Walther WTRB-24DC-3500, WTRB-230AC-6000, WTRB-24DC-6000, WTRB-24DC-12000 Operating Manual
Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: +49 (0)7274-7022-0 Telefax: +49 (0)7274-7022-91
http://www.walther-2000.de – info@walther-2000.de
Operating Manual
WALTHER Temperature Controller Bundle (WTRB)
Article Number: WTRB-x-x
IMPORTANT
Please read this manual carefully before the actual start of operation.
The device will only be used, maintained and repaired by personnel who are familiar with the
operating manual and also with the guiding regulations on workplace safety and accident prevention.
When used in or with other machines, the kit will not be operated if the machine does not
comply with the Machine Directive.
Rev. 1.0
WALTHER Temperature Controller Bundle WTRB-x-x
Page 2 of 42
Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: +49 (0)7274-7022-0 Telefax: +49 (0)7274-7022-91
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1 Table of Contents
1 Table of Contents ................................................................................................................... 2
2 General Information .............................................................................................................. 3
2.1 Scope of Delivery ................................................................................................................................... 3
2.2 Target Group of the Operating Manual .................................................................................................. 5
2.3 Contents of the Manual .......................................................................................................................... 5
2.4 List of Signs and Symbols ...................................................................................................................... 5
2.5 Warranty and Liability ............................................................................................................................. 5
2.6 Copyright ................................................................................................................................................ 5
3 Safety Information ................................................................................................................. 6
3.1 General Information ............................................................................................................................... 6
3.2 Basic Safety Instructions ........................................................................................................................ 6
3.3 Dangers from Using the Device ............................................................................................................. 6
3.4 Dangers from Residual Energy .............................................................................................................. 6
3.5 Correct Use ............................................................................................................................................ 7
3.6 Incorrect Use .......................................................................................................................................... 7
3.7 Personal Protective Equipment and Other Measures ............................................................................ 7
3.8 Required Qualification of Personnel....................................................................................................... 7
4 Transport ............................................................................................................................... 8
4.1 Packaging ............................................................................................................................................... 8
4.2 Transport ................................................................................................................................................ 8
4.3 Damages in Transport ............................................................................................................................ 8
4.4 Location of Set-up .................................................................................................................................. 8
5 Description of Product ............................................................................................................ 9
5.1 General Information ............................................................................................................................... 9
5.2 Electrical Installation / Start of Operation ............................................................................................. 11
5.3 Operation .............................................................................................................................................. 14
6 Technical Data / Installation Information ............................................................................. 16
6.1 Walther Temperature Controller WTR-x .............................................................................................. 16
6.2 Solid-state Relay WSSR-x-x ................................................................................................................ 22
7 Advanced Settings ............................................................................................................... 26
7.1 Concept of Levels................................................................................................................................. 26
7.2 Parameters ........................................................................................................................................... 28
7.3 Configuration (ConF) ............................................................................................................................ 29
7.4 Factory Configured Standard Parameters ........................................................................................... 37
8 Troubleshooting ................................................................................................................... 39
8.1 Error Messages .................................................................................................................................... 39
8.2 Self-Optimization .................................................................................................................................. 40
9 Service and Maintenance ..................................................................................................... 41
10 Spare Parts / Accessories .................................................................................................. 42
Rev. 1.0
WALTHER Temperature Controller Bundle WTRB-x-x
Page 3 of 42
Walther Systemtechnik GmbH – D 76726 Germersheim
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2 General Information
This operating manual is provided for a safe use and start of operation of our product series „Walther Temperature Controller Bundle (WTRB-x-x)“. The operating manual contains safety instructions for a smooth operation
as well as information on the function principle of the temperature controller. Above that, you will find information
and instructions for the mechanical and electrical installation. Please refer to Table 1 for an overview of all
available types and ordering numbers of the Walther Temperature Controller Bundles (WTRB).
Walther Temperature Controller Bundle (WTRB)
Ordering key
Version for 230 [VAC] heating
230AC
Solid-state Relay 230 [VAC] 6000 [mA]
6000
Version for 24 [VDC] heating
24DC
Solid-state Relay 24 [VDC] 3500 [mA]
3500
Solid-state Relay 24 [VDC] 6000 [mA]
6000
Solid-state Relay 24 [VDC] 12000 [mA]
12000
WTRB
- x
- x
Table 1: Ordering keys for the different versions of the Walther Temperature Controller Bundle (WTRB)
2.1 Scope of Delivery
The Walther Systemtechnik Temperature Controllers will be delivered as bundles, consisting of the temperature
controller itself and a solid-state relay (SSR) for top hat rail mounting. The scope of delivery varies depending
on the selected temperature controller bundle and is shown in the below figures:
Scope of Delivery for WTRB-24DC-3500
➀
Temp.Controller WTR-24DC
➁ Solid-state relay 24 [VDC] 3500 [mA] incl. mounting
base (WSSR-24DC-3500)
Scope of Delivery for WTRB-24DC-6000
➀
Temp.Controller WTR-24DC
➁ Solid-state relay 24 [VDC] 6000 [mA]
(WSSR-24DC-6000)
Rev. 1.0
WALTHER Temperature Controller Bundle WTRB-x-x
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Scope of Delivery for WTRB-24DC-12000
➀
Temp.Controller WTR-24DC
➁ Solid-state relay 24 [VDC] 12000 [mA]
(WSSR-24DC-12000)
Scope of Delivery for WTRB-230AC-6000
➀ Temp.Controller WTR-230AC
➁ Solid-state relay 230 [VAC] 6000 [mA]
(WSSR-230AC-6000)
Rev. 1.0
WALTHER Temperature Controller Bundle WTRB-x-x
Page 5 of 42
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2.2 Target Group of the Operating Manual
➢ Operating personnel
➢ Maintenance personnel
2.3 Contents of the Manual
This Operating Manual contains information on:
➢ Safety
➢ Correct use
➢ Operation
➢ Service, maintenance and troubleshooting
2.4 List of Signs and Symbols
Symbols are used to indicate dangerous situations and specific behavior. These symbols are also used in this
operating manual. All warning, danger and information symbols describe situations which can be harmful to
persons, material or environment if rules are not followed.
The operating manual uses the following signs and symbols for dangers:
WARNING
Signals a potentially dangerous situation.
Death or severe injuries can follow, if you do not avoid this situation.
CAUTION
Signals a potentially dangerous situation.
Slight or minor injuries can follow, if you do not avoid this situation. This sign is also used
where damage to property is possible.
IMPORTANT
Indicates tips for usage and other particularly useful information.
No dangerous situation.
2.5 Warranty and Liability
According to the conditions laid down by the German Engineering Federation (VDMA), Walther Systemtechnik
GmbH has a guarantee of 12 months under normal European operating conditions on its own parts (spare parts
are excluded); or according to the conditions of the manufacturer.
This guarantee can only be granted by Walther Systemtechnik GmbH, if:
• the user has thorough knowledge of the content of this operating manual;
• the user follows the instructions and notes contained in this operating manual;
• the user does not rebuild or make changes on parts of the device without prior consent of Walther
Systemtechnik GmbH.
2.6 Copyright
We reserve the copyright for this operating manual. This operating manual is exclusively designated for the
operator and his personnel.
➢ Any copying – also only in part – or processing, or distribution or other use is strictly prohibited.
Rev. 1.0
WALTHER Temperature Controller Bundle WTRB-x-x
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3 Safety Information
3.1 General Information
The construction of this device is according to the latest technology and is absolutely reliable. The individual
components as well as the complete device are continuously checked by our quality management team.
3.2 Basic Safety Instructions
Basic conditions for a safe handling and a failure-free operation of the device are:
Caution!!
• It is the customer’s responsibility that all relevant safety measures are followed.
• The device will only be used for the designated purpose.
• No changes will be made at the device. The customer carries the sole responsibility for
consequences resulting from failure to observe this guideline. Please contact Walther Systemtechnik GmbH for any desired modifications.
• Make sure that the device is always in a safe operational condition. Checks for proper
function or damages have to be performed by specialists on a regular basis. Dismounting
will only be made by authorized personnel and while using the operating manual. If requested, we will also offer trainings on the device in order to teach your personnel the
required knowledge.
• Disconnect the device from compressed air / grease supply for all maintenance tasks. All
lines and hoses have to be pressure-less.
• Check all lines, hoses and screwed joints regularly for leakages and apparent damages!
Repair damages immediately!
• Always make sure that the actual workstation and the device are clean and clearly arrange;
and this is routinely checked.
• Please observe the guiding rules and regulations for accident prevention at the workplace.
3.3 Dangers from Using the Device
The construction of this device and all assembly groups is according to the latest technology and is absolutely
reliable. However, there may be dangers for the user or third parties or other physical assets, if not used correctly.
Warning!! Use device only:
• for the designated purpose; and
• in a safe and operational condition.
• Immediately correct failures which can adversely affect safety and security!
3.4 Dangers from Residual Energy
Please instruct the operating personnel on the respective measures to be taken against the occurrence of mechanical, hydraulic, pneumatic and electric / electronic residual energies.
Rev. 1.0
WALTHER Temperature Controller Bundle WTRB-x-x
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3.5 Correct Use
CAUTION
The device will only be used under the designated operating conditions as outlined in the offer
and the confirmation of order. It was exclusively designed for certain media in accordance with
the detailed description. Any different or further use will be regarded as incorrect. The manufacturer cannot be made liable for damages resulting from incorrect use.
Correct use also includes:
• Observing and following all instructions of this manual;
• Performing the inspection and routine maintenance tasks.
3.6 Incorrect Use
• Operating the device with insufficient knowledge about the operation, maintenance and care of the
device.
• Making changes, extensions or alterations on the device that may hamper its safety without the prior
consent of Walther Systemtechnik GmbH.
• Operating the device with defective safety installations or not properly attached or malfunctioning
safety devices.
• Using unsuitable materials.
• Handling the device while energized.
• Processing aggressive media (e.g. acids, alkaline solutions, detergents, chemicals, etc.) or media which
have not been approved in writing by the manufacturer.
• Making changes in the software of the controls
3.7 Personal Protective Equipment and Other Measures
• The operator company is responsible for providing the required personal protective gear.
• All safety devices and installations should be checked at regular intervals.
3.8 Required Qualification of Personnel
Only trained and instructed personnel may conduct work on the equipment.
The responsibilities of the personnel for assembly work, operation, repair work or maintenance work must be
clearly assigned to individuals!
Persons in training may work with the equipment under supervision of an experienced person only.
Personnel
Task
Instructed personnel
Personnel with technical qualification
Specialist
Supervisor
Packaging, transport
X - - - Commissioning
X X - Operation
X - Troubleshooting, general
X X - Troubleshooting, mechanical
- X - - Troubleshooting, electrical
- - X - Setting up
- X - - Maintenance
- X - - Repair
- X X
-
Taking out of service, storage,
disposal
- X X
-
Rev. 1.0
WALTHER Temperature Controller Bundle WTRB-x-x
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4 Transport
4.1 Packaging
The device will be prepared by Walther Systemtechnik GmbH for a transport to the first destination.
The type of packaging depends on the individual mode of shipping. If not separately contracted, the packaging
is in accordance with the rules and regulations of Walther Systemtechnik GmbH. This rule is in accordance with
the Federal Association for Packaging HPE.
The packing unit will not be exposed to any additional strain. Packaging and contents will be protected against
any kind of humidity. The temperature for transport and storage will strictly range between –20°C and + 40°C.
4.2 Transport
The actual transport of the device and its individual parts requires special care in order to prevent damages from
external forceful impact or careless on- and off-loading. Depending on the mode of transportation, suitable
transport and load securing has to be selected. The device will be aligned and leveled by appropriate fastening
elements.
4.3 Damages in Transport
The following will be observed when the receiving checks reveal damages in transport:
• Contact the carrier (carrier, train etc.)
• Write a protocol of damages
• Contact the supplier
4.4 Location of Set-up
• All legal requirements for the mounting site should be clarified and fulfilled.
• Prior to installation of the equipment, the condition of the floor and the size of the surrounding space
should be checked to ensure safety of operation for both personnel and equipment. The installation must
be such that continuous operation at a high safety level is ensured.
• The installation of the equipment as well as commissioning or storage of the equipment must be conducted by specialists that are trained and made familiar with the equipment only.
• The equipment is designed for use in areas which are protected from climatic conditions.
• Operation or storage of the equipment in an aggressive or moist environment or outdoors may lead to
corrosion or other damage for which Walther Systemtechnik GmbH will not assume liability.
• All exposed parts and lines must be mounted as such that no injuries or damage can occur
• The minimum allowed space around the device will be closely observed.
Rev. 1.0
WALTHER Temperature Controller Bundle WTRB-x-x
Page 9 of 42
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5 Description of Product
5.1 General Information
Walther Temperature Controller Bundles (WTRB) are available for all heating plates and heating hoses from
Walther Systemtechnik GmbH. Based upon the selected heating technology product, Table 2 is your reference
guide for choosing the matching temperature controller bundle; the individual bundle contains a suitable temperature controller (WTR) and the adapted solid-state relay (WSSR). Please observe the following instructions
when using the Walther Temperature Controller Bundles (WTRB):
• The device is not suitable for installing in explosion-prone areas.
• Make sure that you follow the regulations of the DIN VDE 0100 "Construction of Low-Voltage Systems",
respectively the guiding state regulations (e.g. based upon the IEC 60364) when selecting the wiring
material, or during the installation, or for the electrical connection of the device.
• For maximum load, the lines have to be heat-resistant up to 80 °C.
• Only a trained and qualified technician will take care of the electrical connection.
• The device was designed for installation in switch cabinets or systems. The customer fuse protection
must not exceed 20 A. For all service / repair work, the device has to be completely disconnected from
current.
• Make sure that the load circuit will be protected for the maximum relay current; this will prevent a welding
of the output relay in case of a short circuit.
• The electromagnetic compatibility is accordance with standards and regulations mentioned under ‘tech-
nical data‘.
• Make sure that the lines for input, output and supply are physically separated and will not be laid paral-
lelly.
• Lines for sensors and interfaces will be twisted and shielded. Do not carry out near current-carrying
components or lines. Make sure that the shielding is grounded on one side.
• Do not connect other or additional users to the terminal plugs.
IMPORTANT
The WTR-x Temperature Controllers come with a standard configuration which matches most
of the heating elements of Walther Systemtechnik. The following chapters of this operating
manual refer to this standard configuration.
Rev. 1.0
WALTHER Temperature Controller Bundle WTRB-x-x
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Product
Art.- No.
[V]
[A]
[W]
Temperature Cont. Bundle
Heating plates 24 [VDC]
HZP-x, etc.
24
1,0
25
WTRB-24DC-3500
Heating hoses 24 [VDC]
979524.001
24
2,5
60
WTRB-24DC-3500
979524.002
24
3,8
90
WTRB-24DC-6000
979524.003
24
1,9
45
WTRB-24DC-3500
979524.004
24
2,1
50
WTRB-24DC-3500
979524.007
24
7,5
180
WTRB-24DC-12000
979524.008
24
11,3
270
WTRB-24DC-12000
979524.009
24
5,0
120
WTRB-24DC-6000
979524.001M
24
2,5
60
WTRB-24DC-3500
979524.002M
24
3,8
90
WTRB-24DC-6000
979524.003M
24
1,9
45
WTRB-24DC-3500
979524.004M
24
2,1
50
WTRB-24DC-3500
979524.007M
24
7,5
180
WTRB-24DC-12000
979524.008M
24
11,3
270
WTRB-24DC-12000
979524.011M
24
3,2
76
WTRB-24DC-3500
979524.012M
24
5,6
135
WTRB-24DC-6000
979524.013M
24
5,6
135
WTRB-24DC-6000
Heating hoses 230 [VAC]
979524.102M
230
1,6
360
WTRB-230AC-6000
979524.103M
230
2,2
500
WTRB-230AC-6000
979524.104M
230
3,0
700
WTRB-230AC-6000
979524.100M
230
3,0
700
WTRB-230AC-6000
Heating pipes
979524.200
24
2,5
59
WTRB-24DC-3500
979524.201
24
2,5
59
WTRB-24DC-3500
Table 2: Reference guide for determining the correct Walther-Temperature Controller Bundle, based upon the selected heating technology
product.
Rev. 1.0
WALTHER Temperature Controller Bundle WTRB-x-x
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5.2 Electrical Installation / Start of Operation
The Walther Temperature Controllers WTR-x have inlets and outlets, as listed in Table 3. Please refer to Figure
1 for the numbering of the connections. Please refer to model WTR-24DC or WTR-230AC for the voltage supply
at the marked pins (L+ / L- resp. L1 / N).
Pins 10 and 8 were configured as analog inputs for a PT100 2-wire resistance thermometer. The alarm outlets
for insufficient or excess temperature errors are integrated as make contacts at the pins 4 and 5, resp. 6 and 7.
The solid-state relay WSSR-x-x will be connected at the pins 13 and 14 of the logic output.
IMPORTANT
In order to also detect sensor errors and cable breaks at the alarm outputs, the make-contact
relays are permanently locked within the valid temperature range. If the preset temperature is
exceeded or fallen below, the contact will be interrupted (see also chapter 5.3.2 Limit Monitoring ).
Input
Symbol
Pin
Voltage supply
WTR-24DC: 24V DC
WTR-230AC: 230V AC
L1 (L+)
N (L-)
Analog input
Resistance thermometer PT100 2-wire
10
8
Output
Relay output (make contact) 1
Alarm output – error insufficient temperature
4
5
Relay outlet (make contact) 2
Alarm output - excess temperature error
6
7
Logic output (DC 0/12V)
Solid-state relay
13
14
Table 3: Overview of the inputs and outputs for the WTR-x and the pin assignment
Figure 1: View of back with terminal assignment for the WTR-24DC and WTR-230AC
AC/DC
Ux
Rev. 1.0
WALTHER Temperature Controller Bundle WTRB-x-x
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5.2.1 Circuit Example
Figure 2 below shows you an example of connecting a 24 [VDC] heating device (e.g. a heating plate HZP-x)
to the components of a Walther Temperature Controller Bundle „WTRB-24DC-3500“.
CAUTION
This connection example only refers to the 24 [VDC] versions of the WTRB-x-x. Connecting
the 230 [VAC] models will not be similar. Pay special attention to the intended use and the
connection of the alarm outputs.
WTRB-24DC-3500
Figure 2: Sample connection for a WTRB-24DC-3500.
IMPORTANT
The Walther Systemtechnik heating elements come with a status LED which indicates the
heating operation. Pay close attention to a correct polarity of the heating elements in order to
guarantee a proper function.
Rev. 1.0
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5.2.2 Circuit Diagram
Figure 3: Circuit Diagram WTRB-24DC-3500
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