MOULDPRO TCU-90 Instruction Manual

[1]
User Guidelines –TCU-90 12-06-2019 Vers. 003
_________________________________________________________________
User Guideline
Temperature control unit TCU-90
_________________________________________________________________

[2]
User Guidelines –TCU-90 12-06-2019 Vers. 003
General information
This documentation is copyrighted. Unauthorized duplication is prohibited bylaw. 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

[3]
User Guidelines –TCU-90 12-06-2019 Vers. 003
Contents
1 Indhold
2GENERAL SAFETY INFORMATION............................................................................................................................... 5
2.1 SAFETY SYMBOLS................................................................................................................................................................ 5
2.2 RANGE OF APPLICATION...................................................................................................................................................... 5
2.3 INTENDED USE ..................................................................................................................................................................... 5
2.4 SAFETY INFORMATION.......................................................................................................................................................... 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 USING THIS DOCUMENTATION.............................................................................................................................................. 8
2.5.1 Additional Documentation........................................................................................................................................ 8
3OVERVIEW TEMPERATURE CONTROL UNIT ............................................................................................................. 9
3.1 FRONT VIEW.......................................................................................................................................................................... 9
3.2 REAR VIEW.......................................................................................................................................................................... 10
3.3 IDENTIFICATION OF RESIDUAL RISK ON THE UNIT............................................................................................................... 11
4TECHNICAL SPECIFICATIONS..................................................................................................................................... 12
5INSTALLATION................................................................................................................................................................ 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
6OPERATIONS................................................................................................................................................................... 16
6.1 OVERVIEW.......................................................................................................................................................................... 17
LEDS PROCESS INFORMATION AND START PUMP. ...................................................................................................... 18
7DISPLAY AND PARAMETER SETTINGS..................................................................................................................... 19
8ALARM DISPLAY ............................................................................................................................................................ 21
9STANDARD PCB SETTINGS......................................................................................................................................... 22
9.1 ADVANCED PARAMETER SETTINGS.................................................................................................................................... 24
10 LEAK MONITORING........................................................................................................................................................ 30
10.1 DEACTIVATE LEAK MONITORING ........................................................................................................................................ 31
11 CONFIGURABLE RELAYS............................................................................................................................................. 32
12 DESCRIPTION PCB CARD CONNECTORS................................................................................................................. 34
13 MAINTENANCE................................................................................................................................................................ 34
13.1 INSPECTION........................................................................................................................................................................ 35
13.2 CLEANING........................................................................................................................................................................... 35

[4]
User Guidelines –TCU-90 12-06-2019 Vers. 003
13.3 REPAIR ............................................................................................................................................................................... 35
14 OUT-OF-SERVICE / TRANSPORT ................................................................................................................................ 36
15 DISPOSAL........................................................................................................................................................................ 36
16 WATER QUALITY............................................................................................................................................................ 37
17 ELECTRICAL DIAGRAM ................................................................................................................................................ 38
18 WATER CIRCUIT DIAGRAM........................................................................................................................................ 39
19 CONTROL CIRCUIT DIAGRAM .............................................................................................................................................. 40
19 COMPONENTS AND SPARE PART LIST ...................................................................................................................... 41

[5]
User Guidelines –TCU-90 12-06-2019 Vers. 003
2 General Safety Information
2.1 Safety Symbols
DANGER
Denotes imminent danger.
Failure to heed the information can result in death or grave personal injury
(disability)!
WARNING
Denotes a dangerous situation.
Failure to heed the information can result in death or grave personal injury
(disability)!
CAUTION
Denotes a potentially dangerous situation.
Failure to heed the information can result in property damage as well as minor
or 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 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 moulds, extruders, and mixers in areas in which there is
no risk of explosion.

[6]
User Guidelines –TCU-90 12-06-2019 Vers. 003
Any use beyond this shall be deemed to constitute improper use. The manufacturer is not responsible for
damage resulting from improper use; the user is solely responsible for such risks. The temperature control
unit may not be used under other operating conditions and/or with other media, in deviation from our
specifications, without the prior consent of MOULDPRO.
Use as intended also entails compliance with the operating, servicing and maintenance conditions stipulated
by the manufacturer. The temperature control unit may only be operated, serviced and maintained by
personnel who are familiar with these tasks and have been instructed as to the risks.
2.4 Safety Information
2.4.1 General Information
The MOULDPRO temperature control unit is safe to operate, but this device can pose danger to life and limb
if it is used incorrectly or for a purpose other than that intended. It should be noted that this poses risks to the
life and limb of the user or third parties, adverse effects on the equipment and other material assets
belonging to the user, and risks to the efficient operation of the equipment.
Start-up (i.e., commencement of intended use) is prohibited until it has been determined that the temperature
control unit has been 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 is used in combination with products by other manufacturers, their notices and
safety regulations must also be obeyed.
2.4.2 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.
2.4.3 Information for Operators and Personnel
The operator and all persons who are tasked with working on the temperature control unit must obey the
fundamental regulations regarding work safety and accident prevention. The operator must ensure that only
persons who have read and understood these operating instructions, particularly the chapter on safety, work
on the temperature control unit.
WARNING
People with pacemaker should not be allowed to demount or maintain the
magnetically coupled pump!
Any working methods that have a negative effect on the technical safety of the temperature control unit must
not be used. The operator must ensure that the temperature control unit is operated only in flawless condition.

[7]
User Guidelines –TCU-90 12-06-2019 Vers. 003
If necessary, the company using the equipment must obligate the operating personnel to wear protective
clothing.
For all tasks having to do with set-up, start-up, operating, modification of operating conditions and operational
modes, maintenance, inspection and repair, any shutdown procedures stated to be necessary in the
operating instructions must be followed.
2.4.4 Changing the Parameters
The parameters of the control system may only be changed by personnel trained by MOULDPRO.
No parameters in the device configuration may be changed without consultingMOULDPRO.
The relevant accident prevention regulations and the generally accepted principles of safety engineering,
occupational medicine and structural engineering must be observed. The national safety regulations must
also be obeyed.
2.4.5 Residual risks
Any unauthorized modifications and changes to the temperature control unit as well as unauthorized changes
to the parameters of the control system are prohibited for reasons of safety.
If the temperature control unit is damaged, it must not remain in use; the defective part must be replaced 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, connecting lines, 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 always be kept clean. Insulation that is soaked with
thermal oil poses an increased risk of fire.
Burning thermal oil can be extinguished using a spray foam fire extinguisher, a powder fire extinguisher
(avoid with dust-sensitive plants, control systems, EDP, etc.) or a CO2 fire extinguisher. The appropriate fire
extinguisher must be provided by the operator, taking into account the equipment located in the room and the
mandatory safety regulations.
The temperature control unit may only be operated when all safety systems are completely installed and
intact. The temperature control unit must be protected against sprays and cleaning agents.

[8]
User Guidelines –TCU-90 12-06-2019 Vers. 003
Before detaching connecting lines in the temperature control circuit and depending on the outlet temperature,
allow the temperature control unit to cool down first and then turn it off. Check that the pump is no longer
running.
WARNING
Important - danger of injury in the event of escaping water or oil!
2.5 Using this Documentation
This documentation contains important information for safe, economical operation and for proper
maintenance of the device.
Compliance with this 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. Components that do not
belong to the basic hardware are noted as extra equipment. The corresponding additional documents are
included with special versions of devices. Any additional documents supplement and/or replace the
descriptions contained in this documentation, which are then either invalid or only conditionally valid.

[9]
User Guidelines –TCU-90 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

[10]
User Guidelines –TCU-90 12-06-2019 Vers. 003
3.2 Rear view

[11]
User Guidelines –TCU-90 12-06-2019 Vers. 003
3.3 Identification of residual risk on the unit
On the temperature 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!

[12]
User Guidelines –TCU-90 12-06-2019 Vers. 003
4 Technical Specifications
Temperaturerange
up to 90°C with water
Temperaturecontrol
self-optimizing,electronic microprocessor controller
Heatingcapacity
Wateroperation: 9 kW,
Pump capacity
motor 0,50 kW
Pressure mode: max. 3,5 bar / max. 60 l/min
Vacuum mode:
vacuum max. 8mH2O
Coolingcapacity
approx. 40 kW at 90°C
Filling amount
approx. 12 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)
575 × 295 × 495 mm
Weight
approx. 40 kg empty
Category of protection
IP-44
Electric
In separate switch cabinet, easily accessible from the front

[13]
User Guidelines –TCU-90 12-06-2019 Vers. 003
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
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 must be free.
Check the unit of completeness and possible damages.
The unit has to be installed in a suitable location on even ground. It must be stand up right on the
wheels (castors).
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 unit must not be transported lying down, transport in any other position than up right, will damage
the unit.

[14]
User Guidelines –TCU-90 12-06-2019 Vers. 003
WARNING
The temperature control unit can release excess pressure. Danger of injury in
the event of escaping steam!
Never start up the unit without the protection cover! Never use the unit in
hazardous location!
Repair leaks immediately! Observe local laws during set-up!
CAUTION
The temperature control unit may be pressurized!
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 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 in the consumer.
For the connecting lines (to and from mould, cooling water inlet and outlet, etc.) the following internal
diameters of hoses are recommended:
Thread on the unit
Internalhose-Ø
3/8“
10 mm
1/2“
15 mm
3/4“
20 mm
1“
25 mm
DN32
32 mm

[15]
User Guidelines –TCU-90 12-06-2019 Vers. 003
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 that way pressure, drops can be avoided.
For the cooling water connections it’s enough to use pressure- and temperature-resistant rubber hoses. The
tap water pressure has to be between 2,0 and 5,0 bar. Werecommend to conduct the water from the unit
(cooling water outlet) to an unpressurized 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 maximum temperature for which the connections are
suitable!
5.3 Power supply
Compare supply voltage and frequency with the information on the serial plate. Verify the rating of the
preliminary fuse according to the information in the electrical diagram. Observe local laws during set-up!
Power cable:
Phases
black / brown
L1 / L2 / L3
Earth
yellow/green
PE

[16]
User Guidelines –TCU-90 12-06-2019 Vers. 003
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 level.
Do not connect the power supply until the heating medium hoses are
connected!
5.4 Initial operation - Filling
The temperature control unit has to be connected hydraulically and electrically. Possible block valve must be
open.
Switch on the unit electrically: Turn on the main switch and press the unit ON/OFF-switch
After switching on the unit the pump starts and fills the system with water, as well as automatically ventilating
the machine. In the meantime the yellow lamp lights and the horn 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 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.
5.6 Display of pump pressure
The pump pressure is shown on the manometer.
WARNING
The temperature control unit may be pressurised!
Only when the pressure gauge shows 0 bar, disconnect hoses!
6 Operations
The temperature controller controls the unit
The temperature controller is a universal controller for all MOULDPRO units.

[17]
User Guidelines –TCU-90 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)

[18]
User Guidelines –TCU-90 12-06-2019 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)

[19]
User Guidelines –TCU-90 12-06-2019 Vers. 003
7 Display and Parameter settings
Zone A
Zone B

[20]
User Guidelines –TCU-90 12-06-2019 Vers. 003
To change set point press . Digit on the right side will flash, to change the value press or .
In order to change the digit press .
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 .