in mould cavity

At this level the operator selects the sensor(s) to be used. The control system can, for example, be set to
PID outlet, even if a sensor is in the consumer.

P 5.2 Control par. PID selection

Control par. PID fix
Control par. PID man.
The operator can choose between PID fix and PID man. For the fixed parameter sets, the operator can choose
between set 1 (strong reaction to control deviations) and set 10 (weak reaction to control deviations).
The units are set to set 5 when they leave the factory.

P 5.3 Control par. PID fix

Par. set heating fix

Parameter set heating

Entry xx
Setting range 1 to 10

Par.set cooling fix

Parameter set cooling

Entry xx
Setting range 1 to 10

P 5.4 Control par. PID man.

P heating in % Tmax
Entry x.x % Proportional band in %
xx °C
The proportional band in °C appears on the display, with reference to Tmax.
Setting range 0 to 50.0 %

I heating
Entry xxxx s Run-out time (integral) in seconds.
Setting range 0 to 9999 s

10 PA RT50 0309/e
 D heating
Entry xxx s Rate time (differential) in seconds.
Setting range 0 to 999 s

Capacity lim. heating

Entry xxx % No heating command below the set value.
Setting range 10 to 100 %

P cooling in % Tmax.
Entry xx.x % Proportional band in %
xx °C
The proportional band in °C appears on the display, with reference to Tmax.
Setting range 0 to 50.0 %

I cooling
Entry xxxx s Run-out time (integral) in seconds.
Setting range 0 to 9999 s

D cooling
Entry xxx s Rate time (differential) in seconds.
Setting range 0 to 999 s

Capacity lim. cooling

Entry xxx % No cooling command below the set value.
Setting range 10 to 100 %

Cooling dead zone

Entry x.x °C
The cooling dead zone is the zone over the set-point in which cooling commands are suppressed.
Setting range 0 to 9.9 °C

P 5.5 Control par. casc. sel

Control par. casc. fix

Control par. casc. man

P 5.6 Control par. casc. fix

Control par. casc. fix

Control par. casc. man
Fix cascade par. set
Entry xx
Setting range 1 to 10

P 5.7 Control par. casc. man

Cascade amp.
Setting range 0 to 99.9
Cascade integral
Setting range 0 to 9999 s
Cascade differential
Setting range 0 to 999 s
M.Diff.heat Int/Ext
Max. acceptable temperature difference between internal and external sensor during heating.
Setting range 0 to 420 °C. Enter a value not higher than Tmax.
M.Diff cool Int/Ext
Max. acceptable temperature difference between internal and external sensor during cooling.

PA RT50 0309/e 11
 Setting range 0 to 420 °C. Enter a value not higher than Tmax.
P heat aux controller
Setting range 0 to 50 %
I heat aux controller
Setting range 0 to 9999 s
D heat aux controller
Setting range 0 to 999 s
P cool aux controller
Setting range 0 to 50 %
I cool aux controller
Setting range 0 to 9999 s
D cool aux controller
Setting range 0 to 999 s
Dead zone aux contr
Setting range 0 to 9.9 °C
These parameters should be entered by a control specialist.

P6 Offset
Offset can be used to compensate for errors caused by instrument leads, measurement errors from sensors,
etc.

P 6.1 Offset outlet sensor

Entry 0.0 °C
Setting range ±20 °C

P 6.2 Offset ext. sensor

Entry 0.0 °C
Setting range ±20 °C

P 6.3 Offset inlet sensor

Entry 0.0 °C
Setting range ±20 °C

P 6.4 Offset analog input

Entry 0.0 °C
Setting range ±20 °C

P 6.5 Offset analog out. 1

Entry 0.0 °C
Setting range ±20 °C

P 6.6 Offset analog out. 2

Entry 0.0 °C
Setting range ±20 °C

P7 Analog output 1
On this level the measuring method is first chosen for analog output 1 and then the corresponding upper and
lower values are entered.

12 PA RT50 0309/e
P 7.1 Outpt 1 Outlet 4-20mA

Lower end of scale Upper end of scale

Entry 4 mA =^ 0.0 °C Entry 4 mA ^= 0.0 °C
Setting range 0 to 500.0 °C Setting range 0 to 5000 °C

Entry P 7.2 to P 7.18 as P 7.1.

P8 Analog output 2
On this level (P 8.1 to P 8.21), analog output 2 is placed. It is programmed in the same way as analog output 1
was, as described in Section 7.1. The exception is that no upper and lower values can be entered for the outputs
Actual TE-FE and Actual TE-Cu.

P9 Analog input
The analog input is programmed in the same way as the analog output as described in Section 7.1

P 9.1 Analog input inactive

P 9.2 Analog input 4-20 mA

P 9.3 Analog input 0-20 mA

P 9.4 Analog input 0-10 V

P 10 Common alarm
On this level, the alarm relays (common alarm), when present, can be activated at the next malfunction.

P 10.1 Alarm repeat time

Entry 0s
Once this time has elapsed and the alarm has been acknowledged, the alarm (horn, lamp) is reactivated.
Setting range 0 to 600 s

P 10.2 Alarm heating 1

Alarm H1 inactive
Alarm H1 active

P 10.3 Alarm heating 2

Alarm H2 inactive
Alarm H2 active

P 10.4 Alarm flow rate

Alarm flow inactive

Alarm flow active

P 10.5 Alarm flow monitor

Alarm flow ind. inact

Alarm flow ind. act

PA RT50 0309/e 13
P 10.6 Alarm level

Alarm level inactive

Alarm level active

P 10.7 Alarm pump current

Alarm P.curr. inact

Alarm P.curr. active

The following alarms always trigger the common alarm relay:

Sensor outlet defect

Sensor extern defect.

Contr. w/outlet sens

Phase seq wrong

Malf. motor contactor

Safetytherm.triggered
Cooling on

Max setpoint exceeded

Cooling on

Dev. sp/outl exceeded

Dev sp/outl exceeded

Dev sp/ext act excd.

Dev sp/ext act exdc.

Dev sp/inlet exceeded

Dev sp/inlet exceeded

Ext sp signal interrupted or not present

Analog-dig transf def

Memory chip defect

Malf. microprocessor

Calibration values changed or wrong

Unit mains voltage too low

No data present

14 PA RT50 0309/e
P 11 Relay configuration

P 11.1 Relay K1 function

Relay K1 pick up
Relay K1 release

P 11.2 Relay K1 selection

The following selection is available:

K1 Common alarm
K1 Heat 1
K1 Heat 2
K1 Flow rate
K1 Flow indicator
K1 Level 1
K1 Level 2
K1 Pump current
K1 Dev set/outlet …
K1 Dev set/outlet †
K1 Dev set/extern …
K1 Dev set/extern †
K1 Dev set/inlet …
K1 Dev set/inlet †

K1 Temp. breakover
Actual value of the active sensor, through which the relay picks up or releases.
K1 Temp. breakover
Entry xxx °C
Setting range 0 to Tmax.

K1 Band deviation
Band deviation, with respect to the active set point. For example, an entered value of 20 corresponds to a band
of 20°C above and below the set point.
K1 Band deviation
Entry xx °C
Setting range 0 to 99 °C

K1 Control on
K1 Timer active
K1 Pump runs
K1 Level 1 reached
K1 Level 2 reached
K1 Heat 1 on
K1 Heat 2 on
K1 Cooling on

P 11.3 Relay K2
Programmed as described under Relay K1.

P 11.4 Relay K3
Programmed as described under Relay K1.

P 11.5 Relay K4
Programmed as described under Relay K1.

PA RT50 0309/e 15
P 12 Programming the timer
10 steps are available for programming the timer. A weekday or group of days of the week, a time, and the type
of time (On/Off time) must be programmed for each step. This means that to turn the unit on and off again
requires 2 steps.
The unused steps are set to inactive. On the second sublevel, it can be seen at a glance which steps are active
(On/Off) and which are inactive.

P 12.1 01 Day of the week

01 Monday
01 Tuesday
01 Wednesday
01 Thursday
01 Friday
01 Saturday
01 Sunday
01 Mo-Th
01 Mo-Fr
01 Mo-Sa
01 Mo-Su

P 12.2 Hour/minute

01 Time
Entry xx:xx

P 12.3 Inactive/On/Off

01: Inactive
01: On
01: Off
The remaining steps are programmed as needed.
To ensure that the On and Off times are correct, the timer must be synchronised.

P 13 Synchronising the timer

P 13.1 Enter day

Day Monday etc.

P 13.2 Enter hour/minute

Enter hour/minute
Entry 00:00

P 14 Reset/Factory/User
For saving and loading set values.

P 14.1 Save as fact. setting

This can be programmed only at the factory.

P 14.2 Reset to fact. set

When this level is left, the factory settings will be reloaded.

16 PA RT50 0309/e
P 14.3 Save user set 1
When this level is left, all currently programmed values will be saved as User settings 1.

P 14.4 Reset to user set 1

When this level is left, User settings 1 will be loaded.

P 14.5 Save as user set 2

When this level is left, all currently programmed values will be saved as User settings 2.

P 14.6 Reset to user set 2

By entering the correct code and leaving this level, User settings 2 will be loaded.

P 15 Change code

P 15.1 Code <Entry value>

Code
Entry xxxx
The code must first be entered here.
Code <Entry value>
Change entry xxxx
The new code can be entered here. When this level is left, the new code is activated.

P 15.2 Code <Set-point>

Entry as 15.1

P 15.3 Code <Fact setting>

Entry as 15.1

P 15.4 Code <User setting 1>

Entry as 15.1

P 15.5 Code <User setting 2>

Entry as 15.1

P 16 Additional display
Select the additional display. It will appear after this level is left, in the operating level as the second to last line.

P 16.1 No additional display

P 16.2 Outlet
P 16.3 External
P 16.4 Inlet
P 16.5 Heat/cool cap.
P 16.6 Flow rate
P 16.7 Operating hours
P 16.8 Service after
P 16.9 Day/time

PA RT50 0309/e 17
8. Programming example
The sheet entitled “Programming example” shows the entry of an individual code and the programming of the deviation
between set-point value and actual value. See also sheets entitled “Menu RT50” and “Temperature limit values” in the
Appendix.
Entering the value 5 °C means that when the actual value exceeds the set-point value entered, the alarm Deviation Set-
point/Actual will appear on the controller display.

9. Types of control
The RT50 control system works with the following computer programs (control algorithms):
- PID control to outlet, inlet or external sensor. For this type of control, there are 10 fixed parameter sets for each of
heating and cooling as well as a manual set.

Cascade control with external and outlet sensors or outlet and inlet sensors. This type of control also has 10 fixed
parameter sets as well as a manual set.

9.1 Fixed parameter sets

To save the operator the time-intensive determination of the P, I und D control parameters for heating and cooling, the
fixed parameter set which best matches the application can be loaded.
In most cases, the operator can determine the best fixed parameter set for his application, by following these simple
rules:
1. Basic setting: Parameter set 5
2. If the set-point value entered is not attained after a reasonable amount of time, the next lower parameter set should be
selected (Example parameter set 4 instead of 5).
3. If the actual value exceeds the set-point value, or the set-point oscillates, the next higher fixed parameter set is chosen.
If none of these parameter sets results in the desired control, because the controlled system deviates from the standard,
an individual set can be entered.
Note: The set-point is reached most quickly when the actual value exceeds the set-point a bit. If an overshoot is not
acceptable, the operator must expect a somewhat longer heat-up time.

9.2 Fixed cascade set

Notes and procedure as described in Section 9.1.

10. Operation with data interface (optional equipment)

Control of the unit from the process control computer by connecting the “unit/process control computer”.
For selection of the protocol and address, see Section 3.4 of the Programming section.
Available protocols:
1 Arburg 4800 Bd 20 mA-CL
2 Engel 4800 Bd 20 mA-CL
3 Bühler Datacess 4800 Bd RS 422 spec.
4 Firsttech 4800 Bd 20 mA-CL
5 Stork 1200 Bd 20 mA-CL
6 Ferromatik Milakron 4800 Bd 20 mA-CL
7 Klöckner Desma 4800 Bd 20 mA-CL
8 Demag Ergotech 4800 Bd 20 mA-CL
9 Krauss Maffei 4800 Bd 20 mA-CL
10 Dr. Boy 4800 Bd RS 232
11 Euromap 17 9600 Bd RS 485
12 Euromap 17 4800 Bd RS 485
13 Euromap 17 2400 Bd RS 485
14 Euromap 17 1200 Bd RS 485
15 Sächsische Kunststofftechnik 4800 Bd RS 485
16 CAN Demag Ergotech 615 kBit/s Can RS 485
17 Müller-Weingarten 4800 Bd RS 422 spec.
18 Engel 4800 Bd RS 232
19 SPI 19200 Bd RS 485
20 SPI 9600 Bd RS 485
21 SPI 4800 Bd RS 485
22 SPI 2400 Bd RS 485
23 SPI 1200 Bd RS 485
24 Bühler Dataspeed 4800 Bd RS 485
25 Frech Datacontrol 9600 Bd RS 485
26 Frech Datacontrol 4800 Bd RS 485
27 Frech Datacontrol 2400 Bd RS 485
28 Frech Datacontrol 1200 Bd RS 485
29 CAN Demag Ergotech 500 kBit/s CAN RS 485

18 PA RT50 0309/e
30 CAN Demag Ergotech 250 kBit/s CAN RS 485
31 CAN Demag Ergotech 125 kBit/s CAN RS 485
32 Euromap 17 Billon 9600 Bd RS 485
33 Profibus DP 12 MBit/s RS 485
34 Ferromatik Milakron 4800 Bd RS 485

11. Appendix

Terminal markings
Temperature limit values
Technical data
Menu RT50
Programming example
Construction

PA RT50 0309/e 19
Terminal labels
No. Label Function No. Label Function
1 Output L Protection pumping 76 Not used
2 Output L Reserve 1 77 Not used
3 Output L Reserve 2 78 Not used
4 Output L Motor cooling SK 79 Not used
5 Output PE Motor cooling SK 80 Not used
6 Output N Motor cooling SK 81 Input External heating signal
7 Output L Flush valve 82 Input External cooling signal
8 Output PE Flush valve 83 Input External heating/cooling active
9 Output N Flush valve 84 Input External on/off signal
10 Output L Cooling valve 85 Input External set-point 2(SP2)
11 Output PE Cooling valve 86 Input Acknowledgement monitor flow
12 Output N Cooling valve 87 Input Acknowledgement level 2
13 Output L Refill valve 88 Output Common for inputs
14 Output PE Refill valve 81–87 and 89–90
15 Output N Refill valve 89 Output Flow measurement F150
16 Output L Valve pressure release 90 Input Flow measurement F150
17 Output PE Valve pressure release 91 Input External heating signal
18 Output N Valve pressure release 92 Input External cooling signal
19 Output L Blow out valve/air inlet 93 Input External heating/cooling active
20 Output PE Blow out valve/air inlet 94 Input External on/off signal
21 Output N Blow out valve/air inlet 95 Input Ext. set-point signal 2(SP2)
22 Output L Contactor heater 1 96 Input Acknowledgement flow monitor
23 Input L NC T-Max switch 97 Input Acknowledgement level 2
24 Output L T-Max switch common 98 Output Common for inputs
25 Input L NO T-Max switch 91–97 and 99 –100
26 Input Heater 1 acknowledgement 99 Output Flow measurement F350
27 Output L Heater 1 acknowledgement 100 Input Flow measurement F350
28 Input L1 Motor current measurement 101 Output Analog 1(+)
29 Output L1 Motor current measurement 102 Output Analog 2(+)
30 Input L2 Motor current measurement 103 Output Thermoelement TC (+)
31 Output L2 Motor current measurement 104 Input Analog set-point (+)
32 Input L3 Motor current measurement 105 Gemeinsam Analog for 101–104 (–)
33 Output L3 Motor current measurement 106 Input External heating signal
34 Connection PE Pump 107 Input External cooling signal
35 Input PE Mains connection 108 Input External heating/cooling active
36 Input N Mains connection 109 Output Common for inputs
37 Input L Mains connection 106 –108
38 Output L Acknowledgement reserve 111 20 mA-CL Interface TxD+ RxD+
39 Input Acknowledgement reserve 112 20 mA-CL Interface TxD– RxD–
40 Output L Acknowledgement reserve 113 RS 485– Interface
41 Input Acknowledgement reserve 114 RS 485– Interface
42 Output L Acknowledgement flow 115 RS 485– Interface,
43 Input Acknowledgement flow TxD+ RxD+/A/DATA
44 Input Sensor Sn2+ connection 116 RS 485– Interface,
45 Input Sensor Sn2– connection TxD– RxD–/B/DATA*
46 Input Sensor Sn1+ connection 117 RS 485– Interface, ground
47 Input Sensor Sn1– connection 118 Output PE
48 Input Digital input reserve 3 121 RxD RS422 Bühler/Müller-Weing.
49 Input Digital input reserve 2 122 CTS RS422 Bühler/Müller-Weing.
50 Input Comm. digital input reserve 2 + 3 123 TxD RS422 Bühler/Müller-Weing.
51 Input Digital input reserve 1 124 +5V RS422 Bühler/Müller-Weing.
52 Input Digital input reserve 1 125 GND RS422 Bühler/Müller-Weing.
53 Input Digital input level 131 CAN-L CAN ISO High speed
54 Input Digital input level 132 CAN-H CAN ISO High speed
55 Output Digital output 1, 24V DC 133 V+
56 Ground Ground to digital output 1 134 Rt
57 Output Digital output 2, 24V DC 135 Bus-L
58 Ground Ground tp digital output 2 136 Bus-H
59 Not used 137 Ground
60 Not used 138 Shield
61 Not used 149 Output Flow measurement 4-20 mA
62 Not used 150 Input Flow measurement 4-20 mA
63 Not used
64 Not used
65 Not used
66 Not used
67 Not used
68 Not used
69 Not used
70 Not used
71 Input Sensor Sn3 (Print for options)
72 Input Sensor Sn3 (Print for options)
73 Output Sensor Sn3 (Print for options)
74 Not used
75 Not used
Temperature limit values

H Heating area.

K Cooling area.

SP Set-point value.

TN Pump run-out temperature, measured with sensor S2

(absolute value). Section, 7.2, P 4.3.

† Lower limit value of medium temperature, with respect to the set-point value,
measured with sensor S1. Section 7.2, P 3.1.

… Upper limit value of fluid temperature, with respect to the set-point value,
measured with sensor S1.

†* Lower limit value of consumer temperature, with respect to the set-point value,
measured with S2. Section 3.1.

…* Upper limit value of consumer temperature, with respect to the set-point value,
measured with sensor S2. Section 3.1.

TSP Maximum adjustable set-point value (absolute value). Section 7.2, P 4.4.

Tmax. Trigger temperature of the electromechanical safety thermometer in unit (absolute value).
Set at the factory.

Abb. 2 Temperature limit values

Technical Data

Temperature range 0 to 420 °C

Control method Outlet control: PID, with 1 of 10 pre-programmed PID-parameter

sets or with a manually adjustable PID set.
Separate parameter sets for heating and cooling.
Consumer control: Cascade PI/PID, with 1 of 10 pre-programmed
PID-parameter sets or with a manually adjustable cascade set
PI/PID.

Control parameter input Via keyboard and LCD display.

Data storage Memory chip with min. 10 years of data preservation.

Clock switch with lithium battery and about 10 years of data
preservation.

Limit values Adjustable maximum set-point limit value.

Programmable minimum and maximum deviation of the medium
and consumer temperatures from the set-point value.

Monitoring systems Control and power systems have permanent self-monitoring.

Sensor breakage and short-circuit (only for Pt 100).
Limit values for temperature, pump flow (all 3 phases), level,
function of the heating and pump contactors, as well as flow rate*.
Data plausibility monitoring in memory, monitoring of the service
interval, flow monitor, calibrated values of the pump motor phase
sequence in normal and leak-stop mode*, as well as external set-
point value signal*.
Inputs
Temperature sensor
Outlet Pt 100.
External (consumer)* Choose Pt 100, J (Fe-CuNi), K (NiCr-Ni), or T (Cu-CuNi).
Inlet* Pt 100.
External Set-point value input Normalised and scaleable analogue interface with 0/4 to 20 mA or
0 to 10 V DC.
Heating/cooling commands, external* Via potential-free contacts.
Set-point value changeover Via keyboard (key SP) or via potential-free external contacts.
Serial interface* See "Data interfaces".

Outputs
Heating/Cooling Triac outputs for contactors or valves or solid-state relays.
Individually adjustable cycle times for heating and cooling.
Relay functions* Up to 4 optional relays as either common alarm or with individual
functions such as temperature switching point, deviation, etc.
Analog outlets1 and 2* Galvanically separate analogue outputs with scaleable signal 0/4 to
20 mA or 0 to 10 V DC. Each output can be assigned an actual or
set-point value.
In addition, the thermal e.m.f. of a J, K or T thermocouple output at
analog output 2.

Data interfaces*
Data transmission to master computer
(Hardware) CL-20 mA; RS232; Bühler Datacess; Bühler Dataspeed; RS485;
CAN; SPI; Profibus-DP.
Data transfer to other RS 422 (max. 32 units); CL-20 mA (2 to 4 units); RS485 (max. 32
Regloplas units units); CAN (max. 5 units); Bühler Dataspeed (max. 16 units);
Profibus DP (max. 32 units).
Transmission protocol See section 10 "Data interfaces".

22 PA RT50 0309/e
Display Modern, white backlit DOT matrix LCD display with black writing.
Simultaneous display of actual and set-point values, and an extra
line for an important display value as well as a status line are
shown on the display.

Disturbances Shown on the display

Precision
Class precision/Linearization Pt 100: 0.3 %. Thermocouple: 0.3%
Deviation of display Pt 100: ± 1 digit. Thermocouple: ± 2 digits

Operation Operation via short-stroke keys with pressure points on the

membrane keyboard.
Simple menu system in multiple languages via scroll keys.
Set-point value and parameter setting protected by programmable
codes.

Mains voltage Switched mode power supply unit; 85 to 265 V AC

Degree of protection Display unit with membrane keyboard: IP54

Service Insertable memory chip, attached to the temperature control unit,

allows the operator to switch the electronics quickly and simply
without losing any data.
The user data are read automatically into the new electronic
component.
Integrated operating hours counter and service interval display.

Front dimensions 96 x 96 mm.

Notes * Optional equipment.

PA RT50 0309/e 23
Menu RT50

65
1 Show actual value
Outlet ºC 2
3
Select language
User configuration

S1
4 Unit configuration
5 Control
6 Offset

80ºC
7 Analog output 1
Set value 8 Analog output 2

SP1 9
10
Analog input
Common alarm
11 Relay configuration
12 Programming the timer
13 Synchronising the timer
14 Reset/Factory/User
15 Change code
16 Additional display

0 0 0 0 0 0
1 Show actual value 2 Select language 3 User configuration 4 Unit configuration 5 Control 6 Offset 7 Analog output 1 8 Analog output 2
1.1 Outlet 112 °C 2.1 Sprache Deutsch 3.1 Deviation set/actual 4.1 Heat transfer fluid 5.1 Type of control 6.1 Offset outlet sensor 7.1 Output 1 Outlet 4 –20 mA 8.1 Output 2 Outlet 4 –20 mA
1.2 External 110 °C 2.2 Language English 3.2 Outlet limit 4.2 External sensor type 5.2 Control par. PID selection 6.2 Offset ext. sensor 7.2 Output 1 Outlet 0 –20 mA 8.2 Output 2 Outlet 0 –20 mA
1.3 Inlet 2.3 Langue Français 3.3 Minimum flow rate 4.3 Runout temperature 5.3 Control par. PID fix 6.3 Offset inlet sensor 7.3 Output 1 Outlet 0 –10 V 8.3 Output 2 Outlet 0 –10 V
1.4 Heating/coolingcap. 3.4 Interface 4.4 Maximum set-point 5.4 Control par. PID man. 6.4 Offset analog input 7.4 Output 1 Ext. 4 –20 mA 8.4 Output 2 Actual TE– FE
1.5 Flow rate 3.5 Temperature display 4.5 Evacuation options 5.5 Control par. casc. sel 6.5 Offset analog out. 1 7.5 Output 1 Ext. 0 –20 mA 8.5 Output 2 Actual TE–CA
1.6 Pump current L1 1.2 A 3.6 Flow rate display 4.6 Evacuation time 5.6 Control par. casc. fix 6.6 Offset analog out. 2 7.6 Output 1 Ext. 0 –10 V 8.6 Output 2 Actual TE–Cu
1.7 Pump current L2 1.2 A 3.7 Set-point at start 4.7 Pump current 5.7 Control par. casc. man 7.7 Output 1 Inlet 4 –20 mA 8.7 Output 2 Extern 4 –20 mA
1.8 Pump current L3 1.3 A * 3.8 Next service 4.8 Pump dir. of rotation 7.8 Output 1 Inlet 0 –20 mA 8.8 Output 2 Extern 0 –20 mA
1.9 Operating hours 14725 3.9 Operating hours 14725 * 4.9 Pump run-out time 7.9 Output 1 Inlet 0 –10 V 8.9 Output 2 Extern 0 –10 V
1.10 Service after 275 h 4.10 Power failure behav. 7.10 Output 1 Set 1 4 –20 mA 8.10 Output 2 Inlet 4 –20 mA
1.11 Software version 5005 4.11 Heating 2 7.11 Output 1 Set 1 0 –20 mA 8.11 Output 2 Inlet 0 –20 mA
1.12 Interface RS 485 4.12 Heating cycle time 7.12 Output 1 Set 1 0 –10 V 8.12 Output 2 Inlet 0 –10 mA
1.13 Protocol PROFIBUS 4.13 Cooling cycle time 7.13 Output 1 Set 2 4 –20 mA 8.13 Output 2 Set 1 4 –20 mA
1.14 Address 3 4.14 Suppress heating 7.14 Output 1 Set 2 0 –20 mA 8.14 Output 2 Set 1 0 –20 mA
1.15 Day/time Do 07:16 4.15 Suppress cooling 7.15 Output 1 Set 2 0 –10 V 8.15 Output 2 Set 1 0 –10 V
4.16 Pump. cooling medium 7.16 Output 1 Flow 4 –20 mA 8.16 Output 2 Set 2 4 –20 mA
4.17 Func. of ext. contact 7.17 Output 1 Flow 0 –20 mA 8.17 Output 2 Set 2 0 –20 mA
4.18 Level alarm 7.18 Output 1 Flow 0 –10 V 8.18 Output 2 Set 2 0 –10 V
4.19 Pressure relief valve 8.19 Output 2 Flow 4 –20 mA
4.20 Viscosity 8.20 Output 2 Flow 0 –20 mA
8.21 Output 2 Flow 0 –10 V

0 0 0 0
9 Analog input 10 Common alarm 11 Relay configuration 12 Programming the timer 13 Synchronising the timer 14 Reset/Factory/User 15 Change code 16 Additional display
9.1 Analog input inactive 10.1 Alarm repeat time 10.8 Relay K1 function 12.1 01: Inactive 13.1 Enter day 14.1 Save as fact. setting 15.1 Code ‹Entry value› 16.1 No additional display
9.2 Analog input 4 –20 mA 10.2 Alarm heating 1 10.9 Relay K1 selection 12.2 02: Inactive 13.2 Enter hour/minute 14.2 Reset to fact. set 15.2 Code ‹Set-point› 16.2 Outlet 5 °C
9.3 Analog input 0 –20 mA 10.3 Alarm heating 2 10.10 Relay K2 function 12.3 03: Inactive 14.3 Save as user set 1 15.3 Code ‹Fact setting› 16.3 External 24 °C
9.4 Analog input 0 –10 V 10.4 Alarm flow rate 10.11 Relay K2 selection 12.4 04: Inactive 14.4 Reset to user set 1 15.4 Code ‹User setting 1› 16.4 Inlet 23 °C
10.5 Alarm flow monitor 10.12 Relay K3 function 12.5 05: Inactive 14.5 Save as user set 2 15.5 Code ‹User setting 2› 16.5 Heat/Cool cap. –100%
*
10.6 Alarm level 10.13 Relay K3 selection 12.6 06: Inactive 14.6 Reset to user set 2 16.6 Flow rate
10.7 Alarm pump current 10.14 Relay K4 function 12.7 07: Inactive 16.7 Operation hours 14725
10.15 Relay K4 selection 12.8 08: Inactive 16.8 Service after 275 h
12.9 09: Inactive 16.9 Day/time Do 07:16
* Beispiele 12.10 10: Inactive
Die Zahlen vor den Textzeilen beziehen sich auf die Betriebsanleitung.
Programming example:
65
Show actual value
Outlet ºC Select language
Deviation set /actual 3.1 User configuration

S1 Unit configuration

upper limit entry 5 °C Control

Offset

Set value
80ºC
Analog output 1

SP1

0
3 User configuration

3.1 Deviation set/actual Set-point/outlet Set-point/outlet Code

3.2 Outlet limit Set-point/outlet Entry 0 °C Entry 0
3.3 Minimum flow rate Set-point/external
3.4 Interface Set-point/external
3.5 Temperature display Set-point/inlet
3.6 Flow rate display Set-point/inlet
3.7 Set-point at start

If correct:

Code Set-point/outlet
Entry 282 Entry 5 °C

Legend

Level change
If wrong:

Code
Change of line Entry 0
or value
or code entry
Wrong
Code

The number in front of the text lines refers to the instruction manual.
 Fuse
F 801
2.5 A H

Socket for Socket for Plugg. connection

relay-board relay-board X 801
K3 45807 K3 45807 RJ45

6 sockets for
options

Socket for Socket for

relay-board relay-board
K3 45807 K3 45807
Replacement fuse
2.5 A H
 Regloplas AG
Flurhofstrasse 158
CH-9006 St. Gallen
Tel. + 41 71 282 58 00
Fax + 41 71 282 58 40
E-mail regloplas@regloplas.com
Internet www.regloplas.com

BA 150S-350L/0703/d/f/e