ICS Schneider Messtechnik TC46 User manual

Operating instructions
Betriebsanleitung
Mode d‘emploi
Manual de instrucciones
EN
FR
DE
ES
Hot runner thermocouple, model TC46
Heißkanal-Thermoelement, Typ TC46
Thermocouple pour systèmes d‘injection plastique à
canaux chauds, type TC46
Termopar para la industria de plásticos, modelo TC46
Hot runner thermocouple, model TC46

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14424709.02 01/2022 EN/DE/FR/ES
WIKA operating instructions model TC46
EN
FR
DE
ES
Operating instructions model TC46 Page 3 - 16
Betriebsanleitung Typ TC46 Seite 17 - 30
Mode d'emploi type TC46 Page 31 - 44
Manual de instrucciones modelo TC46 Página 45 - 57
© 05/2021 WIKA Alexander Wiegand SE & Co. KG
All rights reserved. / Alle Rechte vorbehalten.
WIKA®is a registered trademark in various countries.
WIKA®ist eine geschützte Marke in verschiedenen Ländern.
Prior to starting any work, read the operating instructions!
Keep for later use!
Vor Beginn aller Arbeiten Betriebsanleitung lesen!
Zum späteren Gebrauch aufbewahren!
Lire le mode d‘emploi avant de commencer toute opération !
A conserver pour une utilisation ultérieure !
¡Leer el manual de instrucciones antes de comenzar cualquier trabajo!
¡Guardar el manual para una eventual consulta!

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Contents
Contents
1. General information 4
2. Design and function 4
3. Safety 5
4. Transport, packaging and storage 8
5. Commissioning, operation 9
6. Faults 11
7. Maintenance, cleaning and recalibration 12
8. Dismounting, return and disposal 13
9. Specifications 15

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1. General information
■The hot runner thermocouple described in the operating instructions has been
manufactured using state-of-the-art technology. All components are subject to
stringent quality and environmental criteria during production. Our management
systems are certified to ISO 9001 and ISO 14001.
■These operating instructions contain important information on handling the
instrument. Working safely requires that all safety instructions and work instructions
are observed.
■Observe the relevant local accident prevention regulations and general safety
regulations for the instrument's range of use.
■The operating instructions are part of the product and must be kept in the immediate
vicinity of the instrument and readily accessible to skilled personnel at any time. Pass
the operating instructions onto the next operator or owner of the instrument.
■Skilled personnel must have carefully read and understood the operating instructions
prior to beginning any work.
■The general terms and conditions contained in the sales documentation shall apply.
■Subject to technical modifications.
■Further information:
2. Design and function
2.1 Description
The TC46 series thermocouples are custom-designed to suit plastic and rubber
moulding, hot runner and injection moulding applications where sheathed
thermocouples are required. An extensive range of elements, transition sleeves and
process connections can be individually selected for the appropriate application.
With the flexibility and small diameters in which they are available, model TC46
thermocouples can be used in locations that are not easily accessible.
Their unique design, the hot runner thermocouples are especially suited for applications
where the metal sensor tip is fitted directly into a drilled hole or press-fitted into a
grooved channel along the machined parts.
1. General information / 2. Design and function

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In the standard version the thermocouples are manufactured without process
connections. Fastening elements such as a union screw, a compression fitting, or a
spring-loaded or customer-specific hold down device can be attached and are available
as options.
2.2 Scope of delivery
Cross-check scope of delivery with delivery note.
3. Safety
3.1 Explanation of symbols
WARNING!
... indicates a potentially dangerous situation that can result in serious
injury or death, if not avoided.
CAUTION!
... indicates a potentially dangerous situation that can result in light injuries
or damage to property or the environment, if not avoided.
DANGER!
... identifies hazards caused by electrical power. Should the safety
instructions not be observed, there is a risk of serious or fatal injury.
WARNING!
... indicates a potentially dangerous situation that can result in burns,
caused by hot surfaces or liquids, if not avoided.
Information
... points out useful tips, recommendations and information for efficient
and trouble-free operation.
3.2 Intended use
The thermocouples described here are suitable for temperature measurement in the
plastics / rubber moulding, hot runner and injection moulding industry. Depending
on design, they can be mounted directly into the process or within a bored hole.The
design of the bored hole can be selected as desired, but the operational process data
(temperature, pressure, density and flow rate) must be taken into account.
The instrument is not permitted to be used in hazardous areas!
2. Design and function / 3. Safety

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Neither repairs nor structural modifications are permitted, and any would void the
guarantee and the respective certification. The manufacturer shall not be responsible for
constructional modifications after delivery of the instruments.
The instrument has been designed and built solely for the intended use described here,
and may only be used accordingly.
The technical specifications contained in these operating instructions and the related
data sheets must be observed. Improper handling or operation of the instrument
outside of its technical specifications requires the instrument to be taken out of service
immediately and inspected by an authorised WIKA service engineer.
The manufacturer shall not be liable for claims of any type based on operation contrary
to the intended use.
3.3 Improper use
WARNING!
Injuries through improper use
Improper use of the instrument can lead to hazardous situations and
injuries.
▶Refrain from unauthorised modifications to the instrument.
▶Do not use the instrument within hazardous areas.
▶Do not use the instrument with abrasive or viscous media.
Any use beyond or different to the intended use is considered as improper use.
Do not use this instrument in safety or emergency stop devices.
Electrical wires and transition are not to be in contact with hot surfaces (i. e. hot
manifolds).Where this cannot be achieved, a proper selection of electrical wire,
transition or high-temperature sleeve shall be used.
3.4 Responsibility of the operator
The instrument is used in the industrial sector.The operator is therefore responsible for
legal obligations regarding safety at work.
The safety instructions within these operating instructions, as well as the safety,
accident prevention and environmental protection regulations for the application area
must be maintained.
The operator is obliged to maintain the product label in a legible condition.
3. Safety

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To ensure safe working on the instrument, the operating company must ensure
■that suitable first-aid equipment is available and aid is provided whenever required.
■that the operating personnel are regularly instructed in all topics regarding work
safety, first aid and environmental protection and know the operating instructions and
in particular, the safety instructions contained therein.
■that the instrument is suitable for the particular application in accordance with its
intended use.
■that personal protective equipment is available.
3.5 Personnel qualification
WARNING!
Risk of injury should qualification be insufficient
Improper handling can result in considerable injury and damage to
property.
▶The activities described in these operating instructions may only be
carried out by skilled personnel who have the qualifications described
below.
Skilled electrical personnel
Skilled electrical personnel are understood to be personnel who, based on their
technical training, know-how and experience as well as their knowledge of country-
specific regulations, current standards and directives, are capable of carrying out work
on electrical systems and independently recognising and avoiding potential hazards.
The skilled electrical personnel have been specifically trained for the work environment
they are working in and know the relevant standards and regulations.The skilled
electrical personnel must comply with current legal accident prevention regulations.
Operating personnel
The personnel trained by the operator are understood to be personnel who, based
on their education, knowledge and experience, are capable of carrying out the work
described and independently recognising potential hazards.
Special operating conditions require further appropriate knowledge, e.g. of aggressive
media.
3.6 Personal protective equipment
The personal protective equipment is designed to protect the skilled personnel from
hazards that could impair their safety or health during work.When carrying out the
various tasks on and with the instrument, the skilled personnel must wear personal
protective equipment.
Follow the instructions displayed in the work area regarding personal protective
equipment! The requisite personal protective equipment must be provided by the
operating company.
3. Safety

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3.7 Labelling, safety marks
Product label (example)
Custom tag identification
Item description
Sensor type, wiring
Number of the production order
4. Transport, packaging and storage
4.1 Transport
Check the instrument for any damage that may have been caused by transport.
Obvious damage must be reported immediately.
CAUTION!
Damage through improper transport
With improper transport, a high level of damage to property can occur.
▶When unloading packed goods upon delivery as well as during
internal transport, proceed carefully and observe the symbols on the
packaging.
▶With internal transport, observe the instructions in chapter 4.2
“Packaging and storage”.
If the instrument is transported from a cold into a warm environment, the formation of
condensation may result in instrument malfunction. Before putting it back into operation,
wait for the instrument temperature and the room temperature to equalise.
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1
3
4
3. Safety / 4. Transport, packaging and storage

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4.2 Packaging and storage
Do not remove packaging until just before mounting.
Keep the packaging as it will provide optimum protection during transport (e.g. change
in installation site, sending for repair).
Permissible conditions at the place of storage:
■Storage temperature: 0 ... 70 °C
■Humidity: 35 ... 85 % relative humidity (no condensation)
Avoid exposure to the following factors:
■Direct sunlight or proximity to hot objects
■Mechanical vibration, mechanical shock (putting it down hard)
■Soot, vapour, dust and corrosive gases
■Hazardous environments, flammable atmospheres
Store the instrument in its original packaging in a location that fulfils the conditions
listed above. If the original packaging is not available, pack and store the instrument as
described below:
1. Place the instrument along with shock-absorbent material in the packaging.
2. If stored for a prolonged period of time (more than 30 days), place a bag containing a
desiccant inside the packaging.
5. Commissioning, operation
Only use original parts.
WARNING!
Physical injuries and damage to property and the environment
caused by hazardous media
Upon contact with hazardous media (e.g. oxygen, acetylene, flammable
or toxic substances), harmful media (e.g. corrosive, toxic, carcinogenic,
radioactive), and also with refrigeration plants and compressors, there is a
danger of physical injuries and damage to property and the environment.
Should a failure occur, aggressive media with extremely high temperature
and under high pressure or vacuum may be present at the instrument.
▶For these media, in addition to all standard regulations, the appropriate
existing codes or regulations must also be followed.
▶Wear the requisite protective equipment (see chapter 3.6 “Personal
protective equipment”).
4. Transport, packaging ... / 5. Commissioning, operation

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DANGER!
Danger to life caused by electric current
Upon contact with live parts, there is a direct danger to life.
▶The instrument may only be installed and mounted by skilled
personnel.
▶Operation using a defective power supply unit (e.g. short-circuit from
the mains voltage to the output voltage) can result in life-threatening
voltages at the instrument!
5.1 Mechanical mounting
The thermocouples described in this document are robust sensors but they must be
handled properly.
Precautions should be taken to ensure the MI cable is not kinked, torn or pinched.
When mounting/installing the MI cable section
■Use appropriate tools such as a bending apparatus or jig.
■When bending MI cable it cannot be bent within 25 mm [1 in] of the transition region.
■The maximum bend radius for MI cable is 2 times the outside diameter of the sensor
sheath.
■Do not bend, or re-bend past the ASTM recommendations. Multiple bends along the
same area of the MI cable may result in erroneous readings or immediate sensor
failure.
When mounting/installing the transition
■The plastic transition region should never be bent or used as an anchor or pivot point.
Using the transition as a pivot point may result in the transition breaking, resulting in
erroneous readings or immediate sensor failure.
■When bending MI cable or connecting cables it cannot be bent within 25 mm [1 in] of
the transition region.
■Transition must comply with the respective requirements in terms of stability and
temperature.
5.2 Electrical mounting
■Only connect cables and lines in an unpowered state!
■Fine-stranded leads must be finished with end splices.
■Cables used must comply with the respective requirements in terms of stability and
temperature, strain and mobility. Over-working the cable may cause fraying of the
wire.
■Connection cables must be run so that any mechanical damage is prevented.This
includes areas where wear may occur resulting in fraying of the wire.
■When bending connecting cables it cannot be bent within 25 mm [1 in] of the
transition region.
■Connecting cables are not to be in contact with hot surfaces (i. e. hot manifolds).
Where this cannot be achieved proper selection of electrical wire, transition or
high-temperature sleeve shall be used.
5. Commissioning, operation

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5. Commissioning, operation / 6. Faults
Colour coding of thermocouple cable
Thermocouple Standard Positive Negative
Type J IEC 60584 Black White
ASTM E230 White Red
DIN 43714 Red Blue
Type K IEC 60584 Green White
ASTM E230 Yellow Red
6. Faults
CAUTION!
Physical injuries and damage to property and the environment
If faults cannot be eliminated by means of the measures listed, the
instrument must be taken out of operation immediately.
▶Ensure that pressure or signal is no longer present and protect against
accidental commissioning.
▶Contact the manufacturer.
▶If a return is needed, please follow the instructions given in chapter 8.2
“Return”.
For contact details, please see chapter 1 “General information” or the back
page of the operating instructions.
Faults Causes Measures
No signal / cable break /
intermittent signal
Mechanical load too high or
overtemperature
Replace probe or measuring insert
with one of a suitable design
Display of measured
value jumps
Cable break in connecting
cable or loose contact
caused by mechanical
overload
Replace probe or measuring insert
with a suitable design, for example
equipped with a strain relief or a
thicker conductor cross-section

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7. Maintenance, cleaning and recalibration
7. Maintenance, cleaning and recalibration
For contact details, please see chapter 1 “General information” or the back
page of the operating instructions.
7.1 Maintenance
This instrument is maintenance-free.
Repairs must only be carried out by the manufacturer.
Only use original parts.
7.2 Cleaning
CAUTION!
Physical injuries and damage to property and the environment
Improper cleaning may lead to physical injuries and damage to property
and the environment. Residual media in the dismounted instrument can
result in a risk to personnel, the environment and equipment.
▶Carry out the cleaning process as described below.
1. Before cleaning, correctly disconnect the instrument from the process, switch it off
and disconnect it from the mains.
2. Use the requisite protective equipment.
3. Clean the instrument with a moist cloth.
Electrical connections must not come into contact with moisture!
CAUTION!
Damage to the instrument
Improper cleaning may lead to damage to the instrument!
▶Do not use any aggressive cleaning agents.
▶Do not use any hard or pointed objects for cleaning.
4. Wash or clean the dismounted instrument, in order to protect persons and the
environment from exposure to residual media.
7.3 Recalibration
DKD/DAkkS certificate - official certificates:
We recommend that the instrument is regularly recalibrated by the manufacturer, with
time intervals of approx. 12 months.

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8. Dismounting, return and disposal
8.1 Dismounting
WARNING!
Physical injuries and damage to property and the environment
through residual media
Upon contact with hazardous media (e.g. oxygen, acetylene, flammable
or toxic substances), harmful media (e.g. corrosive, toxic, carcinogenic,
radioactive), and also with refrigeration plants and compressors, there is a
danger of physical injuries and damage to property and the environment.
▶Before storage of the dismounted instrument (following use) wash or
clean it, in order to protect persons and the environment from exposure
to residual media.
▶Wear the requisite protective equipment (see chapter 3.6 “Personal
protective equipment”).
▶Observe the information in the material safety data sheet for the
corresponding medium.
WARNING!
Risk of burns
During dismounting there is a risk of dangerously hot media escaping.
▶Let the instrument cool down sufficiently before dismounting it!
DANGER!
Danger to life caused by electric current
Upon contact with live parts, there is a direct danger to life.
▶The dismounting of the instrument may only be carried out by skilled
personnel.
▶Only disconnect the thermometer once the system has been
depressurised and de-energized.
8.2 Return
Strictly observe the following when shipping the instrument:
All instruments delivered to WIKA must be free from any kind of hazardous substances
(acids, bases, solutions, etc.) and must therefore be cleaned before being returned.
WARNING!
Physical injuries and damage to property and the environment
through residual media
Residual media in the dismounted instrument can result in a risk to
persons, the environment and equipment.
▶With hazardous substances, include the material safety data sheet for
the corresponding medium.
▶Clean the instrument, see chapter 7.2 “Cleaning”.
8. Dismounting, return and disposal

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When returning the instrument, use the original packaging or a suitable transport
packaging.
To avoid damage:
1. Place the instrument along with shock-absorbent material in the packaging.
Place shock-absorbent material evenly on all sides of the transport packaging.
2. If possible, place a bag containing a desiccant inside the packaging.
3. Label the shipment as carriage of a highly sensitive measuring instrument.
Information on returns can be found under the heading “Service” on our
local website.
8.3 Disposal
Incorrect disposal can put the environment at risk.
Dispose of instrument components and packaging materials in an environmentally
compatible way and in accordance with the country-specific waste disposal regulations.
Do not dispose of with household waste. Ensure a proper disposal in
accordance with national regulations.
8. Dismounting, return and disposal

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9. Specifications
Specifications Model TC46
Sensor type ■Type K
■Type J
Number of sensors ■Single thermocouple
■Dual thermocouple
Measuring point ■Isolated (ungrounded)
■Non-isolated (grounded)
Recommended max. operating temperature
Type K 1,200 °C [2,192 °F]
Type J 800 °C [1,472 °F]
Sheath diameter ■0.5 mm
■1.0 mm
■1.5 mm
■1.6 mm
■2.0 mm
■3.0 mm
Sheath material ■Stainless steel
■Ni alloy 2.4816 (Inconel 600)
Permissible temperatures
Kapton -25 … +260 °C [-13 ... +500 °F]
Fibreglass -50 … +482 °C [-58 ... +900 °F]
PTFE -50 … +260 °C [-58 ... +500 °F]
PVC -20 … +105 °C [-4 ... +221 °F]
Versions ■Connecting individually insulated lead wires to the
conductors of the sensor
■Connecting pair of insulated lead wire to the
conductors of the sensor
■Optional connectors can be attached to the sensor
conductors
Standard lead length 1,000 mm [39"] with additional intervals of 500 mm [20"]
Process connections ■Formed / bent sensor
■Union screw connection
■Spring-loaded connection
For further specifications see WIKA data sheet TE 65.46 and the order documentation.
9. Specifications

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Inhalt
Inhalt
1. Allgemeines 18
2. Aufbau und Funktion 18
3. Sicherheit 19
4. Transport, Verpackung und Lagerung 22
5. Inbetriebnahme, Betrieb 23
6. Störungen 25
7. Wartung, Reinigung und Rekalibrierung 26
8. Demontage, Rücksendung und Entsorgung 27
9. Technische Daten 29

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1. Allgemeines
■Das in der Betriebsanleitung beschriebene Heißkanal-Thermoelement wird nach
dem aktuellen Stand der Technik gefertigt. Alle Komponenten unterliegen während
der Fertigung strengen Qualitäts- und Umweltkriterien. Unsere Managementsysteme
sind nach ISO 9001 und ISO 14001 zertifiziert.
■Diese Betriebsanleitung gibt wichtige Hinweise zum Umgang mit dem Gerät.
Voraussetzung für sicheres Arbeiten ist die Einhaltung aller angegebenen
Sicherheitshinweise und Handlungsanweisungen.
■Die für den Einsatzbereich des Gerätes geltenden örtlichen Unfallverhütungsvor-
schriften und allgemeinen Sicherheitsbestimmungen einhalten.
■Die Betriebsanleitung ist Produktbestandteil und muss in unmittelbarer Nähe des
Gerätes für das Fachpersonal jederzeit zugänglich aufbewahrt werden. Betriebsan-
leitung an nachfolgende Benutzer oder Besitzer des Gerätes weitergeben.
■Das Fachpersonal muss die Betriebsanleitung vor Beginn aller Arbeiten sorgfältig
durchgelesen und verstanden haben.
■Es gelten die allgemeinen Geschäftsbedingungen in den Verkaufsunterlagen.
■Technische Änderungen vorbehalten.
■Weitere Informationen:
2. Aufbau und Funktion
2.1 Beschreibung
Die Thermoelemente der Baureihe TC46 sind kundenspezifisch ausgeführt und für
Anwendungen zum Formen von Kunststoff und Gummi sowie für Anwendungen zum
Heißkanal- und Kunststoffspritzen geeignet, für die Mantel-Thermoelemente erforderlich
sind. Eine große Bandbreite von Elementen, Übergangshülsen und Prozessanschlüs-
sen können für die jeweilige Anwendung individuell gewählt werden. Aufgrund ihrer
Flexibilität und ihrer kleinen Durchmesser können die Thermoelemente Typ TC46 an
Stellen eingesetzt werden, die nur schwer zugänglich sind.
Durch ihre einzigartige Konstruktion sind die Heißkanal-Thermoelemente besonders
für Anwendungen geeignet, bei denen die Metall-Sensorspitze direkt in eine Bohrung
eingebaut oder in eine Nut entlang der bearbeiteten Teile eingepresst wird.
1. Allgemeines / 2. Aufbau und Funktion

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In der Standardausführung werden die Thermoelemente ohne Prozessanschluss gefer-
tigt. Befestigungselemente wie eine Überwurfschraube, eine Klemmverschraubung, ein
gefederter oder kundenspezifischer Niederhalter können hinzugefügt werden oder sind
optional erhältlich.
2.2 Lieferumfang
Lieferumfang mit dem Lieferschein abgleichen.
3. Sicherheit
3.1 Symbolerklärung
WARNUNG!
... weist auf eine möglicherweise gefährliche Situation hin, die zum Tod oder
zu schweren Verletzungen führen kann, wenn sie nicht gemieden wird.
VORSICHT!
… weist auf eine möglicherweise gefährliche Situation hin, die zu gering-
fügigen oder leichten Verletzungen bzw. Sach- und Umweltschäden
führen kann, wenn sie nicht gemieden wird.
GEFAHR!
... kennzeichnet Gefährdungen durch elektrischen Strom. Bei Nichtbeach-
tung der Sicherheitshinweise besteht die Gefahr schwerer oder tödlicher
Verletzungen.
WARNUNG!
... weist auf eine möglicherweise gefährliche Situation hin, die durch heiße
Oberflächen oder Flüssigkeiten zu Verbrennungen führen kann, wenn sie
nicht gemieden wird.
Information
... hebt nützliche Tipps und Empfehlungen sowie Informationen für einen
effizienten und störungsfreien Betrieb hervor.
3.2 Bestimmungsgemäße Verwendung
Die hier beschriebenen Thermoelemente sind geeignet zur Temperaturmessung in der
Kunststoffverformungs- / Gummiformguss-, Heißkanal- und Spritzgussindustrie. Sie
können je nach Ausführung direkt in den Prozess oder in eine Bohrung eingebaut werden.
Die Bauform der Bohrung ist beliebig auswählbar, jedoch sind die operativen Prozessda-
ten (Temperatur, Druck, Dichte und Strömungsgeschwindigkeit) zu berücksichtigen.
Das Gerät ist nicht für den Einsatz in explosionsgefährdeten Bereichen zugelassen!
2. Aufbau und Funktion / 3. Sicherheit

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Reparaturen sowie bauliche Veränderungen sind nicht zulässig und führen zur
Erlöschung der Garantie und der jeweiligen Zulassung. Bauliche Veränderungen nach
Auslieferung der Geräte obliegen nicht in der Verantwortung des Herstellers.
Das Gerät ist ausschließlich für den hier beschriebenen bestimmungsgemäßen
Verwendungszweck konzipiert und konstruiert und darf nur dementsprechend verwen-
det werden.
Die technischen Spezifikationen in dieser Betriebsanleitung und der zugehörigen
Datenblätter sind einzuhalten. Eine unsachgemäße Handhabung oder ein Betreiben
des Gerätes außerhalb der technischen Spezifikationen macht die sofortige Stilllegung
und Überprüfung durch einen autorisierten WIKA-Servicemitarbeiter erforderlich.
Ansprüche jeglicher Art aufgrund von nicht bestimmungsgemäßer Verwendung sind
ausgeschlossen.
3.3 Fehlgebrauch
WARNUNG!
Verletzungen durch Fehlgebrauch
Fehlgebrauch des Gerätes kann zu gefährlichen Situationen und Verlet-
zungen führen.
▶Eigenmächtige Umbauten am Gerät unterlassen.
▶Gerät nicht in explosionsgefährdeten Bereichen einsetzen.
▶Gerät nicht für abrasive und viskose Messstoffe verwenden.
Jede über die bestimmungsgemäße Verwendung hinausgehende oder andersartige
Benutzung gilt als Fehlgebrauch.
Dieses Gerät nicht in Sicherheits- oder in Not-Aus-Einrichtungen benutzen.
Die elektrischen Leiter und Übergangsstellen sollten nicht mit heißen Oberflächen in
Berührung kommen (z.B. heiße Rohrkomponenten).Wo dies nicht möglich ist, sollte ein
geeigneter elektrischer Leiter, eine geeignete Übergangsstelle oder Hochtemperatur-
hülse verwendet werden.
3.4 Verantwortung des Betreibers
Das Gerät wird im gewerblichen Bereich eingesetzt. Der Betreiber unterliegt daher den
gesetzlichen Pflichten zur Arbeitssicherheit.
Die Sicherheitshinweise dieser Betriebsanleitung, sowie die für den Einsatzbereich des
Gerätes gültigen Sicherheits-, Unfallverhütungs- und Umweltschutzvorschriften einhal-
ten.
Der Betreiber ist verpflichtet das Typenschild lesbar zu halten.
3. Sicherheit