En

RT61-RT70
Control system Conversion P140smart
 V 03/2015

Documentation Retrofit RT61-RT70 - P140smart

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 2014 Regloplas AG

All rights reserved

Printed in Switzerland

Regloplas AG
Flurhofstrasse 158
9006 St. Gallen
Switzerland
Tel.: +41-71-282 58 00
Fax.: +41-71-282 58 40
e-mail: info@regloplas.com
Homepage: www.regloplas.com
 V 03/2015

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 

Conversion Instructions 5 
Retrofit Kit RT61 to RT70........................................................................................ 5 
General Information ................................................................................... 5 
Overview .................................................................................................... 5 
Control system conversion instructions ..................................................... 6 
Options conversion instructions ............................................................... 10 
Retrofit Kit RT61 to RT70 (Parts lists) .................................................................. 13 
Table 1 (Cables and Designations) ......................................................... 13 
Parts list ................................................................................................... 14 
Solenoid valve Set - coils with cables P140smart07 RT70 ..................... 15 
Transformer wired with plug for RT70 (400 V)......................................... 16 
Transformer wired with plug for RT70 (480 V)......................................... 16 
Safety thermostat cable ........................................................................... 17 
Option - MP1000 ...................................................................................... 17 
Option - MP1001 ...................................................................................... 17 
Option - MP1002 ...................................................................................... 17 
Option - MP1003 ...................................................................................... 17 
Option - MP1004 ...................................................................................... 17 
Option - MP1005 ...................................................................................... 18 
Option - MP1006 ...................................................................................... 18 

Retrofit RT61-RT70 - P140smart Contents  i

 V 03/2015

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.

Retrofit RT61-RT70 - P140smart General Safety Information  1

 V 03/2015

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 the normal use for
heating and/or cooling of injection moulds and die casting dies, extruders,
calenders, mixers and other 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 other operating conditions and/or with other me-
dia, in deviation 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 who are familiar with these tasks and have been instructed as to
the risks.

Safety Information

General Information
The Regloplas temperature control unit is safe to operate but can cause
danger if it is used incorrectly or for a purpose other than its intended
use. It should be noted that any such incorrect use or non-compliance
with the intended use can cause risks to the life and limb of the 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 equip-
ment.
Start-up (i.e., commencement of intended use) is prohibited until it has
been determined that the temperature control unit 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 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 temperature control system malfunction leads to en-
dangerment of the operating personnel or destruction of the plant, an in-

2  General Safety Information Retrofit RT61-RT70 - P140smart

 V 03/2015

dependent process monitor that shuts down the plant reliably must be
used.

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 use of third-
party parts voids any and all warranty claims.

DANGER
The temperature control unit must be rendered currentless before it is opened
(unplug mains plug and, if present, press the 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.

Retrofit RT61-RT70 - P140smart General Safety Information  3

 V 03/2015

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
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 unit
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 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.

4  General Safety Information Retrofit RT61-RT70 - P140smart

 V 03/2015

Conversion Instructions

Retrofit Kit RT61 to RT70

General Information
This manual describes the subsequent conversion of the RT61 Control
system to the new RT70 Control system for the P140smart temperature
control unit.

CAUTION

The conversion of the control system may only be performed by trained and au-
thorized personnel!

Overview
Retrofit Kit RT61 to RT70
P140smart (400 V) Item no. 490-100057
P140smart (480 V) Item no. 490-100061

Retrofit RT61-RT70 - P140smart Conversion Instructions  5

 V 03/2015

Control system conversion instructions

Remove the four mounting screws and tilt forward the

Unplug the power cable from the mains, remove the
RT60/61 Control system. Info - as mounting base, the
side panels left and right
packaging (cardboard box) of the RT70 can be used

Unplug all connectors on the RT60/61 Control system

and remove them from the cables. Remove the safety Remove the cover (air deflector) in the unit
thermostat F5 and replace the cable (incl. ground wire)

X10/Y2
X9/Y8
X12/Y6

Replace the solenoid valve coils (Y2, Y6, Y8) incl. ca- Install the protecting sleeves 220-100015 and
bles/plugs by new solenoid valve coils (230 VAC) 211-053747 on the cover 178-100010

6  Conversion Instructions Retrofit RT61-RT70 - P140smart

 V 03/2015

Install the intermediate plate 178-100009 and the cover Transformer T5 (180-100026), ground wire, L=450
with four countersunk screws (M4x16) (191-100120), ground wire L=600 (191-100121)

Install the transformer T5 on the bottom of the cover

Fix the ground wire (191-100120) to the provided
178-100010 (screw M5x60 no. 331-069398, washer
thread (M4x10 + serrated washer + washer)
332-069433)

Loosen the grounding wire of the mains cable from the

Install the safety thermostat F5 on the front of the cover
bottom plate. Replace the ground wire of the bottom
178-100010
plate by the new cable (191-100121)

Retrofit RT61-RT70 - P140smart Conversion Instructions  7

 V 03/2015

Supply the cables on both sides with new designations Supply the cables on both sides with new designations
and replace the RT60/61 plugs by new RT70 plugs (for and replace the RT60/61 plugs by new RT70 plugs (for
details, see Table 1) details, see Table 1)

Insert the mains cable and the grounding wire through

Insert the remaining cables through the protecting
the protecting sleeve (211-053747) on the bottom of
sleeve (220-100015)
the cover

Connect the mains cable to the main switch Q1 to T1-

Put all plugs into the appropriate connectors on the
T2-T3. Cut the grounding wire to the same length as
RT70 - for details see Table 1, connections according
the phases and connect it to the ground terminal. Fix
to wiring diagram (additional)
the red cover on the main switch

8  Conversion Instructions Retrofit RT61-RT70 - P140smart

 V 03/2015

Connect the heating cable to the contactor K20 to T1-

Fix the RT70 Control system to the housing
T2-T3 and the grounding wire to the ground terminal.
(6 screws M4x5)
Fasten the connected cables with cable ties

Install the side panels left and right. Put the tempera-
ture control unit into operation

NOTE

After finishing the conversion of the control system, the rotation direction of the
pump must be checked at the first start of the temperature control unit!

Retrofit RT61-RT70 - P140smart Conversion Instructions  9

 V 03/2015

Options conversion instructions

Option MP1000 / MP1005

Install the MP1000 / MP1005 Option circuit board on Install the MP1000 Option bezel on the rear wall and
the RT70 Control system connect the plug to the circuit board

Install the MP1005 Option bezel on the rear wall and

connect the plug to the circuit board

Option MP1001

Install the MP1001 Option circuit board on the RT70 Connect the plug cable to the circuit board (according
Control system to wiring diagram)

10  Conversion Instructions Retrofit RT61-RT70 - P140smart

 V 03/2015

Option MP1002

Install the MP1002 Option circuit board on the RT70 Connect the plug cable to the circuit board (according
Control system to wiring diagram)

Option MP1003

Install the MP1003 Option circuit board on the RT70 Connect the flow rate meter cable to the circuit board
Control system (according to wiring diagram)

Option MP1004

Install the MP1002 Option circuit board on the RT70 Connect the plug cable to the circuit board (according
Control system to wiring diagram)

Retrofit RT61-RT70 - P140smart Conversion Instructions  11

 V 03/2015

Install the MP1003 Option circuit board on the RT70 Connect the plug cable to the circuit board (according
Control system to wiring diagram)

Option MP1006

Connect the patch cable to the circuit board (according Connect the patch cable to the Profibus board (accord-
to wiring diagram) ing to wiring diagram)

Remove the existing Profibus interface, install the new Connect the Profibus interface connection cable in the
Profibus interface on the rear wall an connect it inside of the unit

12  Conversion Instructions Retrofit RT61-RT70 - P140smart

 V 03/2015

HINWEIS

After finishing the conversion of the control system, the rotation direction of the
pump must be checked at the first start of the temperature control unit!

Retrofit Kit RT61 to RT70 (Parts lists)

Table 1 (Cables and Designations)

Cable Plug-no.
Item Connection
designation (RT70)
Transformer T5 X15-T5 203-100011 RT70-X15
Pump motor M10 X14-M10 203-100007 RT70-X14
Safety thermostat F5 X7-F5 203-100016 RT70-X7
Solenoid valve coil Y2 (Refill) X10-Y2 203-100015 RT70-X10
Solenoid valve coil Y6 (Cooling) X12-Y6 203-100015 RT70-X12
Solenoid valve coil Y8 (Pressure
X9-Y8 203-100015 RT70-X9
release)
Temperature sensor Sn1 X1-B1 203-100000 RT70-X1
Level switch S3 X3-S3 203-100000 RT70-X3
Contactor K20
Heating none no plug (T1-T2-T3)
Terminal PE
Contactor Q1
Mains cable none no plug (T1-T2-T3)
Terminal PE

Retrofit RT61-RT70 - P140smart Conversion Instructions  13

 V 03/2015

Parts list
Numb. Designation Item-No.
Solenoid valve coil Set with cable for P140smart07 RT70
1 pc. 350-100202
(for contents, see Assembly)
1 pc. Assembly Transformer, 100 VA, 400 V/1x230 V 180-100026
Assembly Transformer, 100 VA, 200-600 V/2x115 V
1 pc. 180-100027
(if not 400 V, instead of 180-100026)
Wire yellow/green, 1.5 m², L=450 mm
1 pc. 191-100120
(KS M4/End sleeve 8 mm)
Wire yellow/green, 1.5 m², L=600 mm
1 pc. 191-100121
(KS M4/End sleeve 8 mm)
RT70 Control System, complete with Main switch yel-
1 pc. 178-100001
low/red
Assembly Safety thermostat cable
1 pc. 193-100087
150-100011, L=110 cm/labelled
Connector Push-In 4-pin, T1-T2-T3-PE (RT70/RT100,
1 pc. 203-100007
Pump)
2 pcs. Connector Push-In 2-pin, 1-2 (RT70/RT100, Level/PT100) 203-100000
1 pc. Control system cover EVZ, RT70 178-100010
1 pc. Intermediate plate ST RT61 - RT70, RAL7016 178-100009
1 pc. Protecting sleeve Ø 41x100 220-100015
1 pc. Protecting sleeve SNAP M32 EPDM 211-053747
5 pcs. Cable tie 4.6x300 221-100004

14  Conversion Instructions Retrofit RT61-RT70 - P140smart

 V 03/2015

Numb. Designation Item-No.

5 pcs. Cable tie 3.5x140 221-054311
5 pcs. Cable tie 2.5x100 221-054310
2 pcs. Wire label SFC 0, labelled „X3-S3“ 222-100000
2 pcs. Wire label SFC 0, labelled „X1-B1“ 222-100000
2 pcs. Wire label SFC 3, labelled „X14-M10“ 222-100004
4 pcs. Countersunk screw Torx, M4x16 330-069784
1 pc. Hexagon socket screw, M5x60 330-069176
1 pc. Washer, M5 332-069433
6 pcs. Screw Torx, M4x5 (RT70 Front fixation) 330-069344
1 pc. Screw Torx, M4x8 (Grounding) 330-069713
1 pc. Washer, M4 332-100003
1 pc. Serrated washer, M4 (Grounding) 332-069483
1 pc. Logo plate P140smart, self-adhesive 420-100067
4 Stck. Cylinder screw Torx, self-cutting, M3x6 330-069800
1 Stck. Interface plate seal, IP54 340-100055
1 Stck. Profibus option cover 382-100047
1 pc. Control system Retrofit instructions P140smart RT61-RT70 ----
1 pc. Programming instructions RT70 ----

Solenoid valve Set - coils with cables

P140smart07 RT70
(Assembly 350-100202)

Numb. Designation Item-No.

Solenoid valve coil 230 V 50/60 Hz, 4 Watt, type A
1 pc. 350-100196
(Danfoss)
2 pcs. Solenoid valve coil 230 V 50 Hz, 9 Watt, type A (Danfoss) 350-100063
Valve plug type A silicone, shorten to 1300 mm
3 pcs. 1. End valve plug, type A 350-100102
2. End 100 mm without coating, cable end sleeve 0.5 mm²
3 pcs. Multi-pin connector 3-pin, 1-2-PE (RT70/RT100) 203-100015
1 pc. Wire label SFC 3, labelled „X10-Y2“ 222-100004
1 pc. Wire label SFC 3, labelled „X9-Y8“ 222-100004
1 pc. Wire label SFC 3, labelled „X12-Y6“ 222-100004

Retrofit RT61-RT70 - P140smart Conversion Instructions  15

 V 03/2015

Transformer wired with plug for RT70 (400 V)

(Assembly 180-100026)

Numb. Designation Item-No.

1 pc. Transformer, 100 VA, 400 V/1x230 V 180-100022
1 pc. Connector Push-In 6-pin L1|L2|PE|N|N|L 203-100011
Wire jumper N-PE, 0.75 mm², green/yellow, both ends with
1 pc. 191-100123
cable end sleeves 8 mm (Plug 203-100011)
1 pc. Wire label SFC 3, labelled „X15-T5“ 222-100004

Transformer wired with plug for RT70 (480 V)

(Assembly 180-100027)

Numb. Designation Item-No.

1 pc. Transformer, 100 VA, 480 V/1x230 V 180-100024
1 pc. Connector Push-In 6-pin L1|L2|PE|N|N|L 203-100011
Wire jumper N-PE, 0.75 mm², green/yellow, both ends with
1 pc. 191-100123
cable end sleeves 8 mm (Plug 203-100011)
2 pcs. Wire label SFC 3, labelled „X15-T5“ 222-100004
1 pc. Shrink hose RNF3000 (7 cm) 220-054337
1 pc. Shrink hose RNF3000 (20 cm) 220-054335
1 pc. Shrink hose RNF3000 (4 cm) 220-054336

16  Conversion Instructions Retrofit RT61-RT70 - P140smart

 V 03/2015

Safety thermostat cable

(Assembly 193-100083)

Numb. Designation Item-No.

1 pc. Multi-pin connector 4-pin, 1-2-3-4 (Thermostat) 203-100016
1 pc. Safety thermostat cable P140Smart/150Smart 193-100083

Option - MP1000
Numb. Designation Item-No.
1 pc. RT70 Universal Interface option 178-100004
1 pc. RT70 cable, 20 mA CL, L=1600 mm (X51 X52) 178-100015
4 pcs. Hexagonal spacer (RT70 Options) 331-100017
2 pcs. Cylinder screw Torx, self-cutting, M3x6 330-069800
1 pc. Interface plate seal, IP54 340-100055

Option - MP1001
Numb. Designation Item-No.
1 pc. RT70 Analog Option 178-100003
4 pcs. Hexagonal spacer (RT70 Options) 331-100017

Option - MP1002
Numb. Designation Item-No.
1 pc. RT70 Digital Option with relay 178-100002
4 pcs. Hexagonal spacer (RT70 Options) 331-100017

Option - MP1003
Numb. Designation Item-No.
1 pc. RT70 Sn2/Pressure/Flow rate option 178-100005
4 pcs. Hexagonal spacer (RT70 Options) 331-100017

Option - MP1004
Numb. Designation Item-No.
1 pc. RT70 Digital Option with relay 178-100002
1 pc. RT70 Sn2/Pressure/Flow rate option 178-100005
8 pcs. Hexagonal spacer (RT70 Options) 331-100017

Retrofit RT61-RT70 - P140smart Conversion Instructions  17

 V 03/2015

Option - MP1005
Numb. Designation Item-No.
1 pc. RT70 Universal Interface option 178-100004
1 pc. RT70 Universal Interface cable, L=1600mm 178-100014
4 Stck. Hexagonal spacer (RT70 Options) 331-100017
2 pcs. Cylinder screw Torx, self-cutting, M3x6 330-069800
1 pc. Interface plate seal, IP54 340-100055

Option - MP1006
Numb. Designation Item-No.
1 pc. RT70 RJ45 Adapter, Option Profibus 178-100008
1 pc. RT100/RT70 Profibus X65 176-100012
1 pc. RT70 Profibus Interface X65 extension cable 178-100016
4 pcs. Hexagonal spacer (RT70 Options) 331-100017
6 pcs. Cylinder screw Torx, self-cutting, M3x6 330-069800
2 pcs. Interface plate seal, IP54 340-100055

18  Conversion Instructions Retrofit RT61-RT70 - P140smart

 V 03/2015

Retrofit RT61-RT70 - P140smart Conversion Instructions  19

 V 03/2015

20  Conversion Instructions Retrofit RT61-RT70 - P140smart

 V 03/2015

Retrofit RT61-RT70 - P140smart Conversion Instructions  21

 V 03/2015

22  Conversion Instructions Retrofit RT61-RT70 - P140smart