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MOULDPRO TCU-200, User Manualline

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[3] 

User Guidelines 

– TCU-200 

 

12-06-2019 

Vers. 003 

 

Contents 

1 

Indhold 

2

 

GENERAL SAFETY INFORMATION

 ............................................................................................................................... 5

 

2.1

 

S

AFETY 

S

YMBOLS

 ................................................................................................................................................................ 5

 

2.2

 

R

ANGE OF 

A

PPLICATION

 ...................................................................................................................................................... 5

 

2.3

 

I

NTENDED 

U

SE

 ..................................................................................................................................................................... 5

 

2.4

 

S

AFETY 

I

NFORMATION

 .......................................................................................................................................................... 6

 

2.4.1

 

General Information

 .................................................................................................................................................. 6

 

2.4.2

 

Process Monitoring

 ................................................................................................................................................... 6

 

2.4.3

 

Information for Operators and Personnel

 .............................................................................................................. 6

 

2.4.4

 

Changing the Parameterisation

 .............................................................................................................................. 7

 

2.4.5

 

Residual risks

 ............................................................................................................................................................ 7

 

2.5

 

U

SING THIS 

D

OCUMENTATION

.............................................................................................................................................. 8

 

2.5.1

 

Additional Documentation

 ........................................................................................................................................ 8

 

3

 

OVERVIEW TEMPERATURE CONTROL UNIT

 ............................................................................................................. 9

 

3.1

 

F

RONT VIEW

 .......................................................................................................................................................................... 9

 

3.2

 

R

EAR VIEW

.......................................................................................................................................................................... 10

 

3.3

 

I

DENTIFICATION OF RESIDUAL RISK ON THE UNIT

 ............................................................................................................... 11

 

4

 

TECHNICAL SPECIFICATIONS

 ..................................................................................................................................... 12

 

5

 

INSTALLATION

 ................................................................................................................................................................ 13

 

5.1

 

I

NSTALLING AND DIMENSIONS OF THE TEMPERATURE CONTROL UNIT

 .............................................................................. 13

 

5.2

 

C

ONNECTIONS

 .................................................................................................................................................................... 14

 

5.3

 

P

OWER SUPPLY

 .................................................................................................................................................................. 15

 

5.4

 

I

NITIAL OPERATION 

-

 

F

ILLING

 .............................................................................................................................................. 16

 

5.5

 

P

UMP ROTATION CHECK

 ..................................................................................................................................................... 16

 

5.6

 

D

ISPLAY OF PUMP PRESSURE

 ............................................................................................................................................ 16

 

6

 

OPERATIONS

................................................................................................................................................................... 16

 

6.1

 

O

VERVIEW

 .......................................................................................................................................................................... 17

 

LEDS PROCESS INFORMATION AND START  PUMP.

 ...................................................................................................... 18

 

7

 

DISPLAY AND PARAMETER SETTINGS

 ..................................................................................................................... 19

 

8

 

ALARM DISPLAY

 ............................................................................................................................................................ 21

 

9

 

STANDARD PCB SETTINGS.

 ........................................................................................................................................ 22

 

9.1

 

A

DVANCED 

P

ARAMETER SETTINGS

 .................................................................................................................................... 24

 

10

 

LEAK MONITORING

 ........................................................................................................................................................ 30

 

10.1

 

D

EACTIVATE 

L

EAK MONITORING

 ........................................................................................................................................ 31

 

11

 

CONFIGURABLE RELAYS

 ............................................................................................................................................. 32

 

12

 

DESCRIPTION PCB CARD CONNECTORS

 ................................................................................................................. 34

 

13

 

MAINTENANCE

 ................................................................................................................................................................ 34

 

13.1

 

I

NSPECTION

 ........................................................................................................................................................................ 35

 

13.2

 

C

LEANING

 ........................................................................................................................................................................... 35

 

Summary of Contents for TCU-200

Page 1: ...elines TCU 200 12 06 2019 Vers 003 _________________________________________________________________ User Guideline Temperature control unit TCU 200 _________________________________________________________________ ...

Page 2: ...ation is prohibited by law To the best of our knowledge and belief the information contained in this documentation is true and correct as of the date of publication The contents however do not constitute a binding obligation on the part of MOULDPRO APS and are subject to change without notice Copyright 2019 MOULDPRO APS ...

Page 3: ...2 REAR VIEW 10 3 3 IDENTIFICATION OF RESIDUAL RISK ON THE UNIT 11 4 TECHNICAL SPECIFICATIONS 12 5 INSTALLATION 13 5 1 INSTALLING AND DIMENSIONS OF THE TEMPERATURE CONTROL UNIT 13 5 2 CONNECTIONS 14 5 3 POWER SUPPLY 15 5 4 INITIAL OPERATION FILLING 16 5 5 PUMP ROTATION CHECK 16 5 6 DISPLAY OF PUMP PRESSURE 16 6 OPERATIONS 16 6 1 OVERVIEW 17 LEDS PROCESS INFORMATION AND START PUMP 18 7 DISPLAY AND P...

Page 4: ...200 12 06 2019 Vers 003 13 3 REPAIR 35 14 OUT OF SERVICE TRANSPORT 36 15 DISPOSAL 36 16 WATER QUALITY 36 17 ELECTRICAL DIAGRAM 38 18 WATER CIRCUIT DIAGRAM 39 19 CONTROL CIRCUIT DIAGRAM 40 19 COMPONENTS AND SPARE PART LIST 41 ...

Page 5: ... moderate personal injury NOTE Denotes general information useful advice to users and work recommendations which however do not have any influence on the safety and health of personnel 2 2 Range of Application This general safety information is generally valid for all temperature control units from MOULDPRO 2 3 Intended Use The MOULDPRO temperature control unit is build according to the current st...

Page 6: ...en 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 turning 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 ...

Page 7: ...ed or repaired immediately Only original MOULDPRO 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 Press the main switch on the temperature control unit and unplug mains plug Danger due to electrical shock Repair leaks in the temperature control circuit device ...

Page 8: ...is documentation helps to avoid danger minimize repair costs and downtime and increase the dependability and service life of the unit system NOTE The operating instructions should be kept near the corresponding unit and always be accessible to operating and maintenance personnel 2 5 1 Additional Documentation The included documentation is completely correct for the basic versions of units Componen...

Page 9: ...s TCU 200 12 06 2019 Vers 003 3 Overview temperature control unit 3 1 Front view 1 Temperature Controller 2 Pump ON OFF TCU 90 and TCU 90L pump direction 3 Main switch 4 Cover Electric section 5 Cover Hydraulic section ...

Page 10: ... 10 User Guidelines TCU 200 12 06 2019 Vers 003 3 2 Rear view ...

Page 11: ...erature control unit following pictograms are mounted to identify the residual risk DANGER The temperature control unit must be rendered current less before it is opened Turn off the main switch on the temperature control unit and disconnect the power cord from the wall socket Danger due to electrical shock ...

Page 12: ...0 kW Pressure mode max 3 5 bar max 60 l min Cooling capacity approx 20 kW at 200 C Filling amount approx 20 liters Connections to mould 3 4 BSP female thread from mould 3 4 BSP female thread cooling water inlet with water filter 3 4 BSP female thread cooling water outlet 1 2 BSP male thread Dimensions L W H 610 330 690 mm Weight approx 50 kg empty Category of protection IP 44 Electric In separate ...

Page 13: ...nformation Before installing corresponding chapter of the manual should be read 5 1 Installing and dimensions of the temperature control unit The temperature control unit is designed for an ambient temperature of 10 up to 40 C Sufficient ventilation must be ensured during set up The distance between the temperature control unit and other facilities must be at least 10cm The ventilation opening mus...

Page 14: ...nections Before installing the connecting lines between temperature control unit and consumer must be subjected following inspections Verify that channels on the consumers are unobstructed Remove fouling e g remove shaving in the lines Rust and lime deposits must be removed because the greatly interfere with the heat exchange between consumer and heat transfer medium and increase the pressure drop...

Page 15: ...ed outlet WARNING To ensure the operational safety is essential to use pressure and temperature resistant hoses Pressure resistant up to 20 bar temperature resistant up to 200 C For reason of safety the cooling must always be connected NOTE Process water filter on the return line reduces contamination in the unit which can cause a unit failure pollution of the solenoid valve Mark and take down the...

Page 16: ...rn sound The unit can stop and start until the system is completely filled If only the yellow lamp is lit the unit is running and no horn sounds the automatic refilling is running 5 5 Pump rotation check At the rear side of the unit the direction of rotation can be checked The unit has been connected to the main supply hoses must be mounted and heat transfer medium has been filled Identify the sen...

Page 17: ... 17 User Guidelines TCU 200 12 06 2019 Vers 003 6 1 Overview 1 Display of set value 2 Display of actual value 3 Function keys 4 Led Keys 5 Pump On Off Pump direction on TCU 90 and TCU 90L ...

Page 18: ... 06 2019 Vers 003 LEDs process information and start pump 1 2 3 4 5 6 1 Heating led 2 Cooling led 3 Overload TCU pump led 4 Low fluid level led 5 Pump pressure function 6 Pump depression function 7 5 6 Only model TCU 90 and TCU 90L ...

Page 19: ... 19 User Guidelines TCU 200 12 06 2019 Vers 003 7 Display and Parameter settings Zone A Zone B ...

Page 20: ...Press to save changes To enter the programming SETS hold the key and then hold simultaneously the key Then in A zone of the display will show ST 0 To go to the desired ST press Once in the desired ST press We visualize the first parameter in the ST To change the parameter press to change the parameter value press the keys or to change the digit press To save changes press ...

Page 21: ...ion Disable heating and pump Restarts activation leak monitoring Connection between flow meter and PCB card is broken Disables heating Maximum drive pump User adjustable Disable heating and pump Restarts activation leak monitoring Connection between process pressure transducer and PCB card is broken Maximum temperature difference between process and setpoint User adjustable Connection between retu...

Page 22: ...etpoint value Low water level for more than 10 seconds continuously in the TCU unit tank Disable heating and pump Restarts TCU unit 9 Standard PCB settings Depending on TCU model and activated options pressing the key will be shown on the display in B area Leak monitoring Pressure pump outlet Return pressure process Process flow in return Return temperature Return process thermocouple broken Other...

Page 23: ...T POINT function is activated by a signal 4 20mA or external 0 10Vdc in B area will show in cycles of 3 seconds If TCU unit is working through RS485 or 0 20mA communications in B area will show in cycles of 3 seconds If we had more machines linked second TCU unit will show in cycles of 3 seconds ...

Page 24: ...elay type heating Not modifiable by the user SSR Enables heating through solid state relays Cont Activates the heating through the contactor KM3 Heating ramp Do not change without consulting the manufacturer This parameter is activated when entering the PID control In cycles 10 seconds if the temperature has not exceeded this value in degrees will activate again heating If on the contrary it has e...

Page 25: ...d when entering the PID control In cycles of 8 seconds if the temperature has not exceeded this value it will activate again cooling If on the contrary it has exceeded cooling is not activated until the next cycle which will return him to look ST 2 Type of thermocouple Do not change without consulting the manufacturer We choose if the thermocouple is J type TC 1 or Pt1000 Pt1 Flow meter activation...

Page 26: ...emote set point signal SrC A 4 20mA or SrC u 0 10Vdc Full scale remote set point It is the value in degrees of the maximum temperature of the remote set point Minimum scale remote set point It is the value in degrees of the mínimum temperature of the remote set point IMPORTANT If TCU unit has selected the entry Sr SC as SrC u input 0 10Vdc the minimum range may not be the value in degrees 0Vdc Max...

Page 27: ...bars liters minute depending on the configuration of the previous parameter r1 Not configurable by the user Relay 2 configuration Configurable as OFF Disabled tP1 Output temperature to the process tP2 Return temperature process P1 Pump pressure P2 Return process pressure FM1 Return process flow AL General alarm Value in degrees bars liters minute depending on the configuration of the previous para...

Page 28: ... 5 seconds With value 1 the time to enter the programming SETS is 15 seconds ST 7 Enabling communications Activate or communications On OFF Address assigned to the TCU unit The first TCU unit will be address 1 if more linked machines the following would be address 2 and so on Transmission speed 0 2400bauds 1 4800 baud and 2 9600 baud Parity bit 0 no parity 1 non parity i 2 even parity ...

Page 29: ...evel detection Water filling valve retard disconnection time Value in seconds NO CHANGE WITHOUT CONSULT THE MANUFACTURER Extra time no level detection Water filling valve retard connection time Value in seconds NO CHANGE WITHOUT CONSULT THE MANUFACTURER Display activation drive pump Activate or not the on off display Alarm output drive pump Value in bars Initial scale transducer drive pump Value i...

Page 30: ... process works as follows Water oil TCU units When process start letter L zone B will flash When the TCU pump is more than 2 minutes running in continuous this will mean that there is no demand for water oil in the process the letter L will stop flashing From this moment leak monitoring is enabled Leak detection Once monitoring is enabled in water process if we demand for water more than once in a...

Page 31: ...c filling in area A the message displayed will be Will activate the audible alarm by turning off the pump and heating temperature control unit Once the user has disconnected the pump switch and confirmed the alarm by pressing Fix the leakage problem fixed the leakage connect again the pump switch TCU unit will restart automatically 10 1 Deactivate Leak monitoring If the user disables leak monitori...

Page 32: ... mold temperature has reached the value he wants to start the process Through external thermocouple located in the mold provided by the user to the TCU unit will control the temperature using the r3 relay When the temperature exceeds the set value the relay r3 provide the user a signal it allow to start the application If the mold have no thermocouple could be done as follows We will control the t...

Page 33: ...t withstand high pressures and need early detection to prevent possible damage We will control the pump discharge pressure to the entrance of the user process by r2 with a value example 3 bar If this pressure is higher than the preset in r2 this will provide signal to the user which could perform a bypass between inlet and outlet of the mold and an alarm ...

Page 34: ...tenance Inspection and maintenance have to be done by instructed staff competent The following maintenance intervals may be required subject to use and environment Water filter clean replace every month Pump motor blow out the fan every 6 months Hoses and pipes check tightness every 6 months ...

Page 35: ...o be checked the general condition of the temperature control unit the electrical connection and the tightness of the connections and hoses including the consumer 13 2 Cleaning The temperature control unit has to be checked and cleaned periodically Before maintenance the unit has to be disconnected from the power supply 13 3 Repair Established defects must be repaired To guarantee safety the unit ...

Page 36: ...wing out with compressed air can damage the unit Never transport the unit lying Lying transport will destroy the unit 15 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 MOULDPRO for disposal 16 Water quality Depending on the unit to be cooled or heat balanced certain requireme...

Page 37: ... Systems with stainless steel Systems with aluminium PH value min 7 0 max 8 0 Temperatures below 5 C o When employing chillers at temperatures below 5 C an anti freeze medium with corrosion inhibitor must be added Temperatures over 120 C o At water temperatures over 120 C glycol may not be used If the recommended water qualities are not met the components of the unit will be damaged due to corrosi...

Page 38: ... 38 User Guidelines TCU 200 12 06 2019 Vers 003 17 Electrical diagram ...

Page 39: ... 39 User Guidelines TCU 200 12 06 2019 Vers 003 18 Water Circuit Diagram ...

Page 40: ... 40 User Guidelines TCU 200 12 06 2019 Vers 003 19 Control Circuit diagram ...

Page 41: ... 41 User Guidelines TCU 200 12 06 2019 Vers 003 20 Components and spare part list ...

Page 42: ... 42 User Guidelines TCU 200 12 06 2019 Vers 003 Change log Date of change Change Version 26 04 2019 layout 002 12 06 2019 Spare partslist 003 ...

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