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Manual of instructions TT-188

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5. Installation

Before starting the unit the electrical and hydraulic connections have to be installed. The installation of
the unit has to be done in the order of the following chapters. After the proper installation the unit is
ready to use.

DANGER

The temperature control unit must only be operated with water. Do not use
solvents or other explosive substances such as petrol, toluene, etc. in the
water.

CAUTION

When starting the unit without the prescribed connections the unit can be
damaged.

Water quality

– do not use water with chlorine addition.

NOTE

Observe the General Safety Information!

Before installing corresponding chapter of the manual should be read!

5.1.

Installing and dimensions of the temperature control unit

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Summary of Contents for TT-188

Page 1: ...Manual of instruction Temperature control unit TT 188 with Temperature Controller MP 888 04 2018 Version 06 ...

Page 2: ... 1 5 Using this Documentation 7 1 5 1 Additional Documentation 7 2 Overview temperature control unit 8 2 1 Front view 8 2 2 Rear view 10 2 3 Identification of residual risk on the unit 11 3 Technical Specifications 12 4 EU Declaration of conformity 13 5 Installation 14 5 1 Installing and dimensions of the temperature control unit 14 5 2 Connections 15 5 3 Power supply 16 5 4 Initial operation Fill...

Page 3: ...l 27 7 5 Temperature deviation control 27 7 6 Acoustic indication of faults horn 28 8 Maintenance 29 8 1 Inspection 29 8 2 Cleaning 29 8 3 Repair 29 9 Out of service transport 30 10 Disposal 30 11 Failure corrective action 31 12 Components and spare parts 33 12 1 Overview components and spare parts 33 12 2 List components and spare parts 35 Attachments Electrical diagram MP 888 EL 000012 ...

Page 4: ...lication This general safety information is generally valid for all temperature control units from TOOL TEMP 1 3 Intended Use The TOOL TEMP temperature control unit is built according to the current state of the art and the generally accepted principles of safety engineering The temperature control unit is intended solely for the normal use for heating and or cooling of injection and die casting m...

Page 5: ...ed If the temperature control unit is used in combination with products by other manufacturers their notices and safety regulations must also be obeyed 1 4 2 Process Monitoring In plants in which a temperature control system malfunction leads to endangerment of the operating personnel or destruction of the plant an independent process monitor that shuts down the plant reliably must be used 1 4 3 I...

Page 6: ...r 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 alw...

Page 7: ...ting instructions should be kept near the corresponding unit and always be accessible to operating and maintenance personnel 1 5 1 Additional Documentation The included documentation is completely correct for the basic versions of units Components that do not belong to the basic hardware are noted as extra equipment The corresponding additional documents are included with special versions of devic...

Page 8: ...Manual of instructions TT 188 8 37 2 Overview temperature control unit 2 1 Front view ...

Page 9: ...p motor has responded unit switches off 7 Mould drainage green Cooling the unit below 60 C Switch the unit off by the green ON OFF Switch Changeover switch for pump operation mode to position Vacuum Press the green button approx 5 sec 8 Change over switch for pump operation mode red Pressure for pressure operation normal operation Vacuum for leakstopper operation and mould drainage 9 Level control...

Page 10: ...BSP female thread 16 Manometer pump pressure 17 To mould BSP female thread 18 Cooling water inlet with water filter BSP female thread 19 Cooling water outlet BSP male thread 20 Manually refill with overflow 1 BSP male thread 21 Overflow 22 Drainage BSP female thread ...

Page 11: ...re control unit following pictograms are mounted to identify the residual risk DANGER The temperature control unit must be rendered currentless 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: ... max 4 5 bar max 75 l min Vacuum mode vacuum max 8mH2O Cooling capacity approx 35 kW at 90 C Filling amount approx 6 litres Connections to mould BSP female thread from mould BSP female thread cooling water inlet with water filter BSP female thread cooling water outlet BSP male thread Dimensions L W H 670 260 650 mm Weight approx 55 kg empty Category of protection IP 44 Electric In separate switch ...

Page 13: ...Manual of instructions TT 188 13 37 4 EU Declaration of conformity ...

Page 14: ...DANGER The temperature control unit must only be operated with water Do not use solvents or other explosive substances such as petrol toluene etc in the water CAUTION When starting the unit without the prescribed connections the unit can be damaged Water quality do not use water with chlorine addition NOTE Observe the General Safety Information Before installing corresponding chapter of the manual...

Page 15: ...tion Repair leaks immediately Observe local laws during set up CAUTION The temperature control unit may be pressurised Only when the pressure gauge shows 0 bar disconnect hoses 5 2 Connections 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 s...

Page 16: ...nary fuse according to the information in the electrical diagram Observe local laws during set up Power cable Phases black black black L1 L2 L3 Earth yellow green PE WARNING The unit may only be connected by a competent electrician Ensure easy access to means for cutting the power supply mains adapter or mains connection the access must be positioned in a distance of 0 6 and 1 9m above the access ...

Page 17: ...y the sense of rotation of the motor by switching it on shortly The sense of rotation must be clockwise as shown by the arrow If the sense of rotation is anti clockwise invert two phases on the electrical connection This has to be done by a qualified electrician 5 4 2 Display of pump pressure The pump pressure is shown on the manometer WARNING The temperature control unit may be pressurised Only w...

Page 18: ... Caution residual water temperature control unit consumer hoses water in the oil can lead to dangerous operating conditions The temperature control unit can be overflow Risk of injury by escaping oil water mixture 5 5 1 Close the automatic filling The automatic filling must be closed Close the ball valve behind the solenoid valve Pos 32 P 33 5 5 2 Change stage switching according to the electrical...

Page 19: ...Down arrow Reduction of set value 6 Program button 7 Flow control Flow control active LED green Alarm flow control LED red 8 LED Cooling Lights up when the cooling relay is active 9 LED Heating Lights up when the heating relay is active 10 LED Sensor failure Lights up when the sensor is intermitted 11 LED Temperature deviation control Lights up when the difference between set and actual temperatur...

Page 20: ...compensation 3 Flow control encoder signal 4 Connection external set point 26 28 Analog input 4 20mA 27 28 Analog input 0 10 V 5 Connection actual value output 29 30 Analog output 0 10V 6 Power supply 1 230V AC 2 Neutral 3 PE 7 Flow control alarm 8 Temperature monitoring temperature deviation alarm 9 Cooling command 10 Heating command ...

Page 21: ...s active only when it reaches the set temperature A set point changes the start up lock again P3 Flow measurement function 0 Manual 1 Automatic If the automatic flow measurement is enabled after 20s the measured flow is stored and monitoring is enabled The green LED lights up P4 Alarm value flow 8 0 L 0 1 999 9 L P3 set to manual Alarm is triggered when the set value is exceeded P20 Temperature un...

Page 22: ...s min 3 US gallons min 4 Imperial gallons min Flow unit to display 1 US gallon 3 785 litres 1 Imperial gallon 4 546 litres P60 Flow measurement Calibration table 0 Manual 1 Small units 1 2 Medium units 3 Large units 4 Reserved 5 Small units 2 6 Reserve Selection of the calibration table for flow measurement Navigation in the controller Enter into the controller and navigate to the different parame...

Page 23: ...ive only when it reaches the set temperature A set point changes the start up lock again P3 Flow measurement function 0 Manual 1 Automatic If the automatic flow measurement is enabled after 20s the measured flow is stored and monitoring is enabled The green LED lights up P4 Alarm value flow 8 0 L 0 1 999 9 L P3 set to manual Alarm is triggered when the set value is fallen short of P20 Temperature ...

Page 24: ...S gallons min 4 Imperial gallons min Flow unit to display 1 US gallon 3 785 litres 1 Imperial gallon 4 546 litres P60 Flow measurement Calibration table 0 Manual 1 Small units 1 2 Medium units 3 Large units 4 Reserved 5 Small units 2 6 Reserve Selection of the calibration table for flow measurement Navigation in the controller Enter into the controller and navigate to the different parameter To en...

Page 25: ...his data the alarm value for the minimal flow will be calculated E g at 10 l min the alarm value is at approx 30 7 litres at 40 l min at approx 20 32 litres The control of the flow is now active and is visualized after a few seconds by the green LED in the flow control button As soon as the flow has fallen under the alarm value the alarm is indicated by the red LED in the flow control button The a...

Page 26: ...be drained completely and stored in a dry place at 10 40 C while not in use 6 7 Leak prevention operation If the change over switch for the pump operation mode is in position pressure the pump is operating under pressure and in position vacuum as a leak prevention device The pump now sucks heating medium through the mould the temperature control will not be changed CAUTION Leak prevention operatio...

Page 27: ...dication lamp lights and the unit refills automatically until the level is reached the yellow indication lamp will switch off If not enough water is in the unit the pump switches off the yellow indication lamp lights and the horn sounds The unit fills automatically and the pump will switch on automatically as soon as the level is high enough 7 4 Flow control The electronic flow control measures th...

Page 28: ...rrected If the level falls below the minimum level in the system the thermal relay of the motor or the mechanical safety thermostat shuts off the unit stops and the horn rings with an intermittent sound Flow control or temperature deviation control let the horn rings with intermittent sound The temperature control unit still operate The alarm can be switched off by pressing the flow control button...

Page 29: ...d recommendations of the oil manufacturer 8 1 Inspection Before starting the unit has to be checked the general condition of the temperature control unit the electrical connection and the tightness of the connections and hoses including the consumer 8 2 Cleaning The temperature control unit has to be checked and cleaned periodically Before maintenance the unit has to be disconnected from the power...

Page 30: ...bursting of pipes or other components at low temperatures can be reduced The unit must be transported or stored in the operating position CAUTION Drain the unit to avoid freezing damages Avoid compressed air blowing out with compressed air can damage the unit Never transport the unit lying Lying transport will destroy the unit 10 Disposal The temperature control unit must be drained completely and...

Page 31: ...ches on again Red lamp temperature monitoring lights and the unit switches off Horn sounds Maximum temperature of the unit is reached thermostat has respond Try to establish the cause maybe too low adjustment of the thermostat Check the controller Check the contactors Control lamp Temperature deviation control lights Horn sounds Temperature deviation between required and actual temperature is too ...

Page 32: ... and repair it Replace defective parts The required temperature will not be reached heating lamp on the controller lights Solenoid valve of the water cooling system not closed or defective Maybe to big consumer Heating defective Contactor of heating defective Clean the solenoid valve check signal to valve and function repair or replace it Contact the supplier Measure resistance of heating Replace ...

Page 33: ...Manual of instructions TT 188 33 37 12 Components and spare parts 12 1 Overview components and spare parts ...

Page 34: ...Manual of instructions TT 188 34 37 ...

Page 35: ...r small Packing of 10 pieces 7 Gf0101200 F 10 Capillary pipe thermostat 80 C 370 C 8 Gf0100001 F 15 Level switch for level control Unit off 9 Gf0100001 F 15 2 Level switch for level control Auto filling 10 Gl0400500 Gl0400610 F 23 F 47 Automatic cutout 20A 3 poles Automatic cutout 40A 3 poles 200 240V 50 60Hz 11 Gl0200005 Gl0200006 F 27 2 Fuse 6 3A 6 3 x 32 mm Fuse clip 6 3A WK 10mm2 F27 200 240V ...

Page 36: ...tt Heating 3000 Watt Heating 3000 Watt Heating connection clip Seal for heating 3 x 380 415 V 50 Hz 3 x 200 230 V 50 60 Hz 3 x 440 480 V 60 Hz 3 x 575 600 V 60 Hz 2 pieces with shrinkdown plastic tubing 25 Gk0300700 S 1 H 1 Switch ON OFF unit green 26 Gk0300600 S 2 H 2 S 3 H 3 Double switch green heating 27 Gk0300701 S 5 H 5 Switch ON OFF green horn 28 Gk0200100 Gk0200200 S 7 Switch VAC pressure d...

Page 37: ...4 De0701600 De0701201 Manometer 1 bis 6 bar Fixing clips for manometer Ø 40 mm Ø 40 mm 70 x 35 x 2 mm 35 De0100400 Water filter R3 8 with mesh bottom cooling water inlet 36 Wd0100000 Float Complete with rod and 4 set collars 37 Ca2000500 Screw cap refill pipe 1 38 De0300200 Drain angle 90 for tank drain 39 Db0500200 Seal for tank cover length 900 mm 40 Dc0100000 Steering rollers Ø 50 mm central fi...

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