MOTEMP S 90 WL

TempLine
MOTEMP
S 90 WL
Temperature
Control Units
Operating Manual
CE
05 / 2005 312A-00.0.EN V0.0
07 / 02 - 1 -

MOTEMP S 90 WL
Copyright
© 2005 Motan GmbH, D-88316 Isny im Allgäu
This operating manual is copyright; all rights reserved. This operating manual may only be
reproduced, even in part, with the approval of Motan GmbH only. Anyone violating this provision may
be required to pay damages and may be subject to criminal penalties.
The technical information and operation instructions in the operating and maintenance manual apply
to the most recent delivery version of the dry air generator.
Manufacturer's address
Motan GmbH Telephone: +49 (0) 7562 / 76-0
Max-Eyth-Weg 42 Fax: +49 (0) 7562 / 76-111
D-88316 Isny im Allgäu motan.ger.s@motan.de
Germany
http://www.motan.com
2
05 / 2005

MOTEMP S 90 WL
2.6 Switching on
2.6.1 Operating and display elements
“Page up” for queries and programming (separate RT60 Operating Instructions).
“Page down” for queries and programming ( separate RT60 Operating Instructions).
Up, increase value. Set-point input, queries and programming.
Down, decrease value. Set-point input, queries and programming.
ON/OFF key with LED.
Leak-stop mode key with LED.
Suction mode key with LED.
Alarm reset key with LED.
1 Display field for actual value at temperature
sensor and outlet setting value S1
2 Display field for set-point value (SP)
and setting values
3 LED for display in °C
4 LED for display in °F
5 Heating LED
6 Cooling LED
1
5
6
3
4
2
Fig. 1: Operating and display elements
8
05 / 2005

MOTEMP S 90 WL
2.6.2 Switching on
After checking the consumer, connecting the hoses and establishing the electrical connections,
proceed as follows:
Initial set-up / filling the thermal oil
1 Open the vent valve at the consumer as well as the shut-off valve (when present).
2 Actuate the unit’s main switch. Once the unit has been switched on, the RT60 control system will
run a functional test for approximately 3 seconds. During this test, four dots will appear in each of
the two display fields. Once the test has been successfully completed, the dots will disappear,
indicating that the RT60 is ready for operation.
“FILL” will appear in the upper display field and “Err” in the lower. The acoustic group interrupt is
activated; it can be reset by pressing the ALARM RESET key. The displays will alternate
between “OFF” and “FILL” “Err”.
3 Press the ON/OFF key. The displays will now alternate between
“set-point”, “Actual value”,and “FILL” “Err”. Should a different
message appear, see Section 3.1 and separate RT60 Operating
lnstructions.
4 Water will fill automatically. The unit can also be filled via the
manual fillingport situated on the tank lid (1, Fig. 2,)
1
5 Press the ALARM RESET key. Enter the desired set-point value
using the keys
6 To set other values, please refer to the RT60 Operating Instructions
Fig. 2: Filling port
7 Check the temperature control circuit (unit, hoses, consumer, etc.)
for leakage
8 Close the consumer vent valve once water flows out of it regularly.
Switching on after initial set-up
1 Open consumer vent valve as well as shut-off valve (when present).
2 Actuate the unit’s main switch. Once the unit has been switched on, the RT60 control system
will run a functional test for approximately 3 seconds. During this test, four dots will appear in
each of the two display fields. Once the test has been successfully completed, the dots will
disappear, indicating that the RT60 is ready for operation.
1 “OFF” will appear in the upper display field.
Actuate the ON/OFF key.
The set-point temperature, SP, will appear in the lower display field and the actual temperature
of the internal sensor, S1, in the upper display field.
For other possible messages, please see Section 2.8 and the RT Operating Instructions.
2 Enter the desired set-point value using the keys. To set other values, please refer to the
RT60 Operating Instructions.
3 Check the temperature control circuit for leakage.
4 Once water flows out of it regularly, close the consumer vent valve.
Any component in contact with hot water.
05 / 2005 9

MOTEMP S 90 WL
2.7 Operating modes
– Pressure mode Normal operation. Heat transfer medium is forced through the consumer.
– Leak-stop mode Heat transfer medium is moved through the consumer by means of suction.
Reduced pump capacity.
– Suction Evacuation of the heat transfer fluid from the consumer by means of suction.
mportant: Note maximum expansion volume ( Technical data).
2.7.1 Leak-stop mode and evacuation of the consumer by means of suction
The heat transfer fluid is vacuumed through the consumer by reversing the pump’s direction of
rotation.
2.7.1.1 Leak-stop mode
With the unit in normal mode or switched off, the unit can be switched to leak-stop mode by pressing
the LEAK STOP key. During leak-stop mode, the LEAK STOP LED will be lit.
To interrupt leak-stop mode, press the ON/OFF key.
To return to normal operation, wait until the LEAK STOP LED has gone out, then press the ON/OFF
key once more.
2.7.1.2 Suction mode
To initiate the suction program, press the SUCTION key. The factory setting for suction mode is 60
seconds. The consumer connected to the unit will be evacuated. During suction mode, the
SUCTION LED will be lit.
To interrupt the suction program, press the ON/OFF key.
Suction is possible only when the temperature of the medium, S1, is below the programmed pump
run-out temperature, P.tE. (factory setting 80 °C). If the medium is above this temperature, the unit
will first cool to this value.
The suction program can also be run once after the unit has been switched off using the ON/OFF
key (display reads “OFF”).
To return to normal operation, wait until the SUCTION LED has gone out, then press the ON/OFF
key once more.
10
05 / 2005

MOTEMP S 90 WL
2.8 Operating displays
Switch-on phase. Automatic
functional test runs for approx. 3
sec. During the test, four dots
appear in each of the display
fields.
Control off
RT60 in standby mode.
Display of actual and set-point
values. Control on using the ON
key.
E.g.: Actual value 148.8 °C, Setpoint
value 150.0 °C.
Display during analogue
set-point input. The set
point can be retrieved
using the keys.
Display during interface
operation. The unit’s address is
shown in the lower display field.
E.g.: A.13. The set point can be
retrieved using the keys.
ON/OFF key. Continuous LED: Unit in operation. Blinking LED: Pump run-out active
(factory setting 80 °C).
LEAK STOP key. Leak-stop mode activated when LED lit.
SUCTION key. Suction program activated when LED lit (factory setting 60 sec.).
ALARM RESET key. Alarm activated when LED lit.
05 / 2005 11

MOTEMP S 90 WL
2.9 Menu overview
Actual value display
Control parameter selection
Sensor input settings
Group-interrupt relay settings
1 / 2 relay function
Unit configuration
Level settings
Special control-parameter settings
Operating hours, factory settings
Analogue inputs and outputs
Serial interface
Parameter code input
12
05 / 2005

MOTEMP S 90 WL
3 Malfunctions
Before correcting any malfunctions, switch off the unit, actuate the main
power switch and unplug the power cord.
3.1 Alarm messages
Messages alternate with the current display.
Display Cause Correction
Sensor break or short circuit. Cooling is
switched on
Check sensor connection.
Replace sensor
Level alarm
Refill heat-transfer fluid
Maximum pump current exceeded.
Electromechanical safety thermostat triggered.
Cooling is switched on
Check pump for corrosion.
Check motor
Reset safety thermostat
Temperature control unit’s selected maximum
set point exceeded at sensor S1
Cooling is switched on
Programmed upper limit value exceeded
Programmed lower limit value undershot
Incorrect phase sequence at mains input.
Appears after switching on using ON/OFF key
Missing phase at mains connection. Appears
after switching unit on
Option "analogue I/O": External set point outside
of set range
Short circuit at a 24 V output
Set-point/actual value for leak-stop mode too
high.
Switch two phases at mains input
Check incoming mains cable and
back-up fuse
Check scaling and values at
analogue input
Check valve solenoid, valve plug (if
present)
Correct set point.
05 / 2005 13

MOTEMP S 90 WL
Display Cause Correction
Electromechanical safety thermostat defective.
(If present: Temperature set at heater auxiliary
thermostat exceeded). Cooling is switched on.
Minimum pump current less than 0.2 A. Mains
input phase failed. Motor running on two phases.
Check incoming mains cable, backup
fuse and motor.
Analogue/digital converter defective.
Replace entire controller.
Microprocessor ROM defective.
Replace entire controller.
Microprocessor RAM defective.
Replace entire controller.
Incorrect calibration value for sensor, pump
current.
Replace entire controller.
Incorrect unit data in memory.
Appears for 3 sec. after dAtA Err. is
acknowledged. (Does not blink.)
Mains voltage below 340 V.
Reset by pressing ALARM RESET
key. Default settings will be loaded.
Try to reset the factory settings. If
this does not work, replace the entire
controller
Check mains supply.
No factory settings saved.
Replace entire controller.
Maintenance/Service due. (Does not blink.)
Factory setting 2000 h. Message disappears
when the unit is switched on via the ON/OFF
key, but reappears as soon as the unit is
switched off again.
After service 4 I, enter the number
of operating hours until next
maintenance/service.
Incorrect code entered.
Correct using
key.
14
05 / 2005

MOTEMP S 90 WL
3.2 Switching the unit off
3.2.1 By pressing the ON/OFF key
The switch-off program runs automatically as follows, in accordance with the temperature of the heat
transfer fluid:
1 All display messages and LEDs go blank, except for “OFF” in the upper display field. The pump
and control are switched off. RT60 remains powered, in standby mode.
2 The ON/OFF LED blinks while the pump continues to run. The unit cools until the heat transfer
fluid reaches the programmed pump-run out temperature, P.tE. (factory setting 80 °C).
3 The pump and control are switched off. The RT60 switches to standby mode.
4 All displays except for “OFF” go blank.
3.2.2 By previous evacuation of the consumer
See Section 2.7.
3.2.3 Changing the consumer. Shutting the unit down for longer than one month.
Switching the unit back on.
Before removing the connection hoses, ensure that the unit is switched off and that all circuits are
free of pressure.
The unit must be evacuated completely and stored in a dry location between 10 und 40 °C when not
in use.
Condensation can build up during storage; before switching the unit back on, proceed as described
in Sections 4.8 and 2.6.2.
Hot water escaping from the unit can cause injury!
Before disconnecting the hoses in the temperature control circuit, cool
the unit as needed (as determined by the outlet temperature) and then
switch off. Ensure that the pump has stopped running.
3.2.4 By previous evacuation of the consumer
See Section 2.7.
05 / 2005 15

MOTEMP S 90 WL
4 Maintenance
Switch off the unit before performing any maintenance procedures. Actuate
the main switch and unplug the main power cord.
4.1 Periodic checks and maintenance
To simplify maintenance procedures, the RT60 control system is equipped with a service-interval
display. We recommend entering the appropriate service interval (e.g. 2000 hours). For
programming, RT 60 Operating Instructions, messages “SerU.” and “duE”.
Please note that the following information is for a daily operating interval of 8 hours. When operating
with more than one shift, these checks and maintenance procedures shall be performed in
correspondingly shorter intervals. Defective components shall be repaired or replaced immediately.
• Checks and maintenance procedures shall be performed by qualified personnel.
• Maintenance procedures on the electrical equipment shall be performed by a qualified
electrician.
• Do not replace the RT60 control unit until the power cord has been unplugged.
4.2 Daily checks/maintenance
Check the temperature control circuit (unit, connecting hoses, consumer, etc.) for leaks. Repair any
leaks immediately.
4.3 Monthly checks/ maintenance
1 Check the inlet opening for the pump cooling for blockage. Clean unit from the inside out using
compressed air.
2 Clean the filter.
4.4 Semi-annual checks/maintenance
1 Level control functional test: Evacuate the unit via the drain plug, then switch on as described in
Section 2.6.2, under “Initial set-up”.
2 Check electrical equipment such as grounding wires, RT60 plug, firm connection of power and
other electrical cables, etc.
3 Disassemble solenoid valve: Check diaphragm for scaling and damage. Ensure that the core and
spring bolts move freely. Clean or replace components as needed.
4 Descale cooler.
16
05 / 2005

MOTEMP S 90 WL
4.5 Annual checks/maintenance
Always replace the oil after approximately 2000 hours of operation (approximately one year of
single-shift operation).
Please note that this value is provided as a guideline only. Actual operating conditions (temperature,
small consumer diameter, operation in primarily heating mode, etc.) may require more frequent
replacement. ( 4.6).
4.6 Replacing the heat transfer fluid
Replace the heat transfer fluid as follows:
1 Evacuate the unit and consumer completely via the corresponding drain
plugs (1, Fig. 3).
2 Depending upon the number of hours in operation, clean the unit and
consumer ( Cleaning).
3 Refill the unit ( 2.6.2 Initial set-up) and switch on.
1
Fig. 3: Drain plug
4.7 Cleaning
– Always cool the unit prior to cleaning.
– Switch off the unit, actuate the main power switch and unplug
the power cord.
– Due to danger of explosion, rinse the tank and cooler when using
solvents for cleaning; do not blow them out. Follow all manufacturer’s
regulations when using solvents.
– Solvents are flammable under certain conditions. Cleaning shall not be
performed in the vicinity of heat sources.
We recommend that the following cleaning procedures be performed each time the heat transfer
fluid is added or replaced. Suboptimal operating conditions require that the procedures listed below
be performed with greater frequency.
05 / 2005 17

MOTEMP S 90 WL
1 Evacuate the unit via the drain plugs (1, Fig. 3).
2 Clean the circuit filter (when present).
3 Disassemble the unit ( Repairs).
4 Remove the tank cover and clean tank.
5 Check the cooler for scaling; clean using MTA descaling agent as
NO
needed.
6 Clean heating elements
7 Level monitor: Remove and clean floater. Attention: Ensure that the
floater is reinstalled properly
(NO up, Fig. 4).
8 Disassemble solenoid valve: Check diaphragm for scaling and damage.
Fig. 4: Level switch
Ensure that the core and spring bolts move freely. Clean or replace
components as needed.
9 Check pump for corrosion; replace as needed.
10 We also recommend checking the consumer for lime deposits every time the unit
is cleaned as well as cleaning it with the aid of the descaling unit MTA. As previously
mentioned, rust and lime deposits drastically reduce the exchange of heat between
the consumer and circulating fluid.
Lime deposits also increase the pressure drop
within the consumer, so that the pump capacity of the unit may no longer be sufficient
to transfer the required amount of heat.
18
05 / 2005

MOTEMP S 90 WL
5 Repairs
Before performing any repairs:
– Cool the unit.
– Switch the unit off, actuate the main power switch and unplug the
power cord.
– Disconnect all hoses from the unit.
To simplify and expedite repairs, the unit can be disassembled as follows:
1 Remove side panel.
2 Detach the control unit from the housing by removing the four screws. Attention: First disconnect
all plugs.
3 Remove filter.
4 Detach the housing from the base by removing four screws and pull it off over the hydraulic
connections from the rear. The tank unit is now free.
5 Remove the pump and heater.
6 Remove the tank cover by removing four screws.
7 Remove the cooler and float switch.
Reassemble by reversing the above procedure.
Replacement parts and order forms Service.
05 / 2005 19

MOTEMP S 90 WL
6 Shipping
– Cool the unit.
– Switch the unit off, actuate the main power switch and unplug the
power cord.
– Disconnect all hoses from the unit.
Before shipping, evacuate the unit completely via the drain.
1 Switch the unit on: Actuate the main power switch and press the ON key.
2 Set the set-point value at the controller to 0 °C.
3 Ensure that the Cooling LED is lit, i.e. the cooling solenoid valve is open.
4 At low temperatures, to avoid damage due to freezing (cooling hose collapse), blow out with
compressed air at a maximum pressure of 6 bar.
5 Switch the unit off using the OFF/OFF key, actuate the main power switch and unplug the power
cord.
6 Do not tip the unit.
7 Use the original packing material.
8 Follow any instructions on the packing material.
7 Spare parts Spate
Use only genuine spare parts.
To ensure efficient ordering of replacement parts and to avoid errors, we need the details below.
1 Unit type
2 Serial number
3 Voltage
4 Frequency
5 Item number of the part
20
05 / 2005

MOTEMP S 90 WL
35 - M10
A1
A1 – F1-4
Q1
F5
E2
S3 – B1
38
9
30
72
67
73
66
70
43
60
54
41
75
Y6
Y2a
Y1
43
05 / 2005 21

MOTEMP S 90 WL
Pos. Item Part no.
9 Castor with wheel brake 460-100016
35 Pump with outlet pipe TP20 380-420V/50 Hz 322-100018
38 Tank 371-100012
Insulation 440-100012
41 Cooler 440-100000
43 Valve-block without coils 350-100016
54 Tank lid, Set of seals tank/pump/heater 340-100005
60 Filter cooling water 3/8" 352-100008
Strainer 352-100016
68 Deckel zu Ablass-Stutzen 300-070160
Dichtung ∅ 15x2 340-070302
75 Castor 460-100015
A1 Control unit with main switch 163-100005
E21 Heater with safety thermostat 311-100007
F5 Safety thermostat 150-10000
F1-3 Fuse FF 16 A H 143-100011
F4 Fuse T 1.6 A L 143-100010
S3 Level switch with sensor Pt100 154-100008
Y2a Automatic water refillmagnet control part 350-100022
Y6a Cooling magnet control part 350-100022
Y6d Diaphragm 350-100012
Y6a Draining magnet control part 350-100022
Y2c-6c
13c
Assembly with 3 coils 350-100023
22
05 / 2005