En

90smart/150smart
Operating Instructions
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Documentation Temperature Control Unit 90smart/150smart

This documentation is copyrighted. Unauthorised duplication is prohibited

by law. To the best of our knowledge and belief, the information con-
tained in this documentation is true and correct as of the date of publica-
tion. The contents, however, do not constitute a binding obligation on the
part of Regloplas AG and are subject to change without notice.

© Copyright 2013 Regloplas AG

All rights reserved

Printed in Switzerland

Regloplas AG
Flurhofstrasse 158
9006 St. Gallen
Switzerland
Tel.: +41-71-282 58 00
Fax.:
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 Parameter Settings .............................................................. 3 
Residual Risks ........................................................................................... 3 
Using This Documentation ...................................................................................... 4 
Additional Documentation .......................................................................... 4 

Operating Instructions 5 
General ................................................................................................................... 5 
Introduction ................................................................................................ 5 
Operating Range ........................................................................................ 5 
Start-up ................................................................................................................... 6 
Setting up the temperature control unit...................................................... 6 
Operating Instructions ................................................................................ 6 
Inspection of Consumers ........................................................................... 7 
Water Quality ............................................................................................. 7 
Connecting Lines ....................................................................................... 7 
Electrical Connections ............................................................................... 8 
Operation of the Temperature Control Unit ............................................................ 8 
RT34 Control System .............................................................................................. 8 
Powering Up............................................................................................... 9 
Operating mode switch .............................................................................. 9 
Displays.................................................................................................... 10 
Setting the set-point value ....................................................................... 10 
Changing the parameter .......................................................................... 10 
Switch off.................................................................................................. 10 
Malfunctions .......................................................................................................... 11 
Error messages on the device ................................................................. 11 
Device malfunctions ................................................................................. 11 
RT70 Control System ............................................................................................ 12 
Buttons ..................................................................................................... 12 
Status LEDs ............................................................................................. 13 
Device Functions ..................................................................................... 13 
Symbols ................................................................................................... 13 
RT70 Operation and Status Displays ...................................................... 13 
Setting the Set-point values ..................................................................... 13 
Parameter Menu ...................................................................................... 14 
RT70 Control System - Functions ......................................................................... 14 
Powering Up............................................................................................. 14 
Shutdown ................................................................................................. 14 
Leak-stop operation ................................................................................. 14 
Emptying (option) ..................................................................................... 15 

Temperature Control Unit 90smart/150smart Contents  i

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Operation with Code/Password ............................................................... 16 

Alarm Reset and Alarm History ............................................................... 16 
Save/Reset of the Setting Values............................................................ 16 
Changing Consumer/Decommissioning ............................................................... 16 
Alarm Messages ................................................................................................... 17 
Alarm list ............................................................................................................... 17 
Warnings.................................................................................................. 17 
Alarms...................................................................................................... 17 
System Errors/System Notes .................................................................. 18 
Maintenance ......................................................................................................... 18 
Periodic Inspections and Maintenance Procedures ................................ 18 
Cleaning................................................................................................... 20 
Repairs .................................................................................................... 20 
Transport .............................................................................................................. 21 
Disposal ................................................................................................................ 21 

Maintenance 23 
Guidelines for Connecting Hoses ......................................................................... 23 
Technical Data 90smart/150smart ....................................................................... 24 
Block diagram 90smart ......................................................................................... 25 
Block diagram 150smart ....................................................................................... 26 
Graph (pump capacity) ......................................................................................... 27 
Graph (Cooling capacity 90smart) ........................................................................ 28 
Graph (Cooling capacity 150smart) ...................................................................... 28 
Components/Spare parts 90smart ....................................................................... 29 
Components/Spare parts 150smart ..................................................................... 32 
Dimension sheet 90smart ..................................................................................... 35 
Dimension sheet 150smart ................................................................................... 36 

ii  Contents Temperature Control Unit 90smart/150smart

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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.

Temperature Control Unit 90smart/150smart 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 temperature control unit is built according to the current
state of the art and the generally accepted principles of safety engineer-
ing. The temperature control unit is intended solely for normal use in the
heating and/or cooling of injection moulds and die casting dies, extruders,
calenders, mixers and other energy-consuming loads ("consumers") in
areas where 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 temperature control unit
may not be used under operating conditions and/or with media deviating
from our specifications without the prior consent of Regloplas AG.
The intended use also entails compliance with the operating, servicing
and maintenance conditions stipulated by the manufacturer. The temper-
ature control unit may only be operated, serviced and maintained by per-
sonnel that are familiar with these tasks and have been instructed as to
the risks.

Safety Information

General information
The Regloplas temperature control unit is safe to operate but can cause
danger if it is used incorrectly or for a purpose other than its intended
use. It should be noted that any such incorrect use or non-compliance
with the intended use can cause risks to the life and limb of the operator
or third parties, adverse effects on the equipment and other material as-
sets belonging to the user, and risks to the efficient operation of the
equipment.
Start-up (i.e., commencement of intended use) is prohibited until certifica-
tion that the temperature control unit has been set up and wired in ac-
cordance 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 switching on
and operating the temperature control unit. The information regarding the
intended use and foreseeable misuse must be observed. Local safety
regulations must also be obeyed.
If the temperature control unit is used in combination with products made
by other manufacturers, the notices and safety regulations of these man-
ufacturers must also be obeyed.

Process Monitoring
In plants in which a malfunction of the temperature control system leads
to endangerment of the operating personnel or destruction of the plant,
an independent process monitor that reliably shuts down the plant 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, in
particular the chapter on safety, may 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 relating to set-up, start-up, operating, modification of operat-
ing conditions and operational methods, maintenance, inspection and re-
pair, any shut-down procedures stated to be necessary in the Operating
Instructions must be followed.

Changing the Parameter Settings

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
unit as well as 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 the use of
third-party parts renders any and all warranty claims null and void.

DANGER
The temperature control unit must be disconnected from the electrical power
supply before it is opened (unplug the mains plug and, if fitted, press the main
switch on the temperature control unit). Danger of electric shock!

Any leaks in the temperature control circuit (control unit, connecting lines,
consumers, etc.) must be repaired immediately.
In the case of temperature control units that use oil as the heat transfer
medium, please remember that oil is flammable under certain conditions.
For this reason, the temperature control unit must not be located close to
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 an AFFF spray foam fire
extinguisher, a powder fire extinguisher (to be avoided in the case of
dust-sensitive plants, control systems, EDP, etc.) or a CO2 fire extin-

Temperature Control Unit 90smart/150smart General Safety Information  3

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guisher. The appropriate fire extinguisher must be provided by the opera-

tor, taking into account the equipment located in the room and the man-
datory 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 from the temperature control circuit,
first allow the temperature control unit to cool down, as a function of the
outlet temperature, and then switch it off. Check that the pump is no
longer running.

WARNING

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

Using This Documentation

This documentation contains important information for safe and economi-
cal operation and 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 documentation is completely correct for the basic versions
of devices. Components that do not belong to the basic hardware are
noted as extra equipment. The corresponding additional documents are
included with special versions of devices. Any additional documents sup-
plement and/or replace the descriptions contained in this documentation,
which are then either invalid or only conditionally valid.

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Operating Instructions

General

Introduction
These Operating Instructions contain a detailed description of the Tem-
perature Control Unit 90smart/150smart as well as important information
for safe operation and optimal maintenance.
The Operating Instructions must be kept near the temperature control
unit and must always be accessible to operating and maintenance per-
sonnel.

Operating Range
The operating range and heat transfer fluid of the Temperature Control
Unit 90smart/150smart are shown in the following table (in this regard,
see also the chapter "Technical Data" in the Maintenance section).

Temperature Control
90smart 150smart
Unit Type
Temperature range up to 90 °C up to 150 °C
Heat carrier/medium Water Oil

NOTE
The technical data and information for installation, start-up and maintenance of
the temperature control unit can be found in the maintenance section of these
operating instructions. The Operating Instructions should be kept near the de-
vice/system and always be accessible to operating and maintenance personnel.

Temperature Control Unit 90smart/150smart Operating Instructions  5

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Start-up

Setting up the temperature control unit

The temperature control unit is designed for an ambient temperature
range of 10-40 °C. Sufficient ventilation must be provided during setup.
The distance between the devices and/or between the temperature con-
trol unit and a wall must be at least 10 cm. The ventilation slits must not
be covered.
 Check the temperature control unit to ensure that it is undam-
aged and complete
 Do not tip the temperature control unit! Heat transfer medium
remaining in the unit from the test run could spill, and there is a
risk that the thermal insulation could become soaked with the flu-
id (medium)
 Position the temperature control unit on a horizontal surface and
engage the wheel brake

WARNING
The temperature control unit may be pressurised - Danger of injury in the event
of escaping hot water or steam.
Never start up the temperature control unit without the side panels and hous-
ing.
Never use the temperature control unit in potentially explosive environments
and protect it against sprays and cleaning agents that contain solvents.
Any leaks in the temperature control circuit (temperature control unit, connect-
ing lines, consumers, etc.) must be repaired immediately.
Observe local laws during set-up.

CAUTION
Before detaching connecting lines in the temperature control circuit, the tem-
perature control unit must first be allowed to cool down. The cooling time will
depend on the outlet temperature. The shutdown procedure is initiated by
pressing the ON/OFF button. The pump continues to run. The temperature con-
trol unit cools down until the temperature of the heat transfer medium has
reached the programmed coastdown temperature (factory default 60 °C). The
pump and the control system are then switched off!
Check that the pump is no longer running and that the system pressure gauge
reads 0 bar (display on the screen reads OFF)!
The corresponding chapters of the Operating Instructions must be read before
starting up the temperature control unit!

Operating Instructions
The Operating Instructions for the temperature control unit must be kept
at all times close at hand for the personnel responsible for start-up and
operation. Please ensure that the operating instructions are read. By do-

6  Operating Instructions Temperature Control Unit 90smart/150smart

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ing so, you will avoid unnecessary expense and problems during start-up
as well as production downtime.

Inspection of Consumers
Before installing the connecting lines between consumer and tempera-
ture control unit, the consumer must be subjected to the following inspec-
tions:
 Verify that channels are unobstructed
 Remove residual fluid and dirt with compressed air (foreign ob-
jects such as shavings etc. can damage the pump)
 Rust and scale deposits must be removed because they greatly
interfere with the heat exchange between consumer and heat
transfer medium and increase the pressure drop in the consum-
er. Descaling can be carried out using the Regloplas REG de-
scaling unit (see the "Regloplas Temperature Control Technolo-
gy" brochure, REG data sheet)

Water Quality
The water used must meet the following requirements to avoid damage
to the cooler of the temperature control unit:

Criterion Requirement
Appearance clear/without sediment
Cloud < 0.5 NTU (very light cloud)
Total hardness < 10 °dH
pH-value 6.5-8.5
Conductivity max. 500 µS/cm
Carbonate hard-
< 5 °dH
ness

Addition of RK93 corrosion inhibitor is urgently recommended (see the

"Regloplas Temperature Control Technology" brochure, RK93 data sheet).

Connecting Lines
The connecting lines must consist only of pressure-resistant and temper-
ature-resistant hoses and screw fittings. The cross-section of the con-
necting lines may not be reduced (see Maintenance section).
 The connecting lines must be routed so that they are protected
against unintentional contact. Thermal expansion must be taken
into account in pipe joints
 When connecting to public water mains, the applicable laws and
safety regulations must be observed (e.g., connection of the unit
via backflow preventer). The water mains pressure must be with-
in the range of 2-6 bar
 Cooling water outlet - must prevent reverse flow and must be al-
ways open. The hose must be fastened so that any escaping
steam at the start of the cooling procedure does not pose a haz-
ard

Temperature Control Unit 90smart/150smart Operating Instructions  7

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 For reasons of safety, the cooling system must always be con-

nected

CAUTION

When escaping, the temperature of the cooling water can increase to the same
temperature as the heat transfer medium.

Electrical Connections
The temperature control unit may only be connected by a qualified elec-
trician.
 Compare supply voltage and frequency with the information on
the rating plate of the temperature control unit
 Verify the rating of the preliminary fuse according to the infor-
mation in the electrical diagram, and check that the power con-
sumption conforms to the value on the rating plate of the temper-
ature control unit
 Observe the applicable local laws and safety regulations when
connecting to the mains

Operation of the Temperature Control Unit

The temperature control unit must only be switched on after inspecting
the consumer, connecting the connecting lines and electrical connec-
tions, and opening the outlet/inlet shut-off valves. The vent valves on the
consumer and the shut-off valves (if present) must be open.

RT34 Control System

RT34 Control System - front panel

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Powering Up
After carrying out the checks on the consumer, connecting the hoses and
electrical connections, proceed as follows:
 Open the vent valve on the consumer, and also the shut-off valve
(if fitted)

 Switch on the control unit/pump with the I/O switch

 The operating mode switch on the front panel must be at position
+ (normal mode). After switching on, a function test runs in the
RT34 controller for about 5 seconds. All displays flash during the
test. After successful conclusion of the test, the actual value ap-
pears in the upper display field and the set-point value in the
lower display field
 The water is now automatically refilled. This process can take 2-4
minutes depending on the water mains pressure. An alarm rings
during this time. The control unit can also be filled manually via
the filling opening on the filler cap
 Check direction of rotation of the pump following the arrows on
the fan shroud (remove side panels). If the direction of rotation is
incorrect, two phases must be reversed on the unit plug

NOTE
Important - The operating mode switch must be at position +, i.e. pressure
mode!

 Check the temperature control circuit (control unit, connecting

lines, consumers, etc.) for leaks
 Do not close the vent valve on the consumer until water is flow-
ing out of the consumer at a regular rate

Operating mode switch

Pressure mode
Normal mode - The heat carrier is pumped through the consumer by
pressure (switch position +)

Leak stop mode

The heat carrier is drawn by the consumer (reduced pump capacity,
switch position -)

Suction
The heat carrier is drained out of the consumer by suction, switch posi-
tion A. Cool down device and switch off, turn switch to position - and
switch device on again. Turn switch to position A and hold down until fully
drained (observe maximum expansion volume!)

Temperature Control Unit 90smart/150smart Operating Instructions  9

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NOTE
Important - When switching between the operating modes Pressure and Leak
stop mode, the temperature control unit must be switched off at the I/O switch!

Displays
Display Remark
OUT 1 The heating is switched on when the LED is on
ALM The cooler is switched on when the LED is on
Level The light is on if there is insufficient heat carrier
Motor The light is on if the thermal relay has been triggered

Setting the set-point value

 Press SET, Sv flashes

 Set the set-point value using the or button

 Press SET, the new value is activated

Changing the parameter

 Press SET for a few seconds until Pv appears
 Pv value flashes
 Tap SET until Lkv appears
 Set Lkv to 1 (clearance)
 Tap SET until the desired parameter appears

 Set the value using the or button

 Press SET for a few seconds - End (set-point value/actual value
is displayed)

Switch off
 Cool down device or temperature control circuit to a minimum of
80 °C

 Switch off the device/pump with the I/O switch

WARNING
Danger of injury from escaping hot cooling water!
Before detaching connecting lines from the temperature control circuit, first al-
low the temperature control unit to cool down, as a function of the outlet tem-
perature, and then switch it off!
Check that the pump is no longer running!

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Malfunctions

WARNING

Unplug the mains plug before performing troubleshooting!

Error messages on the device

Display Remark
The light is on if there is insufficient heat carrier - possible
causes:
 Device is refilled
 Cooling water supply not connected or shut off (shut-
off valve)
 Filter dirty
 Solenoid valve water filling (Y2) dirty
 Level switch defective
This light is on if the thermal relay has been triggered - possi-
ble causes:
 Pump overheated (lines blocked)
 Incorrect value set on thermal relay (see information
on electrical wiring diagram and rating plate on the
pump)
 Switch thermal relay on again using the reset button
(S5) on the back of the control unit

Device malfunctions
Malfunc-
Remark
tion
Safety thermostat (F5) triggered:
Device  Check level control (water level in the device) and
does not switch safety thermostat (F5) on again using reset
heat up button on the heating
 Heating contactor defective
Water flow in cooler too low - possible causes:
Device  Solenoid valve cooling defective or dirty
does not
 Filter dirty
cool
down  Cooler coated with lime
 Replace cooler or clean using descaling unit
Automatic water filling does not switch off. Possible causes:
 Float switch defective
Device
 Solenoid valve water filling (Y2) defective or dirty
overfilled
 Leak in cooler
 Clean or replace defective parts

Temperature Control Unit 90smart/150smart Operating Instructions  11

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Pt100 Malfunction

This indication means that the internal temperature sensor Pt100 is de-
fective. In this case, the float switch has to be replaced.

RT70 Control System

Display of actual
value

Additional display
Display of set-point
value SP1/SP2 or ex-
ternal operation

Interface address
Status display

Selection of the
device functions
Symbol area

Status LEDs

RT700 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 Enter key

Navigation upward Navigation downward

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Status LEDs
Normal mode Warning Alarm

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

Leak-stop mode

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, counterclockwise rotation

Feed pump, clockwise rotation Alarm

Maintenance due (flashes if maintenance is

due)

RT70 Operation and Status Displays

In the off state of the RT70 control system, the message OFF appears in
the display area. Upon switching on with the ON/OFF button, 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
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-point values

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

Temperature Control Unit 90smart/150smart Operating Instructions  13

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control knob. This setting is also possible in the parameter positions. The
set-point values can be selected via an external digital signal.
To toggle between set-point values SP1 and SP2, press the F3 button
and select the set-point toggling function. Set-point toggling is only possi-
ble if there is no alarm pending.

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.

RT70 Control System - Functions

Powering Up
Upon switching on the main switch, the message OFF appears in the
display. The RT70 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.
The display, depending on the programming, shows the set-point and ac-
tual values, as well as information on the operational state of the control
system or the temperature control unit.

Rotational field detection / Direction reversal

The rotary field detection of the RT70 control system detects a wrong
phase sequence and reports this in the display or corrects the direction of
rotation automatically.

Shutdown
The RT70 control system is switched off by pressing the ON/OFF button,
by the timer, via a digital input or an interface.
Depending on the temperature of the heat transfer medium, the shut-
down program runs as follows:
 The pump and the control system are switched off. The RT70
control system will then be in standby mode and the message
OFF appears on the display.
 The pump continues to run. The unit cools down until the tem-
perature of the heat transfer medium has reached the pro-
grammed coastdown temperature. On reaching this temperature,
the pump and the control system are automatically switched off.
In the case of pressurised water units, the pump then continues
running for a further few seconds in the opposite direction (pres-
sure release). The RT70 control system will then be in standby
mode and the message OFF appears on the display.

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.

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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.
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.

Emptying (option)
The consumer device can be drained using the delivery pump (suction)
or by means of 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 button
and selecting the suction symbol. The pump is switched off, and after the
pump coastdown time has elapsed the pump is switched on again in the
opposite direction. The consumer is drained by suction during the defined
period (draining time).
Draining is only possible if the temperature of the heat transfer medium is
below the programmed coastdown 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 enables the user to drain the consumer con-
nected to the temperature control unit by means of compressed air. Blow-
ing out is activated after the pump coastdown time has elapsed and di-
rects compressed 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 aborted 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.

Temperature Control Unit 90smart/150smart Operating Instructions  15

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NOTE
In the case of pressurised water units, the pressure release valve (Y8) closes at
5 °C above the coastdown temperature (max. 85 °C) and opens at the pro-
grammed coastdown temperature during the cooling process (only devices with
1K/2K).

Operation with Code/Password

In order to prevent the values that have already been set or programmed
from being unintentionally reset/adjusted, the use of a code/password is
urgently recommended. The code is defined in the parameter Code.
The RT70 control system has three password levels that are organised
hierarchically:
 User password - Default 0000 (switched off)
 Technician password - Default 0070
 Service password - only for personnel trained by Regloplas

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

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 reme-
died, the alarm can be reset by again pressing the Alarm Reset button.

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 RT70 control system provides the facility to reload the factory set-
tings or user settings at any time by a simple procedure. Two different
new customer-specific settings can be loaded (user setting 1 and 2).

Changing Consumer/Decommissioning
Before detaching the connecting lines, it is necessary to verify that the
temperature control unit is turned off and that all circuits are depressur-
ised (see the chapter "Switching off the Temperature Control Unit"). The
temperature control unit must be drained completely and stored in a dry
place at 10-40 °C when not in use. To restart the unit, proceed as in-
structed in the "Start-up" chapter.

16  Operating Instructions Temperature Control Unit 90smart/150smart

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Alarm Messages
The RT70 control system can display various error messages (warnings
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 cleared by once again pressing the
Alarm Reset button.
The Alarm Reset button also allows manual acknowledgement of the au-
tomatic switchover (toggling) from consumer temperature control (or cas-
cade control) Sn2 to outlet temperature control Sn1 in the event that
sensor Sn2 is defective or removed from the consumer.

Alarm list
Pressing the Alarm Reset button opens the alarm list, as long as there is
no active alarm. The last ten alarm messages are displayed in this list,
complete with date and time.

Warnings
Error message Rectification
Carry out maintenance procedure according to the
Service is due operating manual. Increment the parameter Next
Maintenance by 1000 hours
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
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

Alarms
Error message Rectification
Level 1 underrun Refill heat transfer medium
Toggling of heat transfer medium - unit must be re-
Switch the main switch off and on again
started
External set-point value signal interrupted or not pre- External set-point value signal must be present (if re-
sent quired, check external control system)
Connect analog option or switch off in the parameter
Analog option missing or defective
Hardware Options
Connect digital option or switch off in the parameter
Digital option missing or defective
Hardware Options
AD converter failure Replace base module
Place the temperature control unit in a place with low
Attention - temperature control cabinet too high
ambient temperature
Check the outlet pressure (min. 0.7 bar must be pre-
Flow switch act
sent)
Max. temperature exceeded Max. temperature of the heat transfer medium may

Temperature Control Unit 90smart/150smart Operating Instructions  17

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Error message Rectification

not exceed the maximum device temperature (if re-
quired, check the tool temperature)
Check the pump/pump motor (with Ohmmeter) and if
Motor current underrun
required, replace them
Phase sequence failure Correct the phase sequence (interchange 2 phases)
Phase sequence unidentified Switch off phase sequence monitoring
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
Check the pump/pump motor (with Ohmmeter) and if
Motor current exceeded
required, replace them
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 triggered mine the cause and reset the thermostat (by using the
reset button)
Check the cooling water circuit and the cooling circuit
Turn on time refill exceeded
for leaks

System Errors/System Notes

Error message Rectification
Parameter data corrupt Replace the control unit
Save/Load not possible during device is on Switch the temperature control unit to OFF
Error, password not reset Enter he reset code correctly
Password reset Password has been reset

Maintenance

WARNING
Before all maintenance procedures, turn off the temperature control unit, press
the main switch and unplug the mains plug!
The temperature control unit may be pressurised - Danger of injury in the event
of escaping hot water or steam!
Check that the system pressure gauge is displaying the value 0 bar.
Before disconnecting the feed lines to the temperature control unit/consumer,
first allow the temperature control unit to cool down.

Periodic Inspections and Maintenance Proce-

dures
The RT70 control system has a service interval display to simplify
maintenance work on the temperature control unit. We recommend enter-
ing the corresponding maintenance interval (e.g., 2000 hours, see the
RT70 control system programming instructions).
Please note that the instructions below are based on a daily operating
time of 8 hours. In multi-shift operation, the inspections and maintenance

18  Operating Instructions Temperature Control Unit 90smart/150smart

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procedures must be carried out at correspondingly shorter intervals. De-

fective parts must be repaired or replaced immediately.
 Temperature control unit inspections and maintenance proce-
dures must be carried out by an expert
 Maintenance procedures involving electrical equipment may only
be carried out by qualified electricians
 The RT70 control system unit may only be replaced when the
mains plug is unplugged
 The safety valve should be vented from time to time by brief acti-
vation (blow off)

WARNING
Danger of magnetic fields in the case of feed pumps with magnetic drive.
Persons with pacemakers and surgically implanted metal parts must remain at
a safe distance or should not be required to perform maintenance and repairs
on these pumps.
When assembling the magnetic drive, the motor must be securely retained to
prevent any possibility of fingers being crushed between components due to
the magnetic forces.
All computers, data media, credit cards, electronic watches etc. must be kept at
a safe distance.

Daily Inspections/Maintenance Procedures

 Check the entire temperature control circuit (temperature control
unit, connecting lines, consumers, etc.) for leakage and repair
any leaks immediately
 Check filters and clean if necessary

Monthly Inspections/Maintenance Procedures

 Inspect the cooling air inlet port of the pump motor to ensure that
it is free of obstructions. Clean the port by blowing compressed
air from inside to outside
 Clean the level switches
 Check filters and clean if necessary

Semi-annual Inspections/Maintenance Procedures

 Inspect the electrical equipment such as grounding wires, secure
connection of power supply cord and connecting lines, etc.
 Dismantle solenoid valves (see maintenance section), inspect
membranes for lime deposits and damage. Check the core and
spring bolt for free movement. Clean or replace parts if neces-
sary
 Descale cooler - exercise caution when tightening the screwed
connections on the heat exchanger (max. 170 Nm).
 Check pump capacity (the flow rate and final pressure must
comply with the pump characteristic)

Temperature Control Unit 90smart/150smart Operating Instructions  19

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Annual Inspections/Maintenance Procedures

 Replace the heat transfer medium (water and corrosion inhibitor)
after approx. 2000 working hours (equivalent to approx. one year
in single-shift operation). In the event of poor water quality or
multi-shift operation (contamination, etc.), the medium must be
replaced correspondingly earlier

Cleaning
CAUTION
Always allow the temperature control unit to cool down!
Switch off the temperature control unit: press the main switch and unplug from
the mains!
When using a solvent for cleaning - do not blow out the tank and the cooler, but
flush them instead (explosion hazard)!
When using a solvent, the manufacturer's instructions for use must be ob-
served. Solvents are flammable under certain conditions. For this reason,
cleaning must never take place near heat sources!
In the event of unfavourable operating conditions, the procedures listed
below must be carried out correspondingly earlier.
1) Drain the temperature control unit by suction or blowing out
2) Clean the filters in the circuit
3) Inspect the cooler for scale deposits and clean using the REG
Descaling Unit if necessary
4) Level control - remove and clean the level switches. Important -
reinstall level switch correctly (NO marking must be on top, see
Maintenance section)
5) Dismantle solenoid valves (see Maintenance section), inspect di-
aphragms for scale deposits and damage. Check the core and
spring bolt for free movement. Clean or replace parts if neces-
sary
6) Inspect pump for corrosion and replace if necessary
7) It is also advisable to inspect the consumers for contamination.
Impurities lead to a sharp reduction in heat exchange between
consumer and heat transfer medium. Deposits increase the
pressure drop in the consumer, so that, over time, the pump ca-
pacity of the temperature control unit is no longer sufficient to
handle the necessary heating or cooling load

Repairs
CAUTION
Allow the temperature control unit to cool down and, if necessary, drain it be-
fore any repair!
Switch off the temperature control unit: press the main switch and unplug from
the mains!
Disconnect all hose couplings from the temperature control unit!

20  Operating Instructions Temperature Control Unit 90smart/150smart

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For fast, error-free supply of spares, we need the following data without
fail:
 Device type
 Device number
 Voltage and frequency
This information is given on the rating plate on the temperature control
unit.
The item numbers of the components can be found in the corresponding
drawings in these operating instructions and the electrical circuit dia-
grams of the temperature control unit.

CAUTION
Only authentic (OEM) Regloplas spare parts may be used!
In case of damage from the use of non-OEM parts, the warranty will be rendered
null and void!

Transport

CAUTION
Allow the temperature control unit to cool down, turn it off, press the main
switch and unplug the mains plug!
Disconnect all hose couplings from the temperature control unit!

Before shipping, the temperature control unit must be drained through the
discharge port on the delivery pump (see maintenance section). Because
of the danger of freezing (bursting of the cooling pipes) at low tempera-
tures, the cooler must be blown out as follows:
1) Switch on the temperature control unit - press the main switch
and press the ON/OFF button
2) Set the set-point value on the controller to 0 °C
3) Check that the cooler solenoid valve (Y6) is open
4) Blow out the cooler with compressed air (max. 6 bar)
5) Switch off the temperature control unit with the ON/OFF button,
and then press the main switch and unplug the mains plug
6) Do not tip the temperature control unit - heat transfer medium
remaining in the unit could spill out
7) Use the original packaging and mark the top side clearly

Disposal
The temperature control unit must be drained completely and disposed of
in accordance with local regulations.
The temperature control unit can also be returned to Regloplas AG, Swit-
zerland, for disposal.

Temperature Control Unit 90smart/150smart Operating Instructions  21

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22  Operating Instructions Temperature Control Unit 90smart/150smart

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Maintenance

Guidelines for Connecting Hoses

Wrong Right

Provide sufficiently long

Hose too short - hose is
neutral hose ends (3-5 x
bent at the connections
DN)

Wrong Right

Excessive bending load

Pipe elbows fitted
at the connections

Wrong Right

Incorrect installation -
compression along the Pipe elbows fitted
longitudinal axis

Wrong Right

The pipe axes must be

Torsion - hose axis and
parallel and in the same
direction of movement
plane as the direction of
not in the same plane
movement

Important - twisting of the When attach-

hoses can also be ing/detaching a hose, al-
caused during installa- ways hold it in place with
tion. a second wrench

Temperature Control Unit 90smart/150smart Maintenance  23

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Technical Data 90smart/150smart

Temperature Control Unit Type 90smart 150smart

Max. outlet temperature 90 °C 90 °C/150 °C
Heat carrier/medium Water Oil
Filling capacity 7.0 l 7.5 l
Max. expansion volume 2.5 l 4.5 l
Heating capacity 6/9 kW 6 kW
Heating switch SSR relay SSR relay
51 kW (1K)
Cooling capacity 29 kW
75 kW (2K)
at outlet temperature 80 °C 140 °C
at cooling water temperature 20 °C 20 °C
Pump type TP20 TS22 TP20 TS22
Motor power (pump) 0.5 kW 1.1 kW 0.5 kW 1.1 kW
Max. delivery rate 60 l/min 70 l/min 60 l/min 70 l/min
Max. delivery pressure 3.8 bar 5.4 bar 3.8 bar 5.4 bar
Control System RT34 / RT70 Control System
Measurement type (standard) Pt100
Control voltage 115/230 V, 50/60 Hz
200-600 V
Input supply voltages
50/60 Hz
Total power (see specification plate) (see specification plate)
Outlet/inlet connections (standard) G 1/2" G 1/2"
Cooling water supply connections
G 1/2" G 1/2"
(standard)
Degree of protection IP40 IP40
Dimensions W/H/D 202/560/661 mm 202/560/661 mm
Weight approx. 44 kg approx. 50 kg
Colour RAL 9006/7016 RAL 9006/7016
Ambient temperature max. 40°C max. 40°C
Continuous sound pressure level < 70 dB(A) < 70 dB(A)

24  Maintenance Temperature Control Unit 90smart/150smart

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Block diagram 90smart

Block diagram 90smart

Item Designation Item Designation

38 Vessel, reservoir, tank F5 Safety thermostat
41 Cooler M10 Pump
58 Bypass S1 Level control
60 Filter - cooling circuit Y2 Solenoid valve - auto. water refill
99 Consumer Y6 Solenoid valve - cooling
B1 Temperature probe - internal Y13 Solenoid valve - suction (optional)
E21 Heating

Temperature Control Unit 90smart/150smart Maintenance  25

 V 11/2014

Block diagram 150smart

Block diagram 150smart

Item Designation Item Designation

38 Vessel, reservoir, tank F5 Safety thermostat
41 Cooler M10 Pump
60 Filter - cooling circuit S1 Level control
99 Consumer Y2 Solenoid valve - auto. water refill
B1 Temperature probe - internal Y6 Solenoid valve - cooling
E21 Heating Y13 Solenoid valve - suction (optional)

26  Maintenance Temperature Control Unit 90smart/150smart

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Graph (pump capacity)

1 - Pump curve TP20

2 - Pump curve TS22, TS22H

Pump capacity - Delivery rate V as a

function of pressure (p), bypass not tak-
en into account

Temperature Control Unit 90smart/150smart Maintenance  27

 V 11/2014

Graph (Cooling capacity 90smart)

1 - Cooling curve 90smart (1K)

2 - Cooling curve 90smart (2K)

Cooling capacity (P) as a function of out-

let temperature ( )
Cooling water temperature 20 °C
Flow rate 20 l/min

Graph (Cooling capacity 150smart)

1 - Cooling curve 150smart (Oil)

Cooling capacity (P) as a function of out-

let temperature ( )
Cooling water temperature 20 °C
Flow rate 10 l/min

28  Maintenance Temperature Control Unit 90smart/150smart

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Components/Spare parts 90smart

P1 67
30
73

63
72
66

Q1 70
V21

V21a

68

9 75

M10 41

35

E21

60
54

46

38

9 75

Temperature Control Unit 90smart/150smart Maintenance  29

 V 11/2014

30 T5

56h

Y6 F5

58

V21
38

41
69a

Y13

M10

Y2

S3/B1

69

30  Maintenance Temperature Control Unit 90smart/150smart

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Item Designation Item Designation

9 Castor with wheel lock B1 Temperature probe - internal
30 Power cable E21 Heating
35 Pump F5 Safety thermostat
38 Tank with insulation M10 Pump motor
41 Cooler P1 Control system
46 Float Q1 Main switch
54 Filler cap S3 Level switch (see corresponding chapter)
56h Check valve Bypass T5 Control transformer
58 Bypass V21 SSR relay with heat sink
60 Filter - cooling water V21a Seal for SSR relay
63 System water IN Y2 Solenoid valve (auto. water refill)
66 Cooling water IN Y6 Solenoid valve (cooling)
67 Cooling water OUT Y13 Solenoid valve (suction)
68 Discharge port
69 Filler pipe
69a Filler pipe (option)
70 Overflow
72 Outlet
73 Inlet
75 Castor

NOTE
See electrical wiring diagram of the temperature control unit for additional elec-
trical components!

CAUTION
Only authentic (OEM) Regloplas spare parts may be used!
In case of damage from the use of non-OEM parts, the warranty will be rendered
null and void!

Temperature Control Unit 90smart/150smart Maintenance  31

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Components/Spare parts 150smart

66 30
P1

Q1 67

72
73
69
70
V21

V21a

68

9 75

Y6
M10

60

35

E21 54

46

38

F5

9 75

32  Maintenance Temperature Control Unit 90smart/150smart

 V 11/2014

T5

Y2

Y13

69

V21

41

F5

68

Y6

Y13
M10

S3/B1

Temperature Control Unit 90smart/150smart Maintenance  33

 V 11/2014

Item Designation Item Designation

9 Castor with wheel lock B1 Temperature probe - internal
30 Power cable E21 Heating
35 Pump F5 Safety thermostat
38 Tank with insulation M10 Pump motor
41 Cooler P1 Control system
46 Float Q1 Main switch
54 Filler cap S3 Level switch (see corresponding chapter)
60 Filter - cooling water T5 Control transformer
66 Cooling water IN V21 SSR relay with heat sink
67 Cooling water OUT V21a Seal for SSR relay
68 Discharge port Y2 Solenoid valve (auto. water refill) (option)
69 Filler pipe Y6 Solenoid valve (cooling)
70 Overflow Y13 Solenoid valve (suction)
72 Outlet
73 Inlet
75 Castor

NOTE
See electrical wiring diagram of the temperature control unit for additional elec-
trical components!

CAUTION
Only authentic (OEM) Regloplas spare parts may be used!
In case of damage from the use of non-OEM parts, the warranty will be rendered
null and void!

34  Maintenance Temperature Control Unit 90smart/150smart

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Dimension sheet 90smart

Item Designation Item Designation

1 RT70 Control System 5 Inlet
2 Main switch 6 Cooling water IN
3 --- 7 Cooling water OUT
4 Outlet

Temperature Control Unit 90smart/150smart Maintenance  35

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Dimension sheet 150smart

Item Designation Item Designation

1 RT70 Control System 5 Inlet
2 Main switch 6 Cooling water IN
3 --- 7 Cooling water OUT
4 Outlet

36  Maintenance Temperature Control Unit 90smart/150smart

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Temperature Control Unit 90smart/150smart Maintenance  37