REGLOPLAS RT100 Programming Manual
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REGLOPLAS RT100 Programming Manual

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RT100
Programming Manual
SOF1119

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Summary of Contents for REGLOPLAS RT100

  • Page 1 RT100 Programming Manual SOF1119...
  • Page 2 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.

  • Page 3: Table Of Contents

    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  ...
  • Page 4 Service menu ......................39   Multiflow ........................ 39 Data Interfaces     Basic Concept ...................... 41   Protocols ....................... 41 Plug Nomenclature     RT100 Front panel ....................43   RT100 Base Module ..................... 43 ii  Contents RT100 Control System...
  • Page 5 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     RT100 Front Panel - Layout .................. 49  ...

  • Page 7: General Safety Information

    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. General Safety Information  1 RT100 Control System...

  • Page 8: Range Of Application

    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.

  • Page 9: Information For Operators And Personnel

    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.

  • Page 10: Using This Documentation

    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. 4  General Safety Information RT100 Control System...

  • Page 11: Design And Function

    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.

  • Page 12: Operating Control And Display Elements

    Selection of the device functions Symbol area RCD control knob Status LEDs (Regloplas Control Dial) 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...

  • Page 13: Symbols

    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).

  • Page 14: Parameter Menu

    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.

  • Page 15: Draining

    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. Design and Function  9 RT100 Control System...

  • Page 16: Operation With Code/Password

    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.

  • Page 17: Rt100 Control System - Loading Firmware/Bootloader

    V 01/2016 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) Design and Function ...

  • Page 18: Loading The Firmware/Bootloader

    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.
  • Page 19 V 01/2016  Reversal of rotation >9A/suction  Pump regulation  Flushing  Flow deviation  Set-point ramps Design and Function  13 RT100 Control System...

  • Page 21: Technical Data

    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...

  • Page 22: Inputs

    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-...

  • Page 23: Precision

    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...

  • Page 25: Parameterisation

    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.

  • Page 26: Select Language

    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...

  • Page 27: Ramp Program (Software Option)

    (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) Parameterisation  21 RT100 Control System...

  • Page 28: Set-Point

    Selection of the set-point ramp heating (Gradient, Filter or Inactive) Set-point ramp cool- Gradient cooling Setting in °C/min Filter time constant cool- Setting in sec. Set-point ramps Evacuation time Parameter Remarks Evacuation time Evacuation time duration (0-500 sec.) 22  Parameterisation RT100 Control System...

  • Page 29: Next Service

    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)

  • Page 30: Max. Heat./Cool. Time

    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...

  • Page 31: Min. System Pressure

    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) Parameterisation  25 RT100 Control System...

  • Page 32: Control Parameters Cascade

    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...

  • Page 33: Pressure Control

    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 %) Parameterisation  27 RT100 Control System...

  • Page 34: Pump Regulation (Software Option)

    Input run-on time of pump after switching off Cooling capacity Input of cooling capacity for cooling process Input evacuation type ("Inactive", "With pump" or "With pressure") Emptying (Software op- Evacuation type tion) with pressure with Y8/with Y18 28  Parameterisation RT100 Control System...
  • Page 35 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 Parameterisation  29 RT100 Control System...

  • Page 36: Inputs

    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...

  • Page 37: Flow Meter Type F1000 (Software Option, Max. 300 Lpm)

    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- Parameterisation  31 RT100 Control System...
  • Page 38 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...

  • Page 39: Outputs

    Heating 2 on Cooling on Pressure increase Pressure decrease Maintenance Pump regulation Start/Stop Data input output O2 (for functions, see out- put O1) Pump regulation Right/Left Data input: output O3 (for functions, see out- put O1) Parameterisation  33 RT100 Control System...

  • Page 40: Relay

    Relay K1 Service Relay Max heat./cool. time Power ON Common alarm (see the param- eter " Common alarm") Heating 1 Heating 2 Minimum flow rate Alarm Flow monitor Level Pump current Deviation Set-point/Outlet HI 34  Parameterisation RT100 Control System...

  • Page 41: Collective Alarm

    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 Parameterisation  35 RT100 Control System...
  • Page 42 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 36  Parameterisation RT100 Control System...

  • Page 43: Save/Load

    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...

  • Page 44: Options

    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) 38  Parameterisation RT100 Control System...

  • Page 45: Current Monitoring Heating

    Compatibility 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",...

  • Page 47: Data Interfaces

    RS 485 Frech Datacontrol 9600 Bd A11-18 Frech Datacontrol 4800 Bd A11-18 Frech Datacontrol 2400 Bd A11-18 Frech Datacontrol 1200 Bd A11-18 CAN Demag Ergocontrol 500 kBd A13-17 CAN Demag Ergocontrol 250 kBd A13-17 Data Interfaces  41 RT100 Control System...
  • Page 48 Profibus DP (Protocol V2) max. 12 MBd RS 485 A0-124 Profinet IO 100 MBd Profinet IO Profinet IO 100 MBd Profinet IO Engel 4800 Bd RS 485 Ethernet/IP 100 MBd Ethernet IP Address 42  Data Interfaces RT100 Control System...

  • Page 49: Plug Nomenclature

    V 01/2016 Plug Nomenclature RT100 Front panel Plug Designation Options Base module Interfaces Universal RP or 20 mA CL USB Host USB Device RT100 Base Module Plug Designation Display and operations module (front panel) Base module Options Options Options Power supply...
  • Page 50 X32:2 Feedback Heating 1 X33:1 Feedback Heating 2 X33:2 Feedback Heating 2 X34:1 Thermostat F7 X34:2 Thermostat F7 X35:1 AC In X35:2 AC In X36:1 AC In X36:2 AC In X37:1 AC In 44  Plug Nomenclature RT100 Control System...
  • Page 51 Delivery pump M10 X50:3 Delivery pump M10 X50:4 Delivery pump M10 X51:1 Mains input 200-600V X51:2 Mains input 200-600V X51:3 Mains input 200-600V X51:4 Mains input 115/230V X51:5 Mains input 115/230V X51:6 Mains input Plug Nomenclature  45 RT100 Control System...

  • Page 52: Rt100 Digital Option

    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...

  • Page 53: Analog Functions

    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...

  • Page 55: Hardware

    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! Hardware ...

  • Page 56: Rt100 Base Module - Layout

    V 01/2016 RT100 Base Module - Layout RT100 Base Module - Layout 50  Hardware RT100 Control System...

  • Page 57: Analog Option - Layout

    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...

  • Page 58: Digital Option - Layout

    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...

  • Page 59: Option Reversal Of Direction Of Rotation >9A - Layout

    V 01/2016 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 Hardware  53 RT100 Control System...

  • Page 60: Option Profibus Dp - Layout

    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...

  • Page 61: Option Euromap 66 - Layout

    V 01/2016 Option Euromap 66 - Layout Option Euromap 66 - Layout S3 Address 0=Zone 1 1=Zone 2 Board for Mainboard-Options - Layout Hardware  55 RT100 Control System...

  • Page 62: Option Profinet-Io - Layout

    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...

  • Page 63: Fault Rectification

    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.

  • Page 64: Alarms

    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 58  Fault Rectification RT100 Control System...

  • Page 65: System Errors/System Notes

    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 Fault Rectification  59 RT100 Control System...
  • Page 66 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 60  Fault Rectification RT100 Control System...

  • Page 67: Rt100 Control System - Maintenance/Repair

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

  • Page 68: Replacing The Base Module

    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". 62  RT100 Control System - Maintenance/repair...

  • Page 69: Loading The Factory Settings

    V 01/2016 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.

  • Page 70: Can Terminating Resistors And Address Settings

    In the case of dual units, address 1 is set for zone 2 (rotary switch S2). Connection com- Description bination Front panel with one base module Both terminating resistors are switched on (checked by Regloplas) Front panel with two base modules One option Several options 64  RT100 Control System - Maintenance/repair...
  • Page 71 V 01/2016 Connection com- Description bination Front panel with option Front panel with option RT100 Control System - Maintenance/repair  65 RT100 Control System...

  • Page 73: Spare Parts

    (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! Spare Parts ...

  • Page 74: Rt100 Control System - Spare Parts

    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...
  • Page 75 V 01/2016 Spare Parts  69 RT100 Control System...

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