Tool-Temp TT-180 Bedienungsanleitung

Manual

BA 1152e

EL 1634 d/e/f/it

07/2007

B-0670

Temperature control unit

TT-180

TOOL-TEMP AG Tel.: +41 (0)71 644 77 77

Industriestrasse 30 Fax: +41 (0)71 644 77 00

CH-8583 Sulgen E-Mail: [email protected]

Schweiz – Suisse – Switzerland Internet: www.tool-temp.ch

Manual TT-180 - 1 -

Contents page

1. Description..........................................................................................................................................2

2. Technical data.....................................................................................................................................2

3. Safety and use as agreed ...........................................................................................................3 - 4

4. Installation......................................................................................................................................4 - 7

4.1 Fluid connections ...................................................................................................................5

4.2 Power supply..........................................................................................................................5

4.3 Filling......................................................................................................................................6

4.4 Pump rotation check...............................................................................................................7

5. Heat transfer liquid............................................................................................................................7

5.1 Water......................................................................................................................................7

5.2 Heat transfer oil......................................................................................................................7

6. Operations...........................................................................................................................................8

6.1 Setting of the temperature......................................................................................................8

6.2 Change over of the heating power .........................................................................................8

7. Safety devices.....................................................................................................................................9

7.1 Pump......................................................................................................................................9

7.2 Heating...................................................................................................................................9

8. Monitoring devices.....................................................................................................................9 - 10

8.1 Level control...........................................................................................................................9

8.2 Temperature monitoring.......................................................................................................10

8.3 Indication of faults (audible alarm)........................................................................................10

9. Inspection and maintenance (according to DIN 31051)..................................................10 - 11

9.1 Inspection.............................................................................................................................10

9.2 Maintenance.........................................................................................................................11

10. Failure corrective action.........................................................................................................12 - 13

11. Control panel.....................................................................................................................................14

12. Views and dimensions (mm)..................................................................................................15 - 17

12.1 Rear view .............................................................................................................................15

12.2 Front view.............................................................................................................................15

12.3 Connecting dimensions........................................................................................................15

12.4 Inside view............................................................................................................................16

12.5 Inside view switch cabinet....................................................................................................17

13. Temperature controller MP-888.............................................................................................18 - 21

13.1 Programming MP-888: Temperature control units without flow control.........................19 - 21

14. Spare parts and pump spares...............................................................................................22 - 24

14.1 Spare parts....................................................................................................................22 - 23

14.2 Pump spares for pump type E..............................................................................................24

15. Change over water / oil operation ...............................................................................................25

16. Electrics ......................................................................................................................................26 - 28

Manual TT-180 - 2 -

1. Description

The temperature control unit TT-180 is constructed for water operation up to maximum +90°C,

respectively oil operation up to maximum +150°C. For permanent use over +130°C you should use

an other model.

The unit corresponds to the harmonized EU norms as EN 292 / EN 60204 as well as to the relevant

EU directives (see EU conformity declaration) and it is provided with the CE sign.

The TT-180 can be switched from 9 kW for water operation to 3 kW for operation with heat transfer oil.

(see chapter 6.5 and instructions in chapter 15).

serial equipment:

- self-optimizing temperature controller with digital display of the set and actual temperature. Display

in 1/10-° range. Switchable from °C to °F.

- automatic temperature monitoring. Deviation between effective and set temperature activates an alarm.

- switchable from 3 kW oil operation to 9 kW water operation

- heating switchable in stages at 9 kW water operation

- lime-free heat exchanger

- horn for fault messages

- automatic level control to prevent the unit from running dry

- mechanical safety thermostat and electronic temperature limiter installed in the controller

- autom. water refill or manual oil refill

- with main switch, automatic cutout, transformer and motor protection switch

- with castors

2. Technical data

Temperature range Up to +90°C with water / up to +150°C with oil

Temperature control self optimizing microprocessor controller MP-888

heating power water operation: 9 kW, switchable in stages 3/6/9 kW

oil operation: 3 kW

pump capacity connected load 0,75 kW

pressure mode max. 4,5 bar / max. 75 l/min.

suction mode - vacuum max. 8 mWS

cooling power approx. 18 kW at +90°C

filling amount approx. 6 litres

Connections heating medium R 1/2“ female thread

cooling water R 3/8“ male thread

dimensions in mm

(incl. castors)Length: 670

Width: 260

Height: 650

Weight empty ca. 55 kg

category of protection IP-44

Electric In separate switch cabinet, easily accessible from the front

Colour silver grey RAL 7001

heat exchanger low-maintenance

noise level (dBA) < 70 (distance 3 m)

Manual TT-180 - 3 -

3. Safety and use as agreed

The temperature control unit must not be used for other than the described purpose within the fixed

values for temperature and voltage for the temperature control of moulds. Any other use to which we

have not agreed to is strictly forbidden. The use of others than the prescribed heating mediums (water with

9 kW / heat transfer oil with 3 kW - see chapter 5) and/or the use of others than the admitted spare parts

can lead to dangerous operating states and is strictly forbidden. When the unit’s construction state is

changed the operating permission and the conformity declaration become invalid.

Important information in this manual is marked as follows:

remark:

helpful information

CAUTION!

RISKS WHICH CAN LEAD TO MATERIAL DAMAGE

DANGER!

RISKS WHICH CAN LEAD TO PERSONAL INJURY

The TT-180 is equipped with the following pictographs (according to DIN 4844) to mark the remaining

dangers (according to EN 1050) the following:

DANGER! VOLTAGE

DANGER! HOT SURFACE

Manual TT-180 - 4 -

DANGER!

- The temperature control unit must not be used in hazardous location.

- The temperature control unit must not be used in the open air (category of protection IP-44).

- The temperature control unit must not be transported in a horizontal position.

- With 9 kW heating power you are only allowed to use water as heat transfer liquid.

With 3 kW oil operation the admitted heat transfer oils or equivalent products have to be used.

WHEN USING UNSUITABLE HEAT TRANSFER OILS

THE UNIT CAN BE DAMAGED WHICH LEADS TO FIRE RISK

AND THEREFOR TO RISK OF INJURY.

4. Installation

Before starting the unit the external connections of the hydraulics and of the electric have to be mounted.

CAUTION!

WHEN STARTING THE UNIT WITHOUT THE PRESCRIBED

CONNECTIONS THE UNIT CAN BE DAMAGED.

CAUTION!

- THE UNIT HAS TO BE INSTALLED IN A SUITABLE LOCATION

ON EVEN GROUND.

- THE UNIT IS NOT PROTECTED AGAINST SPLASH WATER

AND IS NOT SUITABLE FOR USE IN HAZARDOUS LOCATION.

- THE UNIT MUST NOT BE USED IN THE OPEN AIR.

The starting of the unit has to be done in the order of this chapter.

After the proper starting the unit is ready for use.

Manual TT-180 - 5 -

4.1 Fluid connections

For the hoses of the heating medium circuit and cooling water the following minimum internal diameters

and hose qualities are recommended:

heating medium R 1/2“ female thread

internal hose diameter 13 mm

cooling water R 3/8“ male thread

internal hose diameter 10 mm

water filter at the cooling water inlet R 3/8“ female thread

The use of pressure and temperature resistant hoses is recommended for safety (pressure resistant up to

min. 10 bar). It is important to use hoses which are resistant to heat transfer liquids.

MARK AND TAKE DOWN THE MAXIMUM TEMPERATURE

FOR WHICH THE CONNECTIONS ARE SUITABLE.

Quick release couplings will give reduced flow.

If the recommended tube size cannot be connected to the mould, the connection at the mould should be

reduced and not the connection on the temperature control unit. In this way pressure drops can be avoided.

4.2 Power supply

Mains voltage and frequency according to the serial plate.

Pay attention to the local regulations during the installation of the unit.

CAUTION!

THE CONNECTION TO THE POWER SUPPLY HAS

TO BE DONE BY A COMPETENT ELECTRICIAN.

colours of cables:

phases black / black / black L1 / L2 / L3

earth yellow/green PE

max. power consumption: 10 kW

DANGER!

DO NOT CONNECT THE POWER SUPPLY UNTIL

THE HEATING MEDIUM HOSES ARE CONNECTED.

Manual TT-180 - 6 -

4.3 Filling

filling amount: approx. 6 litres

Automatic filling (only for water operation):

- The unit has to be connected hydraulically and electrically.

- The ball valve (behind the solenoid valve) of the automatic filling has to be open (see chapter 15).

- Switch the unit on.

- After switching on the unit the tank will be filled with water via the cooling connection to the correct level.

- Only when the system has reached the minimum level, the pump will start running.

- We recommend to add an anti-corrosion agent via the filling neck at the rear side of the unit.

CAUTION:

SHOULD THE WATER BE FILLED IN MANUALLY, IT HAS TO

BE CONSIDERED THAT NO WATER WITH CHLORIDE

ADDITIVES SHOUD BE USED. IT IS ALSO FORBIDDEN TO USE

SOLVENTS (FOR EXAMPLE PETROL, TOLUOL, NITRO

THINNER, ETC.)

Manual filling for oil operation:

- The unit has to be connected hydraulically and electrically.

DANGER!

WHEN OPERATING WITH OIL THE BALL VALVE OF THE

AUTOMATIC FILLING HAS TO BE CLOSED (SEE CHAPTER 15).

- Switch the unit on.

- If there is not enough oil in the unit (minimum level not reached) the unit does not start

and the two yellow lamps "level control" are lit.

- Fill oil via the filling neck at the rear side of the unit.

Use a funnel tube to prevent to oil from spilling.

Spilled oil has to be removed immediately and disposed appropriately.

- Fill in the oil till the upper level of the unit is reached and therefore both yellow lamps of the level

control are not lit anymore and the permanent sound of the alarm (in case that it is set to ON)

does not ring anymore. Only when the minimum level in the system is reached, the pump starts.

By pumping away the oil to the consumer the possibility exists that the above lamp

"level control" is lit again (pre-warning) and the horn starts ringing. In this case oil has to be filled in

till the upper level of the system has been reached again.

CAUTION!

- THE FILLING AMOUNT MUST NOT BE EXCEEDED TO

PROVIDE THE BIGGEST POSSIBLE EXPANSION AND

RECIRCULATING VOLUME.

- THE FILLING AMOUNT IS RELATED TO AN AMBIENT

TEMPERATURE OF APPROX. +20°C.

- OVERFLOWN OIL HAS TO BE REMOVED IMMEDIATELY

AND HAS TO BE DISPOSED AS PRESCRIBED BY LAW.

- NEVER LET ANY OIL COME INTO THE SEWAGE SYSTEM

OR SOIL.

Manual TT-180 - 7 -

4.4 Pump rotation check

As soon as the unit has been connected to the mains, hose connections have been mounted and the heat

transfer liquid has been added, the direction of the pump rotation must be checked. The direction of rotation

must be clockwise as shown by the arrow on the ventilation cover.

The direction of rotation can be determined by looking through the ventilation slots.

If the direction of rotation is anti-clockwise invert two phases on the electrical connection.

This has to be done by a competent electrician.

You can also, after the unit has been started, check on the rear side of the unit on the manometer if the

pump is running in the correct direction. If the manometer shows a positive pressure, the pump is running

correctly. If a negative pressure is indicated, two phases on the electrical connection have to be inverted.

This has to be done by a competent electrician.

5. Heat transfer liquid

The unit can be switched from 9 kW heating power for water operation to 3 kW heating power for oil

operation (see chapter 6.5 and change over instructions in chapter 15).

5.1 Water

With 9 kW heating power the unit is for use with water as heat transfer liquid.

The tank can be filled manually or automatically.

CAUTION!

DO NOT USE HEAT TRANSFER OILS OR HEAT TRANSFER

MEDIUM WTF-3 (RESP. POLYGLYCOL) WITH 9 KW HEATING

POWER BECAUSE OF TOO HIGH THERMAL LOAD (CRACKING

OF OIL OR DECOMPOSING OF WTF-3 (RESP. POLYGLYCOL)).

5.2 Heat transfer oil

When using the unit with 3 kW heating power it can be operated with mineral heat transfer oils such as

BP Transcal N, Mobiltherm 605, Shell Thermia Oil B etc. Heat transfer medium WTF-3 resp. polyglycol

can also be used. WTF-3 (resp. polyglykol) affects lacquers and colours, and therefore is not recommended

by TOOL-TEMP AG.

CAUTION!

TOOL-TEMP AG DOES NOT RECOMMEND WTF-3

(RESP. POLYGLYCOL) BECAUSE THIS LIQUID

CORRODES LACQUERS AND COLOURS.

The tank has to be filled manually.

DANGER!

THE USE OF UNSUITABLE OIL SORTS IS NOT PERMITTED

AND IS NOT REGARDED AS USE AS AGREED.

PARTICULALLY DANGEROUS AND THEREFOR PROHIBITED

IS THE USE OF INFLAMMABLE SUBSTANCES.

The used heat transfer oil has to be taken down in a check list. Particularly the maximum operating

temperature according to the specifications of the heat transfer oil manufacturer has to be taken down.

Manual TT-180 - 8 -

6. Operations

For the operating and display elements on the temperature control units see chapter 13 "temperature

controller MP-888 for temperature control units".

6.1 Setting of the temperature

The required temperature on the temperature controller can be adjusted by pressing the flashes

CAUTION!

PAY ATTENTION TO THE MAXIMUM ALLOWED

TEMPERATURES FOR THE USED HEAT TRANSFER

LIQUID AND HOSES.

The lamp in the green switches „heating I – II“ and the red diode in the controller indicate that the operation

mode is HEATING.

Likewise the operating mode COOLING is indicated by the green diode in the temperature controller.

The end user can choose himself if he likes to work with degree Celsius or degree Fahrenheit. When putting

into service the controller the temperature unit will be shown for a short moment.

See instructions „Programming: Temperature controller MP-888“ for details about function and setting

of the controller (see chapter 13).

6.2 Change over of the heating power

Only with a few modifications the unit can be switched over from 9 kW water operation to 3 kW oil operation

and inverse. For the instructions please see chapter 15.

DANGER!

WHEN OPERATING WITH OIL THE BALL VALVE OF THE

AUTOMATIC FILLING HAS TO BE CLOSED (SEE CHAPTER 15).

DANGER!

THE CHANGE FROM WATER TO OIL OPERATION HAS TO BE

DONE VERY CAREFULLY. THE UNIT AND THE PROCESS

MUST BE ABSOLUTELY FREE OF WATER. ONLY A FEW

DROPS OF WATER ARE ENOUGH TO LET THE UNIT EMPTY

BY EXPLOSION AT THE BOILING POINT OF THE WATER.

The change from oil to water operation on the other hand does not need any special measures.

Remaining oil in the water does not cause any problems.

Manual TT-180 - 9 -

7. Safety devices

7.1 Pump

The pump motor is fitted with an overload relay.

7.2 Heating

In the electronic controller the maximum temperature is limited at +150°C.

DANGER:

IT IS NOT ALLOWED TO ADJUST HIGHER TEMPERATURES

THAN 150°C. LOWER TEMPERATURES ARE ALLOWED;

SPECIALLY FOR WATER OPERATION WE RECOMMEND TO

ADJUST THE MAXIMUM VALUES TO 90 – 95°C (DEPENDING

ON THE LOCATION, HIGHT ABOVE SEE LEVEL, THAT HAS

INFLUENCES THE BOILING POINT OF THE WATER).

Exceeding this temperature the heaters switch off.

The temperature of +150°C can be adjusted according to the information sheet „Programming: Temperature

Controller MP-888“.

The mechanical safety thermostat is set to the maximum allowed temperature of approx. +155°C.

Exceeding this temperature the unit stops.

As soon as the temperature falls to approx. +140°C the heaters switch on automatically.

At water operation the maximum temperature on the controller has to be adjusted to +90°C. (Program step

no. 1). The mechanical safety thermostat can be adjusted to +95°C.

8. Monitoring devices

8.1 Level control

The temperature control unit is equipped with two level controls. The yellow lamp above is lit and the

horn (continuous sound) is activated in case that the level is too low.

During water operation the automatic water refill corrects the level. During oil operation oil has to be refilled

on the rear side of the unit.

The unit is still working. The alarm can be set OFF by pressing the horn switch .

If further 2 litres are missing, both lamps are lit. The horn rings with an intermittent sound and the

unit stops. The alarm can be set OFF by pressing the horn switch .

CAUTION WITH OIL OPERATION!

OVERFLOWN OIL HAS TO BE REMOVED IMMEDIATELY

AND HAS TO BE DISPOSED AS PRESCRIBED BY LAW.

NEVER LET ANY OIL COME INTO THE SEWAGE SYSTEM

OR SOIL.

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