En

RT100
Programming Manual

SOF1119
 V 01/2016

Documentation RT100 Control System

This manual is copyrighted. Unauthorised duplication is prohibited by law.

To the best of our knowledge and belief, the information contained in this
manual is true and correct as of the date of publication. The contents,
however, do not constitute a binding obligation on the part of Regloplas
AG and are subject to change without notice.

© Copyright 2013 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: [email protected]
Homepage: www.regloplas.com
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Contents
General Safety Information 1
Safety Symbols ....................................................................................................... 1
Range of Application ............................................................................................... 2
Intended Use ........................................................................................................... 2
Safety Information ................................................................................................... 2
General Information ................................................................................... 2
Process Monitoring .................................................................................... 2
Information for Operators and Personnel .................................................. 3
Changing the Parameterisation ................................................................. 3
Residual Risks ........................................................................................... 3
Using this Documentation ....................................................................................... 4
Additional Documentation .......................................................................... 4

Design and Function 5

Range of Application ............................................................................................... 5
Software Version ..................................................................................................... 5
RT100 Control System - Hardware ......................................................................... 5
Construction ............................................................................................... 5
Operation Concept ..................................................................................... 5
Operating Control and Display Elements................................................... 6
Buttons ....................................................................................................... 6
Status LEDs ............................................................................................... 6
Device Functions ....................................................................................... 6
Symbols ..................................................................................................... 7
RT100 Control System - Displays ........................................................................... 7
Operation and Status Displays .................................................................. 7
Setting the Set-points................................................................................. 7
Parameter Menu ........................................................................................ 8
RT100 Control System - Functions ......................................................................... 8
Powering Up............................................................................................... 8
Power Down ............................................................................................... 8
Leak-stop operation ................................................................................... 8
Draining ...................................................................................................... 9
Operation with Code/Password ............................................................... 10
Operation with Timer................................................................................ 10
Alarm Reset and Alarm History................................................................ 10
Save/Reset of the Setting Values ............................................................ 10
RT100 Control System - Loading firmware/bootloader......................................... 11
USB flash drive ........................................................................................ 11
Loading the firmware/bootloader ............................................................. 12
RT100 Control System - Activating Options ......................................................... 12
Software options ...................................................................................... 12

Technical Data 15
RT100 Control System .......................................................................................... 15
General Data ............................................................................................ 15
Electrical Data .......................................................................................... 15
Inputs ....................................................................................................... 16

RT100 Control System Contents  i

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Outputs .................................................................................................... 16
Data Interfaces (Option) .......................................................................... 16
Display ..................................................................................................... 16
Precision .................................................................................................. 17
Operation ................................................................................................. 17
Dimensions .............................................................................................. 17

Parameterisation 19
General ................................................................................................................. 19
Show actual values............................................................................................... 19
Select language .................................................................................................... 20
User settings ......................................................................................................... 20
Display ..................................................................................................... 20
Clock ........................................................................................................ 20
Switch clock ............................................................................................. 20
Ramp program (Software option) ............................................................ 21
Set-point .................................................................................................. 22
Evacuation time ....................................................................................... 22
Next Service ............................................................................................ 23
Pump regulation ...................................................................................... 23
USB Logging (Service Interface) ............................................................. 23
Monitoring ............................................................................................................. 23
Temperature deviation............................................................................. 23
Max. heat./cool. time ............................................................................... 24
Minimum flow rate ................................................................................... 24
Flow deviation (Software option) ............................................................. 24
Min. system pressure .............................................................................. 25
Interfaces .............................................................................................................. 25
Address ................................................................................................... 25
Temperature control ............................................................................................. 25
Temperature Regulation .......................................................................... 25
Control parameters outlet ........................................................................ 25
Control parameters cascade ................................................................... 26
Settings .................................................................................................... 26
Control system modes ............................................................................. 26
Fixed parameter sets ............................................................................... 26
Pressure control ................................................................................................... 27
Pump regulation (Software option) ....................................................................... 28
Unit configuration.................................................................................................. 28
Inputs .................................................................................................................... 30
Flow meter type F1000 (Software option, max. 300 lpm) ....................... 31
Outputs ................................................................................................................. 33
Relay..................................................................................................................... 34
Collective alarm .................................................................................................... 35
Save/Load ............................................................................................................ 37
Code ..................................................................................................................... 37
Options ................................................................................................................. 38
Current monitoring heating ................................................................................... 39
Service menu ........................................................................................................ 39
Multiflow ................................................................................................................ 39

Data Interfaces 41
Basic Concept ...................................................................................................... 41
Protocols ............................................................................................................... 41

Plug Nomenclature 43
RT100 Front panel................................................................................................ 43
RT100 Base Module ............................................................................................. 43

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RT100 Digital Option ............................................................................................. 46

Digital Functions ...................................................................................... 46
Relay Functions ....................................................................................... 46
RT100 Analog Option ........................................................................................... 46
Digital Functions ...................................................................................... 46
Analog Functions ..................................................................................... 47
RT100 Option Reversal of Direction of Rotation >9A ........................................... 47
RT100 Option Current Monitoring Heating ........................................................... 47

Hardware 49
RT100 Front Panel - Layout.................................................................................. 49
RT100 Base Module - Layout ............................................................................... 50
Analog Option - Layout ......................................................................................... 51
Digital Option - Layout .......................................................................................... 52
Option Reversal of Direction of Rotation >9A - Layout ......................................... 53
Option Current Monitoring Heating - Layout ......................................................... 53
Option Profibus DP - Layout ................................................................................. 54
Option Euromap 66 - Layout ................................................................................. 55
Option Profinet-IO - Layout ................................................................................... 56

Fault Rectification 57
Alarm Messages ................................................................................................... 57
Alarm List .............................................................................................................. 57
Warnings .................................................................................................. 57
Alarms ...................................................................................................... 58
System Errors/System Notes ................................................................... 59

RT100 Control System - Maintenance/repair 61

Replacing the front panel ...................................................................................... 61
Removal ................................................................................................... 61
Installation ................................................................................................ 61
Loading the firmware ............................................................................... 61
Replacing the base module .................................................................................. 62
Removal ................................................................................................... 62
Installation ................................................................................................ 62
Hardware checklist................................................................................... 62
Loading the firmware ............................................................................... 62
Activating options ..................................................................................... 62
Loading the factory settings ..................................................................... 63
Configuration check ................................................................................. 63
Customer-specific settings ....................................................................... 63
CAN terminating resistors and address settings...................................... 64

Spare Parts 67
Ordering Spare Parts ............................................................................................ 67
RT100 Control System - Spare Parts ................................................................... 68

RT100 Control System Contents  iii

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General Safety Information

Safety Symbols

DANGER
Denotes imminent danger.
Failure to heed the information can result in death or grave personal injury (dis-
ability)!

WARNING
Denotes a dangerous situation.
Failure to heed the information can result in death or grave personal injury (dis-
ability)!

CAUTION
Denotes a potentially dangerous situation.
Failure to heed the information can result in property damage as well as minor
or moderate personal injury!

NOTE
Denotes general information, useful advice to users and work recommenda-
tions, which, however, do not have any influence on the safety and health of
personnel.

RT100 Control System General Safety Information  1

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Range of Application
This general safety information is generally valid for all temperature con-
trollers and control systems from Regloplas.

Intended Use
The Regloplas control system is built according to the current state of the
art and the generally accepted principles of safety engineering. The con-
trol system is intended solely for the normal use for heating and/or cool-
ing of injection and die casting moulds, extruders, calenders, mixers and
other consumers in areas in which there is no risk of explosion.
Any use beyond this shall be deemed to constitute improper use. The
manufacturer is not responsible for damage resulting from improper use;
the user is solely responsible for such risks. The control system may not
be used under other operating conditions and/or with other media, in de-
viation from our specifications, without the prior consent of Regloplas AG.
Use as intended also entails compliance with the operating, servicing and
maintenance conditions stipulated by the manufacturer. The control sys-
tem may only be operated, serviced and maintained by personnel who
are familiar with these tasks and have been instructed as to the risks.

Safety Information

General Information
The Regloplas control system is safe to operate, but this device can pose
danger to life and limb if it is used incorrectly or for a purpose other than
that intended. It should be noted that this poses risks to the life and limb
of the user or third parties, adverse effects on the equipment and other
material assets belonging to the user, and risks to the efficient operation
of the equipment.
Start-up (i.e., commencement of intended use) is prohibited until it has
been determined that the control system has been set up and wired in
accordance with the Machinery Directive (2006/42/EC). EN 60204-1
(Safety of Machinery) must also be observed.
These operating instructions must be read carefully before turning on and
operating the temperature control unit. The information regarding the in-
tended use and foreseeable misuse must be observed. Local safety
regulations must also be obeyed.
If the control system is used in combination with products by other manu-
facturers, their notices and safety regulations must also be obeyed.

Process Monitoring
In plants in which a temperature control system malfunction leads to en-
dangerment of the operating personnel or destruction of the plant, an in-
dependent process monitor that shuts down the plant securely must be
used.

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Information for Operators and Personnel

The operator and all persons who are tasked with working on the tem-
perature control unit must obey the fundamental regulations regarding
work safety and accident prevention. The operator must ensure that only
persons who have read and understood these operating instructions, par-
ticularly the chapter on safety, work on the temperature control unit.
Any working methods that have a negative effect on the technical safety
of the temperature control unit must not be used. The operator must en-
sure that the temperature control unit is operated only in flawless condi-
tion. If necessary, the company using the equipment must obligate the
operating personnel to wear protective clothing.
For all tasks having to do with set-up, start-up, operating, modification of
operating conditions and operational modes, maintenance, inspection
and repair, any shut-down procedures stated to be necessary in the op-
erating instructions must be followed.

Changing the Parameterisation

The parameterisation of the control system may only be carried out by
personnel trained by Regloplas. In particular, no parameters in the device
configuration may be changed without consulting Regloplas.
The relevant accident prevention regulations and the generally accepted
principles of safety engineering, occupational medicine and structural en-
gineering must be observed. The national safety regulations must also be
obeyed.

Residual Risks
Any unauthorised modifications and changes to the temperature control
device as also unauthorised changes to the parameterisation of the con-
trol system are prohibited for reasons of safety.
If the temperature control unit is damaged, it must not remain in use; the
defective part must be replaced or repaired immediately. Only original
Regloplas replacement parts may be used. Damage due to use of third-
party parts voids any and all warranty claims.

DANGER
The temperature control unit must be disconnected before it is opened (unplug
mains plug or, if present, turn the yellow/red main switch on the temperature
control unit)! Danger due to electrical shock!

Repair leaks in the temperature control circuit (device, connecting lines,

consumers, etc.) immediately.
In temperature control units that use oil as a heat transfer medium, it
should be noted that oil is flammable under certain conditions. For this
reason, the temperature control unit must not be located in the vicinity of
heat sources. The thermal insulation in the device must always be kept
clean. Insulation that is soaked with thermal oil poses an increased risk of
fire.
Burning thermal oil can be extinguished using a spray foam fire extin-
guisher, a powder fire extinguisher (avoid with dust-sensitive plants, con-
trol systems, EDP, etc.) or a CO2 fire extinguisher. The appropriate fire

RT100 Control System General Safety Information  3

 V 01/2016

extinguisher must be provided by the operator, taking into account the

equipment located in the room and the mandatory safety regulations.
The temperature control unit may only be operated when all safety sys-
tems are completely installed and intact.
The temperature control unit must be protected against sprays and clean-
ing agents.
Before detaching connecting lines in the temperature control circuit and
depending on the outlet temperature, allow the temperature control de-
vice to cool down first and then turn it off. Check that the pump is no
longer running.

WARNING

Important - danger of injury in the event of escaping water or oil!

Using this Documentation

This documentation contains important information for safe, economical
operation and for proper maintenance of the device.
Compliance with this documentation helps to avoid danger, minimise re-
pair costs and downtime, and increase the dependability and service life
of the device/system.

NOTE
The operating instructions should be kept near the corresponding de-
vice/system and always be accessible to operating and maintenance personnel.

Additional Documentation
The included instructions are completely correct for the basic versions of
devices. Components that do not belong to the basic hardware are noted
in the instructions as extra equipment. The corresponding additional doc-
uments are included with special versions of devices. Any additional doc-
uments supplement and/or replace the descriptions contained in these
instructions, which are then either invalid or only conditionally valid.

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Design and Function

Range of Application
The RT100 Control System has been developed for the control and op-
eration of Regloplas temperature control units and in addition, facilitates
connection to a superordinate control system of a production plant.

Software Version

NOTE
The following description of the RT100 Control System and its parameterisation
is valid beginning with software version 1119.

RT100 Control System - Hardware

Construction
The microprocessor-controlled RT100 Control System from Regloplas
consists of a front panel (operation and display section) and a base mod-
ule (power section).

CAUTION

No external, third-party devices may be connected to the 24 VDC supply and the
AC supply of the base module!

Operation Concept
The RT100 Control System is equipped with an RCD control knob. It can
be used for navigation in the user interface through simple rotating and
pressing.
Pressing once selects a value and turning the knob is used for configura-
tion. Pressing again accepts the value.

RT100 Control System Design and Function  5

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Operating Control and Display Elements

Display of Zone and tempera- Display of actual

ture sensor Sn1/Sn2/Sn3 value

Additional
Display of set-point value display
(SP1/SP2), interface (UI)
or external control (Ext.)
Interface
Status display address

Selection of the
device functions
Symbol area

RCD control knob

(Regloplas Control Dial) Status LEDs

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

Alarm reset and alarm history
SP1/SP2, drainage by suction, leak-stop)

Button ON/OFF

Status LEDs
Normal operation Warning Alarm

Device Functions
Set-point value toggling SP1/SP2 Draining (suction or blowing out)

Leak-stop operation

6  Design and Function RT100 Control System

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Symbols
Level of the heat transfer medium (filled
Interface operation
quantity) low

Level of the heat transfer medium (filled

Heating
quantity) OK

Ramp program activated Timer activated

Cooling Feed pump, counter clockwise rotation

Feed pump, clockwise rotation Alarm

Maintenance due (flashes if maintenance is

due)

RT100 Control System - Displays

Operation and Status Displays

In the off state of the RT100 Control System, the message OFF appears
in the display area. Upon switching on with the button ON/OFF, the addi-
tional display is shown. The top left part of the display shows the set-
point temperature SP1 or SP2 (SP = Set point). The top right part of the
display shows the current outlet temperature (actual value of temperature
sensor Sn1, Sn2 or Sn3).
Sn1 = Outlet temperature
Sn2 = Temperature, external
Sn3 = Inlet temperature
Three other selectable values are shown in the middle part of the display.
The additional display can be set by using the F2 key and by turn-
ing/pressing the RCD control knob (turning selects a value, pressing con-
firms it).
The symbols for set-point value display, suction operation (draining) and
leak-stop operation are shown in the lower left part of the display. The
various operational and status displays of the temperature control unit
are shown in the lower right part of the display.

Setting the Set-points

The set-point values SP1 and SP2 are set by pressing the key F1. The
set-point value is then coloured light blue and can be set with the RCD
control knob. This setting is also possible in the parameter positions. The
set-point values can be selected through an external digital signal.
Toggling of the set-point values SP1 and SP2 is achieved with the F3 key
and selection of the set-point toggling function. Set-point toggling is only
possible if there is no alarm pending.

RT100 Control System Design and Function  7

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Parameter Menu
The parameter menu is activated by pressing the Parameter button in
this menu, all the parameters can be configured by turning/pressing the
RCD control knob.

RT100 Control System - Functions

Powering Up
Upon switching on the main switch, OFF appears in the display. The
RT100 Control System is now ready for operation and is switched on by
pressing the ON/OFF button, or by the timer, through a digital input or an
interface.
Depending on the programming, the set-point and actual values, as well
as information on the operational state of the control system or the tem-
perature control unit are displayed.

Rotational field detection / Direction reversal

The rotary field detection of the RT100 Control System detects a wrong
phase sequence and reports this in the display or corrects the direction of
rotation automatically.

Power Down
The RT100 Control System is switched off by pressing the ON/OFF but-
ton, or by the timer, through a digital input or an interface.
Depending on the temperature of the heat transfer medium, the switching
off program runs as follows:
 The pump and the control system are turned off. The RT100
Control System is in standby mode and the display is OFF
 The pump continues to run. The device cools till the temperature
of the heat transfer medium has reached the programmed run-on
temperature then, the pump and the control system are turned
off. In the case of devices using pressurised water, the pump
runs for a few seconds in the opposite direction (pressure re-
lease). The RT100 Control System is in standby mode and the
display is OFF

Leak-stop operation
The leak-stop operation is activated by pressing the F3 key and selecting
the leak-stop symbol and is only possible if it is supported by the device
type.
The leak stop operation is only possible if water is used as the heat trans-
fer medium and the set-point value is in the vicinity of the value run-on
temperature (0-80 °C). Pressurised water units do not have any leak-stop
operation.
When oil is used as a heat transfer medium, the set-point value must be
within the range 0-250 °C. The heating capacity is then max. 60 %, since
the thermal load of the oil must be kept low owing to the reduced pump
capacity.

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The leak-stop operation can be cancelled by pressing the ON/OFF but-

ton. When the ON/OFF button is pressed again (wait until the display
reads OFF), the unit switches back to normal operation.

Clearance for the Leak-Stop Function

The leak-stop function is not permitted with every device (e.g. if a change
in the direction of rotation of the delivery pump is not possible). The
clearance of the leak-stop function is set in the parameter menu.

DANGER
The leak-stop operation is an emergency operation and may only be switched on
or cleared for devices intended for the purpose. A leak-stop operation in the
case of devices not intended for the purpose can cause a fire.

Draining
The consumer device can be drained with the delivery pump (suction) or
with compressed air (blowing out); (setting in the parameter menu).

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 when the
pump run-down time elapses, switched on again in the opposite direction.
The consumer is drained through suction during the defined period
(draining time).
Draining is only possible if the temperature of the heat transfer medium is
below the programmed run-on temperature value. If that is not the case,
the heat transfer medium is first cooled to this value.

Blowing out with Compressed Air

The blowing out program makes it possible to drain the consumer con-
nected to the temperature control unit with compressed air. Blowing out is
activated after the pump run-down time has elapsed and directs com-
pressed air through the consumer. The temperature control unit switches
off automatically after the set period (draining time) has elapsed.
The suction or blowing out program can be cancelled by pressing the
ON/OFF button. When the ON/OFF button is pressed again (wait until the
display reads OFF), the unit switches back to normal operation.

NOTE
In the case of pressurised water units, the pressure release valve closes 5 °C
above the run-on temperature value (max. 85 °C) and opens at the programmed
run-on temperature value during the cooling process.

RT100 Control System Design and Function  9

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Operation with Code/Password

In order to prevent the values that have been set or programmed from
being set again unintentionally, the use of a code/password is earnestly
recommended.
The RT100 Control System has three password levels that are organised
hierarchically:
 User password - Default 0000 (switched off)
 Technician password - Default 0100
 Service password - only for personnel trained by Regloplas

NOTE
It is earnestly recommended that an operator password should be set up when
commissioning the temperature control device.

Operation with Timer

The RT100 Control System has an integrated real-time clock. If the op-
tion Timer is present, the device can be switched on and off with this op-
tion.

Alarm Reset and Alarm History

Alarm Reset
If an alarm has been triggered, the signal horn can be switched off by
pressing the Alarm Reset button. After the malfunction has been recti-
fied, the alarm can be reset by once again pressing the Alarm Reset but-
ton.
The Alarm Reset button also allows the manual acknowledgement of the
automatic toggling from control of the consumer temperature Sn2 to con-
trol of the outlet temperature Sn1 in case of a faulty or removed sensor
Sn2 in the consumer.

Alarm History
If there is no alarm pending, the Alarm Reset button can be used to view
the alarm history.

Save/Reset of the Setting Values

The RT100 Control System provides the facility to load the factory setting
values or the user settings at any time in a simple manner. Two different
customer-specific settings can be loaded afresh (user setting 1 and 2).

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RT100 Control System - Loading firmware/bootloader

USB flash drive

 The empty USB flash drive must be formatted with FAT file sys-
tem (see below)

 The firmware must be extracted from the compressed file and

copied to the USB flash drive (see below)

RT100 Control System Design and Function  11

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Loading the firmware/bootloader

CAUTION

The firmware must be loaded the first time that the device is switched on (main
switch), otherwise, the parameter settings will be incorrect!

 Insert the USB flash drive containing the firmware into the USB
port on the front panel
 Press and hold down front panel buttons F1 and F2 simultane-
ously
 Switch on the RT100 control system
 The RT100 control system will now load the bootloader
 As soon as the bootloader has loaded, the message Update
successful will be displayed
 Press the panel button F1
 The RT100 control system will now load the new firmware
 Attention - during the loading process, the device may not be
switched off under any circumstances!
 As soon as the firmware has loaded, the message Update suc-
cessful will be displayed
 The device can now be started with button F1 on the front panel
 The USB flash drive can be removed now

RT100 Control System - Activating Options

The RT100 control system can be equipped with different hardware and
software options.
The software options must be activated with a file loaded by USB stick.
This operation requires the serial number of the control system, which is
displayed in the Options parameter and can be found on the base mod-
ule next to the barcode. The serial number consists of 6 letters (e.g.
AALASF).
 In the Options parameter, select the Activate options menu
 Now insert the USB stick with the options file (e.g. AALASF.opt -
The options file can be on the same USB stick as the firmware)

Software options
 Universal interface
 Switch clock
 Ramp program
 Cascade inlet (sensor Sn3)
 Flow measuring F150
 Flow measuring F351
 Flow measuring F1000

12  Design and Function RT100 Control System

 V 01/2016

 Reversal of rotation >9A/suction

 Pump regulation
 Flushing
 Flow deviation
 Set-point ramps

RT100 Control System Design and Function  13

 V 01/2016

Technical Data

RT100 Control System

General Data
RT100 Control System
Temperature range -25 - 450 °C
Outlet control:
PID-controller, with 10 hard-coded PID parameter sets or with a PID set
that can be set manually. Separate parameter sets for heating and cooling
Control response
Consumer control:
PID-controller, with 10 hard-coded PID parameter sets or with a PID set
that can be set manually
Parameter input Input via keyboard and RCD control knob
Memory module with at least 10 years data retention time
Data memory
Timer with Lithium battery and about 10 years data retention time
Adjustable maximum set-point value limit
Limit values Programmable minimum and maximum deviation from the set-point value
of the heat transfer medium temperature and consumer temperature
Continuous self-monitoring of the regulation and control system
Probe breakage and sensor short-circuit (only in case of Pt100), probe
breakage
Limit values for temperature, pump current (all 3 phases), level, function
Monitoring equipment of the heating and pump circuit breakers and the flow rate (option)
Monitoring the plausibility of the data in the memory, the maintenance in-
terval, the flow monitor, the calibration values, the phase sequence of the
pump motor in compression or suction operation and of the external set-
point value signal (option)

Electrical Data
RT100 Control System
Input supply voltage Power supply (85-265 VAC)
Degree of protection Front panel with membrane keyboard (IP54)
Plug-in data memory, permanently connected to the temperature control
device, for fast and simple changing of the base module without loss of
Maintenance data The user data are automatically read into the new base module
Integrated working-hour meter and maintenance interval display

RT100 Control System Technical Data  15

 V 01/2016

Inputs
RT100 Control System
Outlet:
Pt 100
External (consumer):
Temperature sensor Optionally Pt100 (2- or 3-conductor), J (Fe-CuNi), K (NiCr-Ni), T (Cu-
CuNi) or N (NiCrSi-NiSi) (Option), 20mA
Inlet:
Pt 100 (2- or 3-conductor)
External set-point value specifica-
Standardised and scalable, analog interface with 0/4-20 mA or 0-10 VDC
tion
External heating-cooling command
Device On/Off Signal via potential-free contacts (option)
Program On/Off
Signal via keyboard (F3 key, standard) or via potential-free external con-
Set-point value toggling
tact (option)
Electrically isolated analog set-point value input with scalable signal 0/4-
Analog input
20 mA or 0-10 VDC (option)

Outputs
RT100 Control System
Heating/cooling Triac outputs for circuit breakers or valves or solid-state relays (SSR)
1 relay (standard), programmable as common alarm or as individual func-
tions (e.g. temperature switching point, deviation etc.)
Relay functions
3 relays (digital option), programmable as common alarm or as individual
functions (e.g. temperature switching point, deviation etc.)
Electrically isolated analog outputs with scalable signal 0/4-20 mA or 0-10
VDC. An actual or set-point value can be assigned to every output. A
Analog outputs
thermal e.m.f. of a J-, K-, T- or N-element corresponding to the current
display-actual can be output as the actual value output (option)

Data Interfaces (Option)

RT100 Control System
Data transmission to control com-
Various serial interfaces, Profibus DP, Euromap 66, Profinet-IO
puter (hardware)

Display
RT100 Control System
Black LCD display with white lettering. Simultaneous display of actual and
Construction, design set-point values, three additional lines for important display values as well
as one status line
Fault Indications Are shown in the display unit

16  Technical Data RT100 Control System

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Precision
RT100 Control System
 0.3 % of the display value, min.  0.5 °C
Class accuracy / linearization Pt100: 0,3 %
Thermocouples: 0,3 %
Pt100: 1 digit
Deviation of the display
Thermocouples: 2 digits

Operation
RT100 Control System
Operation using short-travel membrane key switch with pressure point in
the membrane keyboard and RCD control knob (Regloplas Control Dial).
Operation
Simple menu guidance in different languages. Set-point value and param-
eterisation protected through programmable codes

Dimensions
RT100 Control System
Front dimensions 130 x 140 mm
Base module 170 x 230 mm

RT100 Control System Technical Data  17

 V 01/2016

Parameterisation

General
The parameterisation of the RT100 Control System is carried out with the
Parameter button in the menu Parameters. The corresponding parame-
ter is selected and set by turning/pressing the RCD control knob.
The parameters are described in the following chapters.

CAUTION
The RT100 Control System has a safety concept with different password levels.
Parameters with the password level "Service Engineer" may only be adjusted
by personnel trained by Regloplas. Regloplas AG is not liable for damage that
results from incorrect parameterisation!

Show actual values

(Password level - User password)
The respective current actual values are displayed in this menu:

Parameters Remarks
Temperature of the heat transfer medium in the outlet - sensor Sn1 (in
Outlet temp.
°C/°F)
External temp. Temperature of the consumer in - sensor Sn1 (in °C/°F)
Temperature of the heat transfer medium in the inlet - sensor Sn3 (in
Inlet temp.
°C/°F)
Specification of the momentary output in % of the rated output
Heat./cool. power
(a negative value means cooling capacity in %)
Flow rate Flow rate of the heat transfer medium in l/min or GPM
Pump pressure Differential pressure across the pump
Pressure set-point Pressure set-point value of the heat transfer medium (bar)
System pressure Pressure of the heat transfer medium in the system (bar)
Outlet pressure Pressure of the heat transfer medium in the outlet (bar)
Pump current L1 Current drawn by the pump motor - Phase 1 (in A)
Pump current L2 Current drawn by the pump motor - Phase 2 (in A)
Pump current L3 Current drawn by the pump motor - Phase 3 (in A)
Operating hours Number of operating hours of the temperature control unit

RT100 Control System Parameterisation  19

 V 01/2016

Parameters Remarks
Next service Display of the remaining operating hours up to the next maintenance
Interface Display of the interface (with code)
Address Display of the device address in case of operation via interface
Date Display of the current date
Time Display of the current time
Num. level 1 low Display of the number of level undershoots
Control cabinet temp. Current temperature in the control cabinet (in °C/°F)
Software Version Display of the implemented software version (front panel/base module)
Corr. set-point Set-point value for auxiliary controller of the cascade control
Flow deviation Deviation of the flow rate in l/min or GPM

Select language
(Password level - Technician password)
One of the languages currently available is selected in this menu (second
line, German is in first line, English in second line).
The available languages are English, German, French, Italian, Spanish,
Dutch, Czech, Chinese, Russian, Slovenian, Polish, Danish, Hungarian,
Croatian, Romanian, Portuguese, Swedish and Japanese.

User settings
(Password level - Technician password)

Display
Parameters Remarks
Contrast Contrast of the display (in %)
Temperature display Temperature display (in °C / 0.1 °C or °F)
Flow display Flow display (in lpm or usGPM or ukGPM)
Zone display Zone display (Manually or Auto)
Zone Input of zone display if configuration is set on Manually

Clock
Parameter Remarks
Time format Selection of the time format (12/24-hour format)
Synchronize Synchronisation of date and time

Switch clock
Parameter Remarks
Programming the clock (10 steps)
There are 10 steps (connections) available for programming the clock. A day-of-
Clock programming the-week, a group of days of the week, a time and the type of time (on/off time)
(Software option) must be programmed for every step. 2 steps are required so that the device is
switched on once and off thereafter. The steps that are not required are set to inac-
tive. The active (On/Off) and inactive steps are visible in the second sub-level

20  Parameterisation RT100 Control System

 V 01/2016

Parameter Remarks
On/Off/Program 1-5 (Ramp pro-
gram)/Inactive
Monday, Tuesday, Wednesday, Thurs-
Step 1-10
day, Friday, Saturday, Sunday, Mo-Th,
Mo-Fr, Mo-Sa, Mo-Su
Time

Ramp program (Software option)

(Password level - Technician password)

Parameter Range Remarks

Program
Status
Loop
Step Display the status of the cur-
Status
Actual value rent ramp program
Set-point value
End set-point value
Remaining step time
Program Display ramp program
Status Display status
Program control START Start ramp program
PAUSE Pause ramp program
STOP + RESET Stop/Reset Ramp program
No. of steps Program steps (2-20)
Start step Starting steps (1-20)
Start takes place manual-
Start trigger
ly/clock
Switching off/last set-point
Stop behaviour
value
No. of loops Program passes (1-99)
Set-point (in °C/°F)
Program 1
Ramp time (in hrs./min.)
Step 1 Dwell time (in hrs./min.)
Program admin-
istration Start dwell time ("Directly" or
Steps when "Set-point reached")
Step 2 (Functions like Step 1)
Step 3 (Functions like Step 1)
Step 4 (Functions like Step 1)
Step 5 (Functions like Step 1)
Program 2 (Functions like Program 1)
Program 3 (Functions like Program 1)
Program 4 (Functions like Program 1)
Program 5 (Functions like Program 1)

RT100 Control System Parameterisation  21

 V 01/2016

Ramp program - Overview

Set-point
Parameter Range Remarks
Last set-point value
Upon switching on the temperature control unit, control
Set-point at startup Always SP1
takes place on the selected set-point value
Always SP2
Upon switching on, control is on the basis of the chosen
Set-point 1
set-point value temperature 1 (SP1)
Upon switching on, control is on the basis of the chosen
Set-point 2
set-point value temperature 2 (SP2)
Selection of the set-point ramp heating (Gradient, Filter
or Inactive)
Set-point ramp heat-
Gradient heating Setting in °C/min
ing
Filter time constant heat-
Setting in sec.
Set-point ramps (Soft- ing
ware option) Selection of the set-point ramp heating (Gradient, Filter
or Inactive)
Set-point ramp cool-
Gradient cooling Setting in °C/min
ing
Filter time constant cool-
Setting in sec.
ing

Set-point ramps

Evacuation time
Parameter Remarks
Evacuation time Evacuation time duration (0-500 sec.)

22  Parameterisation RT100 Control System

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Next Service
Parameter Remarks
Operating hours Display of the operating hours
Next service Setting the period up to the next maintenance (0 h = disabled)

Pump regulation
Parameter Remarks
Pump pressure, Flow or
Set-point setting (in bar, lpm or °C)
Delta T set-point
Operating mode Operating mode setting (Manually or Auto)
Hand-value Setting in Hz

USB Logging (Service Interface)

Parameter Remarks
Service Interface (USB
Data-Logging on USB-Stick "Active", "Inactive"
Logging)

The USB Data logger is used for process-logging during production if no

superordinate control is present.
If the USB logging is set on "active" and an USB flash drive is plugged in,
every 10 seconds a record will be made. Per day (24 h) a file with the
date in the file name and with the suffix "lo1" will be created (e.g.
"20120825.lo1"). The records are provided with time and date.
In each case Set-point, Outlet temperature, External temperature, Inlet
temperature, Heating-/Cooling performance, Flow rate, Pump pressure,
System pressure and Pressure set-point will be stored. The csv file can
for example be imported into Excel. There is also a special import filter
for the Famos Reader software for quick overviews of data. Please use a
Regloplas USB flash drive for USB logging (part no. 176-100026).

Monitoring
(Password level - Technician password)

Temperature deviation
Parameter Remarks
Set-point value/outlet LO Monitoring of this parameter can be switched on/off (value adjustable in °C/°F)
Set-point value/outlet HI Monitoring of this parameter can be switched on/off (value adjustable in °C/°F)
Set-point value/external
Monitoring of this parameter can be switched on/off (value adjustable in °C/°F)
LO
Set-point value/external
Monitoring of this parameter can be switched on/off (value adjustable in °C/°F)
HI
Set-point value/Inlet LO Monitoring of this parameter can be switched on/off (value adjustable in °C/°F)
Set-point value/Inlet HI Monitoring of this parameter can be switched on/off (value adjustable in °C/°F)
Outlet/Inlet LO Monitoring of this parameter can be switched on/off (value adjustable in °C/°F)
Outlet/Inlet HI Monitoring of this parameter can be switched on/off (value adjustable in °C/°F)

RT100 Control System Parameterisation  23

 V 01/2016

Max. heat./cool. time

Parameter Remarks
Max. heating time Input ON/OFF
Deviation Input in °C
Time Input in minutes
Max. cooling time Input ON/OFF
Deviation Input in °C
Time Input in minutes

Minimum flow rate

Parameter Remarks
Minimum flow rate Input - monitoring of the minimum flow rate (Active/Inactive)
Minimum flow rate Setting the minimum flow rate (l/min or GPM)
Active from temperature Minimum flow rate active from adjustable temperature (in °C/°F)

Flow deviation (Software option)

Parameter Remarks
Flow deviation Input - deviation of the minimum flow rate (Active/Inactive)
Low pass actual value Actual value setting - low pass (in seconds)
Low pass offset refer-
Offset setting - low pass (in seconds)
ence
Deviation Deviation setting (-100-0%)
Alarm suppression Setting of duration of the alarm suppression (in sec.)

Flow monitoring

24  Parameterisation RT100 Control System

 V 01/2016

Min. system pressure

Parameter Remarks
Min. system pressure Input - min. system pressure (Active/Inactive)
Min. system pressure Input - min. system pressure (in bar)
Alarm suppression Setting of duration of the alarm suppression (in sec.)

Interfaces
(Password level - User password)
The universal interface is available as a software option.

Address
Parameter Remarks
Address Address input (0-999)
Protocol Display of the current protocol with baud rate
Change protocol Selection/setting of the available protocols (see chapter Data Interfaces)

Temperature control
(Password level - Technician password)

Temperature Regulation
Parameter Remarks
Contr. type Ext./outlet casc., Inlet/Outlet casc. or Outlet type
Outlet control par. Control type with sensor in the outlet
Cascade external/outlet Control type with sensor in the consumer and in the outlet
Cascade inlet/outlet Control type with sensor in the inlet and in the outlet

Control parameters outlet

Parameter Range Remarks
Control parameter set Fixed/manual Selection of control parameter set
Control parameter Parameter set Heating Selection of control parameter set Heating (1-10)
outlet defined Parameter set Cooling Selection of control parameter set Cooling (1-10)
P Heating Setting control parameter P Heating (in °C/°F)
I Heating Setting control parameter I Heating (in sec.)
D Heating Setting control parameter D Heating (in sec.)
Capacity limitation
Capacity limitation Heating (0-100%)
Heating
Control parameter
P Cooling Setting control parameter P Cooling (in °C/°F)
outlet manual
I Cooling Setting control parameter I Cooling (in sec.)
D Cooling Setting control parameter D Cooling (in sec.)
Power limit cooling Capacity limitation Cooling (0-100%)
Setting of neutral zone cooling (0-10% of set-
Neutral zone cooling
point value)

RT100 Control System Parameterisation  25

 V 01/2016

Control parameters cascade

Parameter Range Remarks
Control parameter set Input fixed/manual Selection of the control parameter set
Input active/inactive Setting of outlet limitation
Max. outlet limitation (in °C/°F, up to
Outlet limitation Max. outlet limitation
max. set-point value)
Min. outlet limitation Min. outlet limitation (in °C/°F)
Input active/inactive Setting of outlet limitation
Max. difference Int/Ext Max. Diff. Heating Int/Ext Max. Diff. Heating Int/Ext (in °C/°F)
Max. Diff. Cooling Int/Ext Max. Diff. Heating Int/Ext (in °C/°F)
Control parameter cascade Selection of control parameter Cascade
Value 1-10
defined fixed
Strengthening of cascade Input value 0-99
Integral cascade Input in sec.
Differential cascade Input in sec.
P Heating auxiliary controller Input in °C/°F
Control parameter cascade I Heating auxiliary controller Input in sec.
manually D Heating auxiliary controller Input in sec.
P Cooling auxiliary controller Input in °C/°F
I Cooling auxiliary controller Input in sec.
D Cooling auxiliary controller Input in sec.
Neutral zone aux. controller Input in %

Settings
Parameter Remarks
Heating cycle time Input of the pulse time heating (in seconds)
Min. heating control time Input of the minimum actuation time heating (in milliseconds)
Cooling cycle time Input of the pulse time cooling (in seconds)
Min. cooling control time Input of the minimum actuation time, cooling (in milliseconds)

Control system modes

The RT100 Control System works with the following control algorithms:
- PID control on outlet, inlet or external sensor - for this control type,
there are 10 fixed parameter sets each available for heating and
cooling, as well as one manual set
- Cascade control with external sensor and outlet sensor as well as in-
let sensor and outlet sensor

Fixed parameter sets

In order to save the operator the trouble of painstakingly defining the P, I,
and D control parameters for heating and cooling, it is possible to retrieve
fixed parameter sets adjusted to the applications.
Users can determine the best fixed set of parameters for their application
without any special knowledge of control technology by observing the fol-
lowing simple rules:
1. Basic setting - parameter set 5

26  Parameterisation RT100 Control System

 V 01/2016

2. If the programmed set/point value is not attained after some time,

then the next lower fixed parameter set (e.g. parameter set 4 instead
of 5) should be selected
3. If the actual value exceeds the set-point value (overshooting) or var-
ies about the set-point value, the next higher fixed parameter set is
selected.
If none of these parameter sets lead to the desired stability of adjustment
because the controlled system deviates from the standard, it is possible
to create an individual parameter set.
Remark:
The set-point value is attained the fastest if the actual value overshoots
somewhat. If overshooting is not permissible, then one must reckon with
a somewhat longer heating-up time.

Pressure control
(Password level - Service password)

Parameter Range Remarks

Pressure Control Input pressure control active/inactive
Max. system pressure Input max. system pressure (in bar)
Max. pressure set-point value Input of the max. pressure (in bar)
Min. pressure set-point value Input of the minimum pressure (in bar)
Set-point Set-point value, ramp Input set-point value, ramp (in bar/second)
Constant pressure overlay Input constant pressure overlay (in bar)
Percent pressure overlay Input percent pressure overlay (in %)
Input pressure compensation with solenoid
Pressure compensation type
valve "Y2", "Y8.1" or "without"
Pressure balance
Pressure switch point Input of pressure switching point (in bar)
Pressure switching time Input of pressure pulse time (in sec.)
Input of pressure increase with solenoid valve
Pressure increase type
"Y2", "Y2.1" or "Y2 always open"
Pulse time Input of pulse time (in sec.)
Input of the minimum actuation time (in milli-
Minimum actuation time
seconds)
P Band Input P Band (in bar)
Pressure increase
Integral Input integral (in sec.)
Capacity increase at 1 bar Input of capacity increase (in %)
Capacity increase at 7 bar Input of capacity increase (in %)
Capacity limitation Input of capacity limitation (in %)
Hysteresis over set-point value Input of hysteresis (in bar)
Cycle time Input of pulse time (in sec.)
Input of the minimum actuation time (in milli-
Min. actuation time
seconds)
P band Input P band (in bar)
Pressure decrease
Integral Input integral (in sec.)
Power increase Input power increase (in %)
Power limitation at 1 bar Input limitation increase (in %)
Power limitation at 7 bar Input limitation increase (in %)

RT100 Control System Parameterisation  27

 V 01/2016

Parameter Range Remarks

Neutral zone Input neutral zone (in bar)
Min. system pressure Input min. system pressure (in bar)
Vapour suppression Input of steam suppression (in sec.)

Pump regulation (Software option)

(Password level - Service password)

Parameter Remarks
Control type Input of the control type (Pump pressure, Flow rate or Delta T - Outlet/Inlet)
Operating mode Input of operating mode (Manually or Auto)
Pump pressure, Flow
Input of set-point (in bar, lpm or °C)
rate or Delta T set-point
Max. set-point Input of set-point (in bar, lpm or °C)
Min. set-point Input of set-point (in bar, lpm or °C)
Neutral zone Input of neutral zone (in bar, lpm or °C)
Kp Input of gain Kp
Reset time Input of reset time (in sec.)
Derivative time Input of derivative time (in sec.)
Max. output Setting the output (in Hz)
Min. output Setting the output (in Hz)
Hand-value Input of hand-value (in Hz)

Unit configuration
(Password level - Service password)

Parameter Remarks
Device type Selection of heat transfer medium (Water/Oil)
Input of the maximum temperature of the temperature control unit (in °C/°F, normal-
Max. device temp.
ly 5-10 °C above the max. set-point value)
Input of the maximum set-point value of the heat transfer medium temperature in
Max. set-point
°C/°F)
Behaviour after power Input behaviour after power failure ("Remains switched off", "Remains switched off -
failure without error" or "Last status")
Closing temperature Input of closing temperature (in °C/°F)
Input pressure release type ("With pump",
Pressure release type
Pressure release "With Y8/Y8.1" or "Without")
Pressure release time Input pressure release time (in sec.)
Behaviour Input "Cool first" or "Immediately off"
Run-on temperature Input run-on temperature when switching off
Switch off
Run-on time Input run-on time of pump after switching off
Cooling capacity Input of cooling capacity for cooling process
Input evacuation type ("Inactive", "With
Emptying (Software op- pump" or "With pressure")
Evacuation type
tion)
with pressure with Y8/with Y18

28  Parameterisation RT100 Control System

 V 01/2016

Parameter Remarks
Venting time Venting time duration (in sec.)
Evacuation time Evacuation time duration (in sec.)
Leak stop Allow leak stop Input allow leak stop (yes/no)
Nominal current, pump Input nominal current pump (in A)
Monitor phase sequence Input monitor phase sequence (yes/no)
Pump Run-down time of pump Input run-down time of pump (in sec.)
Automatic reversal of direction of Input automatic reversal of direction of rota-
rotation >9A tion >9A (yes/no)
Monitoring Input active/inactive
Maximum running time Input in (in sec.)
Boost pump
Restart lockout Input in (in sec.)
Active from set pressure Input in (bar)
Input 'heating output' ("SSR AC", "SSR DC",
Output Heating
Heating "SSR DC aux. cont." or "Contactor")
Heating 2 Input heating 2 (active/inactive)
Input cooling type ("Direct", "Indirect" or "Indi-
Cooling principle
rect/direct")
Temperature switchpoint indi-
Input of switching point (in °C/°F)
rect/direct
Input of cooling medium conveying ("With
Cooling Cooling medium conveying SK-pump", "Without SK-pump" or "With 3-
way valve")
Active/Inactive if cooling medium conveying
Antiblocking SK-pump is set "With SK-pump" (Activation of SK-
pump every 30 min. for 100 milliseconds)
Cooling valve reset time Input of reset time, cooling valve (in sec.)
Input refilling after ("Power on" or "Control
Refilling after
on")
Run-on time, pump Input run-on time of pump (in sec.)
Refilling time window Input of refilling time window (in sec.)
Level counter Input active/inactive
Number of level undershoots Input possible number of level undershoots
Level
Alarm suppression time Input of alarm suppression time (in minutes)
Number of fluid reservoir Number of heat transfer medium container
Monitoring Y2 Input Active/Inactive
Max. turn on time Y2 Input turn on time (in sec.)
Response delay Input (in sec.)
Min. refill time Input (in sec.)
Input flushing time ("Off", "With Y19" or "With
Flushing
Y2/Y8")
Start flushing (Active/Inactive)
Start flushing time (in sec.)
Max. flushing tem-
Flushing (in °C)
perature
Settings
Interval flushing (Active/Inactive)
Interval time (in min.)
Interval flushing
(in sec.)
time

RT100 Control System Parameterisation  29

 V 01/2016

Inputs
(Password level - Technician password)
The parameters of the signal inputs are displayed in this menu.

Parameter Range Remarks

Temperature sensor Sn1 Offset Input of offset (in °C/°F)
Offset Input of offset (in °C/°F)
Input of sensor type Sn2 ("No ext. Sensor",
Temperature sensor Sn2 "Pt 100 2-conductor", "Pt 100 3-conductor",
Sensor type Sn2
"TE Type K", "TE Type J", "TE Type T", "TE
Type N" or "4-20 mA", "Interface"
Offset Input of offset (in °C/°F)
Temperature sensor Sn3
(Software option) Input of sensor type Sn2 ("No ext. Sensor",
Sensor type Sn2
"Pt 100 2-conductor" or "Pt 100 3-conductor")
Pressure sensor 1 Input pressure sensor 1 (active/inactive)
Pressure sensor 1, sys- Offset Input of offset (in bar)
tem 4 mA Input 4 mA (in bar)
20 mA Input 20 mA (in bar)
Pressure sensor 2 Input pressure sensor 2 (active/inactive)
Offset Input of offset (in bar)
Pressure sensor 2, outlet
4 mA Input 4 mA (in bar)
20 mA Input 20 mA (in bar)
Flow meter Input flow meter (active/inactive)
Input flow meter type ("F150", "F160", "F181",
Flow meter type "F183", "F185", "F350", "F351", "scalable",
"F1000")
Flow rate (Software op- Input (X26-KEM, X27-F150)
tion) Additional parameters in case of
Scaling 1 kHz (in lpm or GPM)
flow meter type "Scalable"
Filtering time constant (in sec.)
Additional parameters in case of
(see the chapter "Flow meter type F1000")
flow meter type "F1000"
Input "Inactive/Pressure switch/Pump pressure"
Flow monitor When selecting "Pump pressure" Min. pump pressure (in bar)
Alarm suppression time Input in (in sec.)
Temp. monitor cooling Input "Active/Inactive"
Analog input Input "Pump current" or "Set-point"
Analog input Input "0-10 V", "0-20 mA", "4-20 mA" or "In-
Analog input
active"
When the external contact closes, the unit is
Code 0
turned off and the ON/OFF button is blocked
When the external contact opens, the unit is
Code 1
turned off and the ON/OFF button is blocked
The unit can be switched on and off via the
Ext Start/Stop command external contact (closing of the external con-
(digital or analog option) Code 2
tact - unit switches off / opening of the exter-
nal contact - device switches on)
The unit can be switched on and off via the
external contact (closing of the external con-
Code 3
tact - unit switches on / opening of the exter-
nal contact - device switches off)

30  Parameterisation RT100 Control System

 V 01/2016

Parameter Range Remarks

The unit can be switched on and off as fol-
lows (closing of the external contact - unit
switches on / opening of the external contact
Code 4
- unit switches off, the ON/OFF buttons, leak
stop and discharge as well as start/stop by
serial interface are inactive)
The unit will be switched off immediately by
closing of the external contact - Warning De-
vice external switched off immediately will
be shown.
Code 5
The unit can not be switched on until the con-
tact will be opened. There will be no cooling
or pressure relief, so the device may still be
very hot and under pressure!
The unit will be switched off immediately by
closing of the external contact - Warning De-
vice external switched off immediately will
be shown.
Code 6
The unit can not be switched on until the con-
tact will be closed. There will be no cooling or
pressure relief, so the device may still be very
hot and under pressure!
For code 2 and 3, the following applies:
Switching on and off with the button ON/OFF is possible at any time
Differential pressure filter
Input "Opening/Closing"
(digital or analog option)

Flow meter type F1000 (Software option, max.

300 lpm)
Parameters Remarks
Flow meter Active/inactive
Flow meter type F1000
Pump type Display of the pump type
Settings (see the following chapter "Settings")

Settings
Parameters Remarks
Deviation in % of the expected max. pump pressure. If this value is not reached,
Pump tolerance
an error message will be shown ("Pump power too low")
Pump calibration value Correction value of the pump calibration (can also be input manually)
ON - Differential pressure outlet/system
Pump pressure
OFF - only outlet pressure
Filtering time constant Averaging time of the flow
Automatic calibration Switching automatic pump calibration on or off
Manual calibration Start manual calibration
Pump pressure Display of the pump pressure during calibration

Manual calibration
Manual calibration starts when, in the menu, the parameter Manual cali-
bration is set to ON. The user is thereupon prompted to close the ball
valve in the outlet (flow = 0 l/min). When the ball valve is closed, the pa-

RT100 Control System Parameterisation  31

 V 01/2016

rameter Manual calibration is set to OFF and then the ball valve is
opened again. Calibration is now complete.
The parameter Manual calibration only appears in the menu when Au-
tomatic calibration is set to OFF.

Automatic calibration
If the parameter Automatic calibration is set to ON, then every time the
pump starts, the time-controlled automatic pump calibration will be exe-
cuted (there must be a solenoid valve present in the outlet for this pur-
pose). The following parameters can be defined for the automatic calibra-
tion:

Parameters Remarks
Time till calibration Time till switching on the solenoid valve in seconds
Calibration time Switching time of the solenoid valve in seconds
Time till repetition of the calibration in seconds.
Time till re-calibration
With 0 seconds, the calibration is not repeated

Time till Calibration Time till re-calibration Calibration

calibration time time

Starting the
pump

Importing the characteristic curve

The characteristic curve must be saved in the csv format and is divided
into a header area and a data area. The existing characteristic curve can
be overwritten by a new characteristic curve at any time. In the menu
item Save/Load / Load characteristic curve F1000, a characteristic
curve can be loaded from the USB stick.

32  Parameterisation RT100 Control System

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Outputs
(Password level - Technician password)
The parameters of the signal outputs are displayed in this menu.

Parameter Range Remarks

Continuously inactive
Continuously active
Common alarm (see the pa-
rameter "Common alarm")
Heating 1
Heating 2
Minimum flow rate
Flow monitor
Level
Pump current
Deviation Set-point value/Outlet
Alarm HI
Deviation Set-point value/Outlet
LO
Deviation Set-point/External HI
Deviation Set-point/External LO
Deviation Set-point/Inlet HI
Deviation Set-point/Inlet LO
O1 Deviation Outlet/Inlet HI
Deviation Outlet/Inlet LO
24 VDC outputs Deviation Flow rate
Temp. switching point (in °C/°F)
Flow switching point (in lpm or GPM)
Band deviation (in °C/°F)
Control on
Clock active
Pump is running
Level 1 reached
Level 2 reached
Heating 1 on
Heating 2 on
Cooling on
Pressure increase
Pressure decrease
Maintenance
Pump regulation Start/Stop
Data input output O2 (for functions, see out-
O2 put O1)
Pump regulation Right/Left
Data input: output O3 (for functions, see out-
O3
put O1)

RT100 Control System Parameterisation  33

 V 01/2016

Parameter Range Remarks

Inactive, 4-20 mA, 0-20 mA, 10 V, TE Type J,
Analog output 1
TE Type N, TE Type T, TE Type K
Outlet temperature, External temperature,
Layout Inlet temperature, Set-point value 1, Set-point
Analog output 1
value 2, Flow, Set-point, Pump regulation
(analog option)
Lower end of scale in corresponding dimension unit
Upper end of scale in corresponding dimension unit
Offset in corresponding dimension unit
Inactive, 4-20 mA, 0-20 mA, 10 V, TE Type J,
Analog output 2
TE Type N, TE Type T, TE Type K
Outlet temperature, External temperature,
Layout Inlet temperature, Set-point value 1, Set-point
Analog output 2
value 2, Flow, Set-point
(analog option)
Lower end of scale in corresponding dimension unit
Upper end of scale in corresponding dimension unit
Offset in corresponding dimension unit

Relay
(Password level - Technician password)
The parameters of the relay functions are displayed in this menu:

Parameter Range Remarks

Input "Opening/Closing/Single shot lead.
Function
edge"
Control unit ON
Clock activated
Pump running
Level 1 reached
Level 2 reached
Heating 1 ON
Heating 2 ON
Cooling ON
Pressure increase
Pressure decrease
Relay K1
Service
Relay
Max heat./cool. time
Power ON
Common alarm (see the param-
eter " Common alarm")
Heating 1
Heating 2
Alarm Minimum flow rate
Flow monitor
Level
Pump current
Deviation Set-point/Outlet HI

34  Parameterisation RT100 Control System

 V 01/2016

Parameter Range Remarks

Deviation Set-point/Outlet LO
Deviation Set-point/External HI
Deviation Set-point/External LO
Deviation Set-point/Inlet HI
Deviation Set-point/Inlet LO
Deviation Outlet/Inlet HI
Deviation Outlet/Inlet LO
Deviation Flow rate
Temp. switch point (actual value in °C/°F)
Flow switch point (in lpm or GPM)
Band deviation (actual value in °C/°F)
Relay K2 Function Input "Normally open/Normally closed"
(digital option) Relay (for functions, see relay K1)
Relay K3 Function Input "Normally open/Normally closed"
(digital option) Relay (for functions, see relay K1)
Relay K4 Function Input "Normally open/Normally closed"
(digital option) Relay (for functions, see relay K1)

Collective alarm
(Password level - Technician password)
The common alarm is configured in this menu. The common alarm can
be assigned to a relay or to a 24 VDC output.

Parameter Remarks
Alarm repeat time Input alarm repeat time (in sec.)
Heating 1 Input alarm heating 1 (On/Off)
Heating 2 Input alarm heating 2 (On/Off)
Min. flow rate Input alarm min. flow rate (On/Off)
Flow deviation Input alarm deviation of flow rate (On/Off)
Flow monitor Input alarm flow monitor (On/Off)
Level Input alarm level (On/Off)
Pump current Input alarm pump current (On/Off)
Temp. monitor cooling Input alarm cooling temperature monitor (On/Off)
Current monitor heating Input alarm Current monitor heating (On/Off)
SSR DC aux. contact Input SSR DC aux. contact (On/Off)

from SOF V1102:

In the case of the following alarms, the common alarm relay is always ac-
tivated:
 Switch over heat carrier - reboot of the machine required
 RTC Error or empty battery - Time and date settings lost
 External set-point signal disconnected or not available
 Direction of rotation cannot be changed

RT100 Control System Parameterisation  35

 V 01/2016

 Software version incompatible:

Analog Option, Digital Option, Heating current monitoring, Re-
versal of direction of rotation, Profibus, Profinet, Ethernet/IP,
CAN Demag, CANopen
 Option missing or faulty:
Analog Option, Digital Option, Heating current monitoring, Re-
versal of direction of rotation, Profibus, Profinet, Ethernet/IP,
CAN Demag, CANopen
 AD converter failure
 Attention - temperature control cabinet too high
 Turn on time refill exceeded
 Maximal operating time boost pump exceeded
 Min. pump pressure underrun
 Max. temperature exceeded Sn3
 Max. temperature exceeded Sn2
 Max. temperature exceeded
 Heating thermostat is activated
 Frequency converter alarm
 Motor current underrun
 Phase sequence failure
 Phase sequence unidentified
 Phase missing
 Motor contactor malfunction
 Temperature sensor Sn1 failure
 Temperature sensor Sn2 failure - switched to outlet control
 Temperature sensor Sn3 failure
 System pressure sensor inactive
 System pressure sensor failure
 Power failure
 Safety thermostat is activated
 Deviation set-point value/outlet exceeded
Deviation set-point value/outlet underrun
Deviation set-point value/external exceeded
Deviation set-point value/external underrun
Deviation set-point value/inlet exceeded
Deviation set-point value/inlet underrun
Deviation outlet/inlet underrun
Deviation outlet/inlet underrun

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Save/Load

Parameter Remarks
Load user setting 1 Loading the user settings 1
Save user setting 1 Saving the user settings 1
Load AIC factory settings Loading the user settings AIC
Save AIC factory settings Saving the user settings AIC
Loading the factory settings Loading the factory settings
Save the factory settings Saving the factory settings (Regloplas password required)
Load settings from USB stick Loading the settings from the USB stick
Save settings to USB stick Saving the settings to the USB stick
Loading the characteristic curve F1000 (pump characteristic) from the
Load characteristic curve F1000
USB stick

Code
The password parameters are displayed in this menu:

Parameter Range Remarks

New password Input new password
User password Repeat Repetition of password input
Set Activation of the password
New password Input new password
Technician password Repeat Repetition of password input
Set Activation of the password
New password Input new password
Service password Repeat Repetition of password input
Set Activation of the password
Reset code (if the password has
been forgotten, a corresponding Input of the reset code (four-digit)
Reset passwords reset code is required)

Reset Resetting to default passwords (ex-factory)

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 V 01/2016

Options
The RT100 Control System options are displayed in this menu.
The RT100 Control System offers a releasing facility of software and
hardware options for function enhancement. The software options are re-
leased through a USB stick.

Parameter Range Remarks

Analog option
Digital option
Option current monit. heating
Option reversal of rotation
Option Profibus Installed hardware options are displayed. To
Hardware options remove an option, it should be manually set
Option CANOpen to OFF
Option CAN Demag
Option Profinet
Option Ethernet/IP
Option Flow
Universal interface
Switch clock
Ramp program
Cascade inlet
Flow rate measurement F150
Flow rate measurement F351 Activated software options are displayed. For
releasing a software option, a code is re-
Software options Flow rate measurement F1000 quired (file on USB stick). The serial number
Reversal of direction of rota- of the control system is required for this pur-
tion/suction pose
Pump regulation
Flushing
Flow deviation
Set-point ramps
USB Logging
Detection of the USB stick, load software op-
tions from the USB stick. The serial number
Activate options Wait for USB stick
of the control system is required for this pur-
pose
Display of the base module serial number of the RT100 Control System
Serial number
(8 letters, e.g. AALARP)

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Current monitoring heating

(Password level - Technician password)

Parameter Range Remarks

Input active/inactive
Current converter ratio
Max. current Heating 1 (in A)
Settings Min. current Heating 1 (in A)
Current monitoring Max. current Heating 2 (in A)
Min. current Heating 2 (in A)
Heating current L1 (display in A)
Heating current L2 (display in A)
Heating current L3 (display in A)

Service menu
(Password level - Service password)

Parameter Range Remarks

Software version Display of the current software version
Compatibility
Analog option
Digital option
Current monitoring option
Software versions Option reversal of direction of rotation Display of the current software version,
Compatibility the corresponding options and the system
Option Profibus
Option CANOpen
Option CAN Demag
Option Profinet
Delete alarm list Input of the Regloplas-AIC password required
"None", "X40-M1", "X41-Y2", "X42-Y8",
"X43-Y16, Y13", "X45-Y19", "X46-M2",
Output "X47-Y6" or "X48-Y8.1"
"Active", "Inactive"
IO Test
"None", "X40-M1", "X41-Y2", "X42-Y8",
"X43-Y16, Y13", "X45-Y19", "X46-M2",
Output "X47-Y6" or "X48-Y8.1"
"Active", "Inactive"

Multiflow
(Password level - Service password)
See therefore the corresponding Multiflow user manual.

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 V 01/2016

Data Interfaces

Basic Concept
The operation with data interfaces makes possible an external, superor-
dinate control system of the temperature control unit. The choice of the
protocol and the address of the data interface is described in the Param-
eterisation chapter.

Protocols

Designation Baud rate Interface Address

Inactive
1 Aarburg 4800 Bd 20 mA-CL
2 Engel CL 4800 Bd 20 mA-CL
5 Stork 1200 Bd 20 mA-CL
6 Ferromatik Milacron 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
15 Sächsische Kunststofftechnik 4800 Bd RS 485
16 CAN Demag Ergocontrol 615 kBd A13-17
18 Engel RS232 4800 Bd RS 232
19 SPI 19.2 kBd RS 485 A32-255
20 SPI 9600 Bd RS 485 A32-255
21 SPI 4800 Bd RS 485 A32-255
22 SPI 2400 Bd RS 485 A32-255
23 SPI 1200 Bd RS 485 A32-255
24 Bühler Dataspeed 4800 Bd RS 485
25 Frech Datacontrol 9600 Bd A11-18
26 Frech Datacontrol 4800 Bd A11-18
27 Frech Datacontrol 2400 Bd A11-18
28 Frech Datacontrol 1200 Bd A11-18
29 CAN Demag Ergocontrol 500 kBd A13-17
30 CAN Demag Ergocontrol 250 kBd A13-17

RT100 Control System Data Interfaces  41

 V 01/2016

Designation Baud rate Interface Address

31 CAN Demag Ergocontrol 125 kBd A13-17
33 Profibus DP max. 12 MBd RS 485 A0-124
34 Ferromatik Milacron RS485 4800 Bd RS 485
35 Bühler Dataspeed 9600 Bd RS 485
36 Ethernet/IP Ethernet IP Address
37 Profibus DP (Alarm Reset) max. 12 MBd RS 485 A0-124
CANOpen
38 Euromap 66 250 kBit/s
(Euromap 66)
Netstal from 31

39 Profibus DP (Pump regulation) max. 12 MBd RS 485 A0-124

40 Profibus DP (Protocol V2) max. 12 MBd RS 485 A0-124
41 Profinet IO 100 MBd Profinet IO
42 Profinet IO 100 MBd Profinet IO
43 Engel 4800 Bd RS 485
44 Ethernet/IP 100 MBd Ethernet IP Address

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Plug Nomenclature

RT100 Front panel

Plug Designation
X2 Options
X3 Base module
X4 Interfaces Universal RP or 20 mA CL
X5 USB Host
X6 USB Device

RT100 Base Module

Plug Designation
X1 Display and operations module (front panel)
X2 Base module
X3 Options
X4 Options
X5 Options
X6 Power supply
X7 EEprom (Memory)
X10:1 Flow monitor F3/B42
X10:2 Flow monitor F3/B42
X11:1 Level switch S3
X11:2 Level switch S3
X12:1 Level switch S1
X12:2 Level switch S1
X13:1 Digi In (Feedback frequency converter)
X13:2 Digi In (Feedback frequency converter)
X14:1 Digi In (Monitoring SK pump)
X14:2 Digi In (Monitoring SK pump)
X15:1 Sensor, internal (Pt100) B1
X15:2 Sensor, internal (Pt100) B1
X16:1 Sensor, external (Pt100 / TC+) B3

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 V 01/2016

Plug Designation
X16:2 Sensor, external (Pt100 / TC-) B3
X16:3 Sensor, external (Pt100) B3
X17:1 Sensor, inlet (Pt100) B14
X17:2 Sensor, inlet (Pt100) B14
X17:3 Sensor, inlet (Pt100) B14
X18:1 Sensor, external (4-20mA) B3
X18:2 Sensor, external (4-20mA) B3
X20:1 Digi In
X20:2 Digi In
X21:1 + Heating 1 24VDC
X21:2 - Heating 1 24VDC
X22:1 + Heating 2 24VDC
X22:2 - Heating 2 24VDC
X23:1 + Digi Out (Frequency converter Start/Stop)
X23:2 - Digi Out (Frequency converter Start/Stop)
X24:1 + Digi Out (Frequency converter Right/Left)
X24:2 - Digi Out (Frequency converter Right/Left)
X25:1 + Digi Out
X25:2 - Digi Out
X26:1 COM flow rate measurement F18x, F35x
X26:2 Signal flow rate measurement F18x, F35x
X26:3 Shield flow rate measurement F18x, F35x
X27:1 BN flow rate measurement F150
X27:2 GN flow rate measurement F150
X27:3 WH flow rate measurement F150
X28:1 + Pressure sensor 1, system B8
X28:2 - Pressure sensor 1, system B8
X29:1 + Pressure sensor 2, outlet B8.1
X29:2 - Pressure sensor 2, outlet B8.1
X30:1 Relay K1 NO
X30:2 Relay K1 COM
X30:3 Relay K1 NC
X31:1 L Feedback Delivery
X31:2 Feedback Delivery
X32:1 L Feedback Heating 1
X32:2 Feedback Heating 1
X33:1 L Feedback Heating 2
X33:2 Feedback Heating 2
X34:1 L Thermostat F7
X34:2 Thermostat F7
X35:1 L AC In
X35:2 AC In
X36:1 L AC In
X36:2 AC In
X37:1 L AC In

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 V 01/2016

Plug Designation
X37:2 AC In
X38:1 COM Safety thermostat F5
X38:2 NO Safety thermostat F5
X38:3 NC Safety thermostat F5
X40:1 N Cooling pump SK M1 / Compressed air Y16.1
X40:2 L Cooling pump SK M1 / Compressed air Y16.1
X40:3 PE Cooling pump SK M1 / Compressed air Y16.1
X41:1 N Valve refill Y2 / Additional lower level lamp H3
X41:2 L Valve refill Y2 / Additional lower level lamp H3
X41:3 PE Valve refill Y2
X42:1 N Valve pressure release Y8
X42:2 L Valve pressure release Y8
X42:3 PE Valve pressure release Y8
X43:1 N Compressed air Y16 / Air inlet Y13
X43:2 L Compressed air Y16 / Air inlet Y13
X43:3 PE Compressed air Y16 / Air inlet Y13
X44:1 N Delivery, Heating 1+2
X44:2 L Heating 1 K21-23
X44:3 L Heating 2 K24-26
X44:4 L Delivery, K10
X45:1 N Valve flushing Y19 / Blow out OFF Y18
X45:2 L Valve flushing Y19 / Blow out OFF Y18
X45:3 PE Valve flushing Y19 / Blow out OFF Y18
X46:1 N Filling pump M2
X46:2 L Filling pump M2
X46:3 PE Filling pump M2
X47:1 N Valve, Cooling Y6
X47:2 L Valve, Cooling Y6
X47:3 PE Valve, Cooling Y6
X48:1 N Valve Additional pressure release Y8.1
X48:2 L Valve Additional pressure release Y8.1
X48:3 PE Valve Additional pressure release Y8.1
X49:1 L Valve Outlet (Flow rate F1000 NO)
X49:2 L AC Out
X49:3 L AC Out
X50:1 T1 Delivery pump M10
X50:2 T2 Delivery pump M10
X50:3 T3 Delivery pump M10
X50:4 PE Delivery pump M10
X51:1 L1 Mains input 200-600V
X51:2 L2 Mains input 200-600V
X51:3 L3 Mains input 200-600V
X51:4 L Mains input 115/230V
X51:5 N Mains input 115/230V
X51:6 PE Mains input

RT100 Control System Plug Nomenclature  45

 V 01/2016

RT100 Digital Option

The digital functions of the RT100 Digital Option are mirrored identically
on the RT100 Analog Option.

Digital Functions
Plug Designation
X80:1 External heating
X80:2 External cooling
X80:3 External heating/cooling active
X80:4 External On/Off
X80:5 External toggling SP1-SP2
X80:6 Differential pressure, filter
X80:7 External Start program
X80:8 External Stop program
X80:9 GND X80: 1-8

Relay Functions
Plug Designation
X81:1 Relay K2 NO
X81:2 Relay K2 COM
X81:3 Relay K2 NC
X81:4 Relay K3 NO
X81:5 Relay K3 COM
X81:6 Relay K3 NC
X81:7 Relay K4 NO
X81:8 Relay K4 COM
X81:9 Relay K4 NC

RT100 Analog Option

Digital Functions
Plug Designation
X100:1 External heating
X100:2 External cooling
X100:3 External heating/cooling active
X100:4 External On/Off
X100:5 External toggling SP1-SP2
X100:6 Differential pressure, filter
X100:7 External Start program
X100:8 External Stop program
X100:9 GND X100: 1-8

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Analog Functions
Plug Designation
X101:1 Analog input set-point value
X101:2 + 15 VDC
X101:3 Analog output 1 V
X101:4 Analog output 1 mA
X101:5 Analog output 1 TC
X101:6 Analog output 2 V
X101:7 Analog output 2 mA
X101:8 Analog output 2 TC
X101:9 GND outputs X101: 1, 3-8

RT100 Option Reversal of Direction of Rotation >9A

The RT100 option for reversal of the direction of rotation >9A is intended
for motor currents >9 A.

Plug Designation
X120:1 Pump motor T1
X120:2 Pump motor T2
X120:3 Pump motor T3
X120:4 Pump motor PE
X121:1 Mains supply L1
X121:2 Mains supply L2
X121:3 Mains supply L3
X121:4 Mains supply PE

RT100 Option Current Monitoring Heating

Plug Designation
X150:1 Current converter 1
X150:2 Current converter 1
X150:3 Current converter 2
X150:4 Current converter 2

RT100 Control System Plug Nomenclature  47

 V 01/2016

Hardware

RT100 Front Panel - Layout

RT100 Front Panel Print - Layout

CAUTION
Electronic parts can be damaged by electrostatic charges. For this reason,
proper grounding must be ensured during installation!
Fasten an antistatic wristband to your wrist before installing electronic compo-
nents!

RT100 Control System Hardware  49

 V 01/2016

RT100 Base Module - Layout

RT100 Base Module - Layout

50  Hardware RT100 Control System

 V 01/2016

Analog Option - Layout

The digital functions of the RT100 Analog Option are mirrored identically
on the RT100 Digital Option.

Analog function

Digital function

Analog Option - Layout

CAUTION
If both a digital option and an analog option are installed, the digital functions
of the digital option must be used!
The digital functions of the analog option are not activated in this case!

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 V 01/2016

Digital Option - Layout

The digital functions of the RT100 Digital Option are mirrored identically
on the RT100 Analog Option.

Relay function

Digital function

Digital Option - Layout

CAUTION
If both a digital option and an analog option are installed, the digital functions
of the digital option must be used!
The digital functions of the analog option are not activated in this case!

52  Hardware RT100 Control System

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Option Reversal of Direction of Rotation >9A - Layout

Option Reversal of Direction of Rotation >9A - Layout

Option Current Monitoring Heating - Layout

Option Current Monitoring Heating - Layout

RT100 Control System Hardware  53

 V 01/2016

Option Profibus DP - Layout

Option Profibus DP - Layout

S3 Address
0=Zone 1
1=Zone 2

Board for Mainboard-Options - Layout

54  Hardware RT100 Control System

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Option Euromap 66 - Layout

Option Euromap 66 - Layout

S3 Address
0=Zone 1
1=Zone 2

Board for Mainboard-Options - Layout

RT100 Control System Hardware  55

 V 01/2016

Option Profinet-IO - Layout

Option Profinet-IO - Layout

S3 Address
0=Zone 1
1=Zone 2

Board for Mainboard-Options - Layout

56  Hardware RT100 Control System

 V 01/2016

Fault Rectification

Alarm Messages
The RT100 Control System can display various error messages (warn-
ings and alarms). Attention must be paid to these error messages without
fail, otherwise, malfunctions of / damage to the temperature control unit
and production downtimes may result.
Pressing the Alarm Reset button allows you to acknowledge/reset an
alarm (e.g. switching off the horn). Only after the malfunction has been
rectified can the alarm display be deleted by once again pressing the
Alarm Reset button.
The Alarm Reset button also allows the manual acknowledgement of the
automatic toggling from control of the consumer temperature (or cascade
control) Sn2 to control of the outlet temperature Sn1 in case of a faulty or
removed sensor Sn2 in the consumer.

Alarm List
Pressing the Alarm Reset button opens the alarm list as long as there is
no alarm queued. The last ten alarm messages with date and time are
displayed here.

Warnings
Error message Rectification
Carry out maintenance procedure according to the
Service is due operating manual. Increment the parameter Next
Maintenance by 1000 hours
Clean filter Clean the corresponding filter or if required, replace it
The RT100 Control System has lost the parameters
Current data lost, load factory settings
and had to load the factory settings
Outlet pressure sensor faulty Replace outlet pressure sensor
The contactor Heating 1 does not get actuated cor-
Heating contactor 1 failure
rectly any more - replace
The contactor Heating 2 does not get actuated cor-
Heating contactor 2 failure
rectly any more - replace
Switch the main switch off and on again. If the fault is
Illegal or broken characteristic curve F1000
still present, re-load characteristic curve F1000
Check/inspect the pump or in the menu F1000 reduce
Pump power too low
the parameter pump tolerance (default 50%)

RT100 Control System Fault Rectification  57

 V 01/2016

Error message Rectification

Adjust the outlet temperature and acknowledge the
Deviation set-point value/outlet underrun
fault
Adjust the outlet temperature and acknowledge the
Deviation set-point value/outlet exceeded
fault
Adjust the external temperature and acknowledge the
Deviation set-point value/external underrun
fault or error
Adjust the external temperature and acknowledge the
Deviation set-point value/external exceeded
fault or error
Adjust the inlet temperature and acknowledge the
Deviation set-point value/inlet underrun
fault
Adjust the inlet temperature and acknowledge the
Deviation set-point value/inlet exceeded
fault
Adjust the inlet temperature and acknowledge the
Deviation outlet/inlet underrun
fault
Adjust the inlet temperature and acknowledge the
Deviation outlet/inlet exceeded
fault
Level 2 underrun Refill heat transfer medium
Check water inflow pipe and water pressure (min. 2
Pressure balance not possible
bar)
Leak stop not possible Reduce the temperature
Leak stop not allowed Unit is not allowed for leak stop
Suction not possible Switch the unit to normal operation mode
SSR DC with auxiliary contact has activated. Check
SSR error
SSR

Alarms
Error message Rectification
Connect the external set-point value signal (optionally
External set-point signal disconnected or not available
check control system)
Check hose connections to the consumer, fix the
Maximal operating time boost pump exceeded
leakages
Flow monitor is activated Check outlet pressure (min. 0,7 bar must be available)
Min. pump pressure underrun Check outlet pressure
Check min. flow rate (the specified min. flow rate must
Min. flow rate underrun
be available)
Large variation in the flow (there may be a leak in the
Flow rate deviation too high
circuit)
Max. temperature exceeded Max. heat transfer medium temperature may not ex-
Max. temperature Sn2 exceeded ceed the die max. device temperature (optionally
Max. temperature Sn3 exceeded check the consumer temperature)
Temperature control unit has become too hot - let it
Heating thermostat is activated
cool down and determine the cause
Heating current monitoring is activated Check heating element(s) and replace, if necessary
Direction of rotation cannot be changed ---
Check pump/pump motor (with ohmmeter) and re-
Motor current underrun
place, if necessary
Check pump/pump motor (with ohmmeter) and re-
Motor current exceeded
place, if necessary
Phase sequence failure Correct the phase sequence (interchange 2 phases)
Phase sequence unidentified Switch off phase sequence monitoring

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Error message Rectification

Phase missing Check the mains, input conductor and pump motor
Motor contactor malfunction Check motor contactor and if required, replace it
Temperature sensor Sn1 failure Replace temperature sensor Sn1
Temperature sensor Sn2 failure - switched to outlet
Replace temperature sensor Sn2
control
Temperature sensor Sn3 failure Replace temperature sensor Sn3
System pressure sensor failure Replace the system pressure sensor
System pressure sensor inactive Activate the system pressure sensor
Failure of the power supply or temperature control
Power failure
unit not switched off properly
Temperature control unit has become too hot - deter-
Safety thermostat is activated
mine the cause and reset the thermostat
Temp. monitor cooling act, cooling disabled Check the cooling and cooling water flow
Frequency converter alarm Remedy the frequency converter fault
Check the cooling water circuit and the cooling circuit
Turn on time refill exceeded
for leaks
Level 1 underrun Refill heat transfer medium

System Errors/System Notes

Error message Rectification
Memory stick missing Insert memory stick
AD converter failure Replace the base module
Place the temperature control unit in a place with low
Attention - temperature control cabinet too high
ambient temperature
Incompatible data on stick Load current software version
Check the connection between the front panel and the
Communication failure
base module
Re-load software (applies to front panel and base
Software version error
module)
Insert new memory stick and re-load device parame-
Data corrupt on stick
ters
Current settings lost / factory settings loaded Carry out a new client-specific settings parameterise
Settings defect / data not loaded Replace the memory stick
No data on USB stick or wrong file extension Load the correct data on USB stick
More than 1 file on USB stick Load the correct data on USB stick
Data failure - no data loaded from USB stick Load the correct data on USB stick
Option not activated Activate the option
DEMO MODE / Pump current measurement inactive System message without remedial action
Saving data Data saving in progress
Data saved Data saving finished
Data error - no data saved to USB stick Replace the USB stick
Pump is off or has wrong direction Adjust the pump rotating field
Please close tap Close the tap on the outlet
Calibration done - please open tap Open the tap on the outlet
Clean the filter Clean the external filter
External set-point signal disconnected or not available Connect the external set-point signal
RTC Error or empty battery - Time and date settings Set the correct date/time and/or replace the battery on

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 V 01/2016

Error message Rectification

lost the front panel
USB Slave mode operation not possible Switch on the temperature control unit again
Save/Load not possible in USB Slave Mode Switch on the temperature control unit again
Save/Load not possible during device is on Switch the temperature control unit to OFF
Switch over heat carrier - reboot of the machine re- Switch on the temperature control unit again with the
quired main switch
Error, password not reset Enter the reset code correctly
Password reset Passwort was reset
Illegal operation Observe the operating sequence
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 incompatible:
Analog Option, Digital Option, Heating current monitor-
Update the software
ing, Reversal of direction of rotation, Profibus, Profinet,
Ethernet/IP, CAN Demag, CANopen
Option missing or faulty:
Analog Option, Digital Option, Heating current monitor- Connect the corresponding option or switch off in the
ing, Reversal of direction of rotation, Profibus, Profinet, parameter Hardware Options
Ethernet/IP, CAN Demag, CANopen

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RT100 Control System - Mainte-

nance/repair

Replacing the front panel

Removal
CAUTION
The exact sequence of operations described below must be strictly followed.
Otherwise, parameterization errors are possible!
The address of the base module must be correct before the control system is
powered up for the first time. Otherwise, the base module boot loader will have
to be reloaded by the manufacturer!

 Disconnect all plug-in connections

 The front panel is fixed with 6 screws on the device door. Loosen
all the screws and remove the defective front panel
 Send the defective front panel to Regloplas AG (Switzerland) in
ESD protective packaging, complete with a description of the
fault

Installation
 Fasten the front panel with 6 screws on the device door
 Reconnect all plug-in connectors

Loading the firmware

See the section "RT100 Control System - Loading the firmware".

RT100 Control System RT100 Control System - Maintenance/repair  61

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Replacing the base module

Removal
CAUTION
The exact sequence of operations described below must be strictly followed.
Otherwise, parameterization errors are possible!
The address of the base module must be correct before the control system is
powered up for the first time. Otherwise, the base module boot loader will have
to be reloaded by the manufacturer!

 Disconnect all plug-in connections

 Carefully unplug the memory card
 The base card is fixed inside the device with 6 screws. Loosen all
the screws in alternation so that the plastic spacer bolts do not
fall out
 Send the defective base module card to Regloplas AG (Switzer-
land) in ESD protective packaging, complete with a description of
the fault

Installation
 Fasten the base card inside the device with 6 screws. Tighten
the screws in alternation to avoid twisting the base card
 Reconnect all plug-in connectors
 Carefully reinsert the memory card

Hardware checklist
 Is the CAN connecting cable correctly plugged in?
 Are the CAN terminating resistors set to the correct ON/OFF po-
sition?
 Are the addresses of the base module (main units) correctly set?
(zone 1 = address 0, zone 2 = address 1 - very important for dual
devices with a single display)
 Is the motor fuse F10 (10 A aM/Class CC) fitted?
 Is the relay plug K1 connected?

Loading the firmware

See the section "RT100 Control System - Loading the firmware".

Activating options
See the section "RT100 Control System - Activating options".

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Loading the factory settings

The factory settings are restored in the Save/Load parameter in the
Load factory settings menu. This returns the RT100 to the manufactur-
er's default settings.

Configuration check
The unit configuration must be checked to determine whether everything
has functioned correctly. Important points to check in the Unit configura-
tion parameter:
 Unit type (oil, water)
 Maximum temperature in device
 Emptying - Evacuation type
 Pump - Nominal pump current in the Unit configuration parame-
ter
 Pump - Automatic reversal of direction of rotation

Customer-specific settings
The corresponding customer-specific parameter settings must be re-
entered (e.g. interface addresses etc.)

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CAN terminating resistors and address settings

On delivery of the assembly, the CAN terminating resistors on the base
module (switch S1) and on the front panel (switch S2) are set to ON.
On delivery, the address of the base module is 0 (rotary switch S2).
In the case of dual units, address 1 is set for zone 2 (rotary switch S2).

Connection com-
No. Description
bination

Front panel with one

1
base module

Both terminating resistors are switched on (checked by Regloplas)

Front panel with two

2
base modules

3 One option

4 Several options

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Connection com-
No. Description
bination

5 Front panel with option

6 Front panel with option

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 V 01/2016

Show actual values

Select language
User settings
RT100 Control System Monitoring
Parameter Menu Structure Interfaces
Temperature control
Pressure control
Pump regulation
Unit configuration
Inputs
Outputs
Relay
Collective alarm
Save/Load
Code
Options
Current monitoring heating
Service menu
Multiflow

Show actual values Select language Pressure control Unit configuration Collective alarm Options

Outlet temperature German Pressure control Device type Alarm repeating time Hardware options
External temperature English Max. system pressure Max. device temp. Heating 1 Software options
Inlet temperature French Set-point Max. set-point Heating 2 Activate options
Heat./cool. power Italian Pressure balance Behaviour after power failure Min. flow rate Serial number
Flow rate Spanish Pressure increase Closing temperature Flow deviation
Pump pressure Dutch Pressure decrease Pressure release Flow monitor
Pressure set-point Czech Switch off Level Current monit. heating
System pressure Chinese Emptying Pump current
Outlet pressure Russian Pump regulation Leak stop Temp. monitor cooling Current monitoring
Pump current L1 Slovenian Pump Current monit. Heating Settings
Pump current L2 Polish Control type Boost pump SSR DC aux. cont. Heating current L1
Pump current L3 Danish Operating mode Heating Heating current L2
Operating hours Hungarian Pump pressure set-point Cooling Heating current L3
Next service Croatian Max. set-point Level Save/Load
Interface Romanian Min. set-point Flushing
Address Portuguese Neutral zone Load user setting 1
Date Swedish Inputs
Kp Save user setting 1
Time Japanese Reset time Outputs Load AIC factory settings
Num. level 1 low Temperature sensor Sn1
Derivative time Save AIC factory settings
Control cabinet temp. Temperature sensor Sn2
Max. output 24 VDC outputs Load factory settings
Software version Temperature sensor Sn3
Monitoring Min. output Analog output 1 Save factory settings
Corr. set-point Pressure sensor 1, system
Hand-value Analog output 2 Load settings from USB stick
Flow deviation Pressure sensor 2, outlet
Temperature deviation Save settings to USB stick
Flow rate
Max. heat./cool. time Load characterist. curve F1000
Flow monitor
Minimum flow rate Service menu Relay Temp. monitor cooling
User settings Flow deviation Analog input
Min. system pressure Relay K1 Code Ext. Start/Stop command
Software versions
Display Delete alarm list Relay K2 Diff. pressure filter
Clock Relay K3 User password
IO Test
Switch clock Relay K4 Technician password
Ramp program Interfaces Service password
Set-point Reset passwords Temperature control
Address
Evacuation time
Change protocol Control type
Next service
Outlet control parameter
Pump regulation
Control parameter cascade
USB Logging
Settings

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Spare Parts

Ordering Spare Parts

For fast, error-free supply of spares, we need the following data without
fail:
- Device type
- Device number
- Voltage
- Frequency
This information is given on the rating plate on the device.
- Position number of the component
This information is given in the corresponding figures in this operating
manual (also see the service section) and in the electrical circuit diagram
of the device.

CAUTION
Only original Regloplas spare parts may be used!
In case of damage from the use of non-original parts, the warranty will be ren-
dered null and void!

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RT100 Control System - Spare Parts

RT Display unit - complete 176-100028

RT100 Base module - 115/230 VAC 176-100001
RT100 Memory print 176-100002
RT100 Digital Option 176-100003
RT100 Analog Option 176-100004
RT100 cable, Universal, L=300 mm, X61 X62 176-100005
RT100 Front panel 176-100006
RT 100 cover for control knob 176-100007
RT100 control knob 176-100008
RT100 Option Reversal of Direction of Rotation >9A 176-100009
RT100 Option Current Monitoring Heating 176-100010
RT100 cable 20 mA CL Aarburg, L=300 mm, X51 X52 176-100011
RT100 Profibus DP 176-100012
RT100 Profinet-IO 176-100040
RT100 Euromap 66 176-100013
Battery for display unit 177-100002
RT100 Protective cover, lockable, for Display RT100 176-100024
Fuse - F100 - 2,5 AF fast-acting 143-042283
Socket, push-in, 2-pin, black, marking 1|2, sensor inputs 24 VDC, 0.5 A 203-100000
Socket, push-in, 3-pin, black, marking 1|2|3, sensor inputs 24 VDC, 0.5 A 203-100001
Socket, push-in, 3-pin, orange, marking NO|C|NC, AC In/Out, relay 250 VAC, 3 A 203-100002
Terminal strip, tension spring, 2-pin, orange, marking 1|2, AC In/Out, relay 250
203-100003
VAC, 3 A
Terminal strip, tension spring, 3-pin, orange, marking 1|2|3, AC In/Out, relay 250
203-100004
VAC, 3 A
Terminal strip, tension spring, 3-pin, orange, marking 1|2|ground symbol, AC
203-100005
In/Out, relay 250 VAC, 3 A
Terminal strip, tension spring, 4-pin, orange, marking 1|2|3|4, AC In/Out, relay
203-100006
250 VAC, 3 A
Socket, push-in, 4-pin, black, marking T1|T2|T3|ground symbol, AC In/Out, motor
203-100007
600 VAC, 12 A
Socket, push-in, 6-pin, black, marking L1|L2|L3|L|N| ground symbol, AC In/Out,
203-100008
motor 600VAC, 12 A
Terminal strip, tension spring, 9-pin, orange 203-100017

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RT100 Control System Spare Parts  69