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09/2011

18

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Operating Instructions

Temperature Control Unit 300L(D)/350L(D)

System Errors

Error message

Remedy

Memory stick missing

Insert memory stick

Incompatible data on stick

Load current software version

Communication failure

Check the connection between the front panel and the
base module

Software version error

Reload software

Data corrupt on memory stick

Insert new memory stick and reload device parame-
ters

Zone 1 missing

Connect Zone 1, check address of Zone 1

Zone 2 missing

Connect Zone 2, check address of Zone 2

Software version option Profibus incompatible

Update the Software

Software version option CANOpen incompatible

Update the Software

Maintenance

WARNING

The temperature control unit must be switched off before carrying out any
maintenance work - press the main switch and disconnect from the mains!

The temperature control unit may still be pressurized - Danger of injury from
escaping hot cooling water or steam!

Before disconnecting the feed lines to the temperature control unit/consumer,
first allow the temperature control unit to cool down!

Periodic Inspections and Maintenance Proce-
dures

The RT100 control system has a service interval display to simplify the
standard maintenance procedures for the temperature control unit. We
recommend entering the corresponding maintenance interval (e.g., 2000
hours, see the RT100 control system programming instructions).

Please note that the instructions below are based on a daily operating
time of 8 hours. In multi-shift operation, the inspections and maintenance
procedures must be carried out at correspondingly shorter intervals. De-
fective parts must be repaired or replaced immediately.

•

Temperature control unit inspections and maintenance proce-
dures must be carried out by an expert

•

Maintenance procedures involving electrical equipment may only
be carried out by qualified electricians

•

The RT100 control system unit may only be replaced when the
mains plug is unplugged

•

The safety valve should be vented from time to time by brief acti-
vation (blow off)

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Содержание 300L

Страница 1: ...En Operating Instructions Temperature Control Unit 300L D 350L D ...

Страница 2: ...s documentation is true and correct as of the date of publica tion The contents however do not constitute a binding obligation on the part of Regloplas AG and are subject to change without notice Copyright 2011 Regloplas AG All rights reserved Printed in Switzerland Regloplas AG Flurhofstrasse 158 9006 St Gallen Switzerland Tel 41 71 282 58 00 Fax 41 71 282 58 40 e mail info regloplas com Website ...

Страница 3: ...sumers 7 Water Quality 7 Thermal Oil 7 Connecting Lines 8 Electrical Connections 8 Operation of the Temperature Control Unit 9 RT100 Control System 9 Buttons 9 Status LEDs 9 Device Functions 10 Symbols 10 RT100 Operation and Status Displays 10 Setting the Set point values 10 Parameter Menu 11 RT100 Control System Functions 11 Switching on the Temperature Control Unit 11 Starting up for the first t...

Страница 4: ...nnecting Hoses 23 Technical Data 300L D 24 Technical Data 350L D 25 Block Diagram300L D 350L D 26 Diagram Pump capacity 27 Diagram Cooling capacity 28 Components Spare parts 300L D 350L D 29 Dimension sheet 300L 32 Dimension sheet 300LD 33 Dimension sheet 350LD 34 Level Switch 35 300L D 35 Dismantling Replacement 35 350L D 36 Dismantling Replacement 36 Solenoid valves 37 Overview 37 Safety thermal...

Страница 5: ...ARNING Denotes a dangerous situation Failure to heed the information can result in death or grave personal injury dis ability CAUTION Denotes a potentially dangerous situation Failure to heed the information can result in property damage as well as minor or moderate personal injury NOTE Denotes general information useful advice to users and work recommenda tions which however do not have any influ...

Страница 6: ...el who are familiar with these tasks and have been instructed as to the risks Safety Information General Information The Regloplas temperature control unit is safe to operate but can cause danger if it is used incorrectly or for a purpose other than its intended use It should be noted that any such incorrect use or non compliance with the intended use can cause risks to the life and limb of the us...

Страница 7: ... parameters in the device configuration may be changed without consulting Regloplas The relevant accident prevention regulations and the generally accepted principles of safety engineering occupational medicine and structural en gineering must be observed The national safety regulations must also be obeyed Residual Risks Any unauthorised modifications and changes to the temperature control unit as...

Страница 8: ... switch it off Check that the pump is no longer running WARNING Important danger of injury in the event of escaping water or oil Using This Documentation This documentation contains important information for safe economical operation and for proper maintenance of the device Compliance with this documentation helps to avoid danger minimise re pair costs and downtime and increase the dependability a...

Страница 9: ...nnel Operating Range The operating range and medium of the Temperature Control Unit 300L D 350L D are shown in the following table in this regard see also the chapter Technical Data in the service section Temperature Control Unit Type 300L D 350L D Temperature range up to 300 C up to 350 C Heat transfer medium Oil Oil NOTE The technical data and information for installation start up and maintenanc...

Страница 10: ...n the temperature control circuit temperature control unit connecting lines consumers etc must be repaired immediately The thermal insulation in the temperature control unit must be kept clean at all times thermal insulation soaked with thermal oil is a fire risk Observe local laws during set up CAUTION Danger of injury due to release of hot thermal oil Before detaching connecting lines in the tem...

Страница 11: ...d out using the Re gloplas REG descaling unit see the Regloplas Temperature Control Technology brochure REG data sheet Oil deposits can be removed with the SR80 system cleaner see the Regloplas Temperature Control Technology brochure SR80 data sheet When converting the consumer from operation with water to thermal oil all residual water in the consumer and in the connecting lines must be ful ly re...

Страница 12: ...the range of 2 6 bar Use only pressure resistant and temperature resistant hoses and screw fit tings Cooling water outlet must be free of back flow and always open The hose must be fastened so that any escaping steam at the start of the cooling procedure does not pose a hazard Overflow must always be open CAUTION If the cooler is leaky thermal oil can enter the wastewater For reasons of safety the...

Страница 13: ... System RT100 Control System front panel Buttons Setting the set point value Scrolling through pages Setting the additional display Setting the parameters Selection of the device functions toggling SP1 SP2 drainage by suction leak stop Alarm reset and alarm history Button ON OFF Status LEDs Normal mode Warning Alarm Status display Display of set point value SP1 SP2 or ex ternal operation RCD contr...

Страница 14: ...ight part of the display shows the current outlet temperature actual value of temperature sensor Sn1 Sn2 or Sn3 Sn1 Outlet temperature Sn2 Temperature external Sn3 Inlet temperature Three other selectable values are shown in the middle part of the display The additional display can be set by using the F2 key and by turn ing pressing the RCD control knob turning selects a value pressing con firms i...

Страница 15: ...ectrical connections proceed as follows Switch on the main switch on the temperature control unit Open the vent valve on the consumer and also the shut off valve if fitted Using a funnel pour thermal oil slowly into the filling port until the red indicator lamp of the level control is switched off After the pump starts up top up again with oil until the pressure displayed on the pressure gauge sta...

Страница 16: ... in the display or corrects the direction of rotation automatically Venting the Temperature Control Unit Each time the unit is filled or refilled with thermal oil the unit and the temperature control circuit must be vented To prevent overheating of the heating elements due to incipient air bubbles in the temperature circuit the inlet pressure in the temperature control unit is monitored by a mini ...

Страница 17: ...erature control unit otherwise the temperature control unit will overflow Drainage by Suction with Pump The suction program allows the draining of the consumer connected at the temperature control unit and is activated by pressing the F3 key and selecting the suction symbol The pump is switched off and after the pump run down time has elapsed the pump is switched on again in the opposite direction...

Страница 18: ...Alarm Reset button also allows manual acknowledgement of the au tomatic switchover toggling from consumer temperature control Sn2 to outlet temperature control Sn1 if sensor Sn2 is defective or removed from the consumer Alarm History If there is no alarm pending the Alarm Reset button can be used to view the alarm history Save Reset of the Setting Values The RT100 control system provides the facil...

Страница 19: ... on the display Changing Consumers Decommissioning Before detaching the connecting lines it is necessary to verify that the temperature control unit is switched off and that all circuits are depressur ized see the chapter Switching off the Temperature Control Unit The temperature control unit must be drained completely and stored in a dry place at 10 40 C when not in use To restart the unit procee...

Страница 20: ...oint outlet underrun Adjust the outlet temperature and acknowledge the fault Deviation set point outlet exceeded Adjust the outlet temperature and acknowledge the fault Deviation set point external underrun Adjust the external temperature and acknowledge the fault or error Deviation set point external exceeded Adjust the external temperature and acknowledge the fault or error Deviation set point i...

Страница 21: ...transfer me dium must not exceed the maximum temperature of the unit if required check the tool temperature Heating thermostat triggered Temperature control unit has become too hot cool down and search the cause Current monitoring heating activated Check the heating element s and replace if neces sary Motor current underrun Check the pump pump motor with ohmmeter and replace if necessary Phase seq...

Страница 22: ... cooling water or steam Before disconnecting the feed lines to the temperature control unit consumer first allow the temperature control unit to cool down Periodic Inspections and Maintenance Proce dures The RT100 control system has a service interval display to simplify the standard maintenance procedures for the temperature control unit We recommend entering the corresponding maintenance interva...

Страница 23: ... inlet port of the pump motor to ensure that it is free of obstructions Clean the port by blowing compressed air from inside to outside Clean the level switches Check filters and clean if necessary Semi annual Inspections Maintenance Procedures Inspect the electrical equipment such as grounding wires secure connection of power supply cord and connecting lines etc Dismantle solenoid valves see main...

Страница 24: ...el switches must be refitted correctly see Maintenance section 5 Dismantle solenoid valves see Maintenance section inspect di aphragms for scale deposits and damage Check the core and spring bolt for free movement Clean or replace parts if neces sary 6 Inspect pump for corrosion and replace if necessary 7 It is also advisable to inspect the consumers for contamination Impurities lead to a sharp re...

Страница 25: ... the discharge port on the delivery pump see maintenance section Because of the danger of freezing bursting of the cooling pipes at low tempera tures the cooler must be blown out as follows 1 Switch on the temperature control unit press the main switch and press the ON OFF button 2 Set the set point value on the controller to 0 C 3 Check that the cooler solenoid valve Y6 is open 4 Blow out the coo...

Страница 26: ......

Страница 27: ...bending load at the connections Pipe elbows fitted Wrong Right Incorrect installation compression along the longitudinal axis Pipe elbows fitted Wrong Right Torsion hose axis and direction of movement not in the same plane The pipe axes must be parallel and in the same plane as the direction of movement Important the hoses may also be twisted dur ing installation When attaching detach ing a hose a...

Страница 28: ...circuit Max delivery rate 90 l min 90 l min per circuit Max delivery pressure 10 bar 10 bar per circuit Control System RT100 Control System Measurement type standard Pt100 Pt100 Control voltage 230 V 50 Hz 230 V 50 Hz Input supply voltages 200 600 V 50 60 Hz 200 600 V 50 60 Hz Input supply voltage standard 400 V 50 Hz 3 PE 400 V 50 Hz 3 PE Outlet inlet connections stan dard G 3 4 female G 3 4 fema...

Страница 29: ...uit Max delivery rate 90 l min 90 l min per circuit Max delivery pressure 10 bar 10 bar per circuit Control System RT100 Control System Measurement type standard Pt100 Pt100 Control voltage 230 V 50 Hz 230 V 50 Hz Input supply voltages 200 600 V 50 60 Hz 200 600 V 50 60 Hz Input supply voltage standard 400 V 50 Hz 3 PE 400 V 50 Hz 3 PE Outlet inlet connections stan dard G 3 4 female G 3 4 female C...

Страница 30: ...n 36 Main circuit filter E21 Heating 37 Expansion tank F3 Flow monitoring 41 Cooler F5 Safety thermostat 56 One way check valve M10 Pump 58 Bypass S1 Level control upper level 60 Cooling circuit filter S3 Level control lower level 61 Pressure gauge Y6 Solenoid valve cooling 99 Consumer Y13 Solenoid valve suction optional B1 Internal temperature probe ...

Страница 31: ...V 09 2011 Temperature Control Unit 300L D 350L D Maintenance 27 Diagram Pump capacity Pump curve FM65 Pump capacity Delivery rate V as a function of pressure p bypass not ta ken into account ...

Страница 32: ... Cooling capacity Cooling curve 300L D 1K Cooling capacity P as a function of inlet temperature Cooling water temperature 20 C Flow rate 20 l min Cooling curve 350L D 1K Cooling capacity P as a function of inlet temperature Cooling water temperature 20 C Flow rate 20 l min ...

Страница 33: ...ure Control Unit 300L D 350L D Maintenance 29 Components Spare parts 300L D 350L D P1 K20 Q1 T5 H3 61 61a 2 2a 68b Y6 2 2a F5 60 66 73 72 69 37 F5 E21 E22 56 68a 68 67 Y13 70 40 B1 70 M10 9 36 72 E21 E22 58 Y6 68a 68 75 ...

Страница 34: ...V 09 2011 30 Maintenance Temperature Control Unit 300L D 350L D 73 37 35 56 66 Y13 70 V21a V22a V21 V22 9 F3 82 61 P1 61a 69 S1 S3 ...

Страница 35: ...ormer 58 Bypass V21 22 SSR relay with heat sink 60 Cooling water filter V21a V22a SSR relay seal 61 System pressure gauge inlet S1 Level switch upper level 61a System pressure gauge outlet S3 Level switch lower level 66 Cooling water ON Y6 Solenoid valve cooling 67 Cooling water OFF Y13 Solenoid valve suction 68 Discharge port 68a Discharge port pump 69 Filling port 70 Overflow 72 Outlet 73 Inlet ...

Страница 36: ...erature Control Unit 300L D 350L D Dimension sheet 300L Item Designation Item Designation 1 Main switch 6 Cooling water ON 2 RT100 Control System 7 Cooling water OFF 3 Pressure gauge 8 Discharge port 4 Outlet 9 Filling port 5 Inlet ...

Страница 37: ...Unit 300L D 350L D Maintenance 33 Dimension sheet 300LD Item Designation Item Designation 1 Main switch 6 Cooling water ON 2 RT100 Control System 7 Cooling water OFF 3 Pressure gauge 8 Discharge port 4 Outlet 9 Filling port 5 Inlet ...

Страница 38: ...rature Control Unit 300L D 350L D Dimension sheet 350LD Item Designation Item Designation 1 Main switch 6 Cooling water ON 2 RT100 Control System 7 Cooling water OFF 3 Pressure gauge 8 Discharge port 4 Outlet 9 Filling port 5 Inlet ...

Страница 39: ...with blue marking for the upper switching point see section on Switching on for the first time Com missioning Level switch with silicone cable and AMP so cket Dismantling Replacement When replacing the level switches after removal the marking NO or NC on the float must be in the correct position otherwise the level control will not work cor rectly ...

Страница 40: ...lue marking for the upper switching point see section on Switching on for the first time Com missioning Level switch with silicone cable and AMP so cket Dismantling Replacement When replacing the level switches after removal the marking NO or NC on the float must be in the correct position otherwise the level control will not work cor rectly ...

Страница 41: ...operating principle The safety thermal cut out micro switch with break contact restart interlock and additional signal contact switches the temperature control unit off when the temperature reaches the preset limit When the tem perature has cooled to roughly 10 below the preset limit the safety thermal cut out can be released by pressing the restart button If the capillary tube is broken or if the...

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