Tool-Temp TT-390 Manual

Manual of instruction
Temperature control unit TT-39016/24kW
with Temperature Controller MP-888
05/2017
Version: 05

Manual of instructions TT-390 2/35
General information
This documentation is copyrighted. Unauthorised duplication 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
TOOL-TEMP AG and are subject to change without notice.
In case of inconsistencies in the English translation, the German version shall prevail.
© Copyright 2017 TOOL-TEMP AG
Contents
1. General Safety Information........................................................................................................... 4
1.1. Safety Symbols.................................................................................................................................................................. 4
1.2. Range of Application.......................................................................................................................................................... 4
1.3. Intended Use..................................................................................................................................................................... 4
1.4. Safety Information.............................................................................................................................................................. 5
1.4.1. General Information.................................................................................................................................................. 5
1.4.2. Process Monitoring................................................................................................................................................... 5
1.4.3. Information for Operators and Personnel.................................................................................................................. 5
1.4.4. Changing the Parameterisation ................................................................................................................................ 6
1.4.5. Residual risks........................................................................................................................................................... 6
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. EC –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................................................................................................................................................................ 17
5.4.1. Heat transfer oil...................................................................................................................................................... 18
5.4.1. Pump rotation check............................................................................................................................................... 18
5.4.2. Display of pump pressure....................................................................................................................................... 18
6. Operations.................................................................................................................................... 19
6.1. Overview MP-888............................................................................................................................................................ 19
6.2. Parameter settings MP-888 ............................................................................................................................................. 21
6.3. Setting of the temperature –Heating / Cooling................................................................................................................. 23
6.4. Adjustment of electronic flow control................................................................................................................................ 23
6.5. Temperature measurement INTERNAL (IN) –EXTERNAL (OUT)................................................................................... 23
6.6. Mould drainage –Changing the consumer....................................................................................................................... 24
6.7. Leak prevention operation................................................................................................................................................ 24
7. Safety and monitoring devices................................................................................................... 25
7.1. Pump............................................................................................................................................................................... 25

Manual of instructions TT-390 3/35
7.2. Heating –Temperature monitoring................................................................................................................................... 25
7.3. Level control.................................................................................................................................................................... 25
7.4. Flow control..................................................................................................................................................................... 25
7.5. Temperature deviation control ......................................................................................................................................... 25
7.6. Acoustic indication of faults (horn) ................................................................................................................................... 26
8. Maintenance................................................................................................................................. 27
8.1. Inspection........................................................................................................................................................................ 27
8.2. Cleaning.......................................................................................................................................................................... 27
8.3. Repair.............................................................................................................................................................................. 27
9. Out-of-service / transport............................................................................................................ 28
10. Disposal........................................................................................................................................ 28
11. Failure corrective action ............................................................................................................. 29
12. Components and spare parts..................................................................................................... 31
12.1. Overview components and spare parts (without isolation)................................................................................................ 31
12.2. List components and spare parts..................................................................................................................................... 33
Attachments:
•Electrical diagram MP-888 EL-1712

Manual of instructions TT-390 4/35
1. General Safety Information
1.1. 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.
1.2. Range of Application
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 moulds, extruders, calendars,
mixers and other consumers in areas in which there is no risk of explosion.
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 TOOL-TEMP.

Manual of instructions TT-390 5/35
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.
1.4. Safety Information
1.4.1.General Information
The TOOL-TEMP 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.
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.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. 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 shut-down procedures stated to be
necessary in the operating instructions must be followed.

Manual of instructions TT-390 6/35
1.4.4.Changing the Parameterisation
The parameterisation of the control system may only be carried out by personnel trained by
TOOL-TEMP. In particular, no parameters in the device configuration may be changed without
consulting TOOL-TEMP.
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.
1.4.5.Residual risks
Any unauthorised modifications and changes to the temperature control unit as well as
unauthorised changes to the parameterisation 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 TOOL-TEMP replacement parts may be used.
Damage due to use of thirdparty 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, 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 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.
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!

Manual of instructions TT-390 7/35
1.5. 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, minimise 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.
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 devices. Any additional documents
supplement and/or replace the descriptions contained in this documentation, which are then
either invalid or only conditionally valid.

Manual of instructions TT-390 8/35
2. Overview temperature control unit
2.1. Front view
1
Temperature Controller MP-888
2
ON/OFF-Switch unit (green)
3
ON/OFF-Switch heating (green)
4
ON/OFF-Switch heating (green)
5
ON/OFF-Switch horn (green)

Manual of instructions TT-390 9/35
6
Change-over switch for pump operation mode (green)
Pressure for pressure operation (normal operation)
Vacuum for leakstopper operation and mould drainage
7
Mould drainage (green)
- Cooling the unit below 60°C
- Switch the unit off by the green ON/OFF-Switch
- Pump operation mode switch to „VAC“
- Press the green button „DRAIN“ until consumer is empty
8
Change-over switch for temperature measurement
Internal - Temperature measurement internal (heater)
External - Temperature measurement external with 2-poles socket for
temperature sensor (e.g. at the mould)
9
Control lamp (red)
Thermal relay pump
10
Control lamp temperature monitoring t1 (red)
The maximum temperature of the unit is exceeded. The unit switches off.
11
Control lamp temperature monitoring t2 (red)
The maximum temperature of the unit is exceeded. The power to the heater is switched off, the
unit works and the cooling can be activated.
12
Control lamp temperature monitoring t3 (red)
Temperature deviation control; Difference between desired and actual temperature is too big.
13
Leven control lamp (yellow)
lights + horn Unit switches off, level has to be corrected (refill)
lights + horn Unit switches off, level has to be corrected (drainage)
14
Lamp (yellow)
leakstopper operation and mould drainage
15
Control lamp flow control (red)
16
Working hour meter
17
Horn
18
Main switch
Emergency stop
19
Name plate with following details:
20
Manometer pump pressure
21
Switch cabinet –safety device
22
Side panel
23
Front panel

Manual of instructions TT-390 10/35
2.2. Rear view
24
Service cover
25
Rear panel
26
To mould
¾“BSP female thread
27
From mould
¾“BSP female thread
28
Cooling water inlet with water filter
1“BSP female thread
29
Cooling water outlet with non-return valve
1“BSP female thread
30
Drainage with stop valve
½“BSP female thread
31
Overflow
32
Filler neck
1“BSP male thread

Manual of instructions TT-390 11/35
2.3. 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 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!
WARNING
Prohibition for people with pacemaker!
People with pacemaker should not be allowed to demount or maintain the
magnetically coupled pump!
There is a risk of injury to people with pacemaker.

Manual of instructions TT-390 12/35
3. Technical Specifications
TT-390 / 16 kW
TT-390 / 24 kW
Temperature range
Up to 360°C with heat transfer oil TOOL-THERM SH-3
Temperature control
self-optimizing, electronic microprocessor controller MP-888
Heating capacity
with stage switching 8/8
with stage switching 8/16
Pump capacity
motor 1,8 kW
max. 5.5 bar / max. 100 l/min
Cooling capacity
approx. 90 kW at 360°C circulating temperature
Filling amount
15 litres
21 litres
Expansion volume
16 litres
16 litres
Connections
to mould
¾“ BSP female thread
from mould
¾“ BSP female thread
cooling water inlet with water filter
1“BSP female thread
cooling water outlet
1“BSP female thread
Overflow
½“ BSP female thread
Dimensions (L×W×H)
1240 × 480 × 1400 mm, incl. castors
Weight
approx. 205 kg empty
approx. 215 kg empty
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 (dB)
< 70 dB (distance 3 m)

Manual of instructions TT-390 13/35
4. EC –Declaration of conformity

Manual of instructions TT-390 14/35
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 heat transfer oil. Do
not use solvents or other explosive substance such as petrol, toluene, etc. in
the heat transfer oil circuit.
CAUTION
When starting the unit without the prescribed connections the unit can be
damaged.
Water quality (cooling circuit) –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

Manual of instructions TT-390 15/35
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 on 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. Lying transport destroy the unit.
WARNING
The temperature control unit can release excess pressure. Danger of injury
in the event of escaping steam/hot oil!
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 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 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
Internal hose-Ø
3/8“
10mm
1/2“
15mm
3/4“
20mm
1“
25mm
DN32
32mm
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.

Manual of instructions TT-390 16/35
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. We recommend 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 +400°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 / 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 level.
Do not connect the power supply until the heating medium hoses are
connected!

Manual of instructions TT-390 17/35
5.4. Initial operation
The temperature control unit can only be operated with heat transfer oil. The unit has to be filled
manually through the filler neck for the operation. A guideline for the required filling amount can be
taken from the technical data.
WARNING
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!
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 unit can be filled through the filler neck. In the meantime the yellow
lamp lights and the horn sound. If the correct level is reached the pump starts. If the unit switches
down after this, the level has to be corrected as soon as the system has enough heat transfer oil.
NOTE
Too much heat transfer oil reduces the expansion volume! The heat transfer
oil expands during the heating and could be overflow.
WARNING
Warning overflow oil has to be removed immediately!
Oil-soaked isolation has to be replaced immediately, they can ignite.
DANGER
Waste oil has to be disposed as prescribed by law. Never let waste oil come
into the sewage system or soil.

Manual of instructions TT-390 18/35
5.4.1.Heat transfer oil
Temperatures up to +250°C ask for heating transfer oils such as TOOL-THERM SH-3, Shell
Thermia B, BP Transcal N, Essotherm 500 or equivalent products. For operating the temperature
control unit up to temperatures +360°C, must be used TOOL-THERM SH-3. Other similar
products must be individually clarified. Please note: The used heat transfer oil has to be taken
down in a check list. Particularly the maximum operating temperatures according to the
specifications of the heat transfer oil manufacturer has to be taken down.
WARNING
The use of unsuitable oil sorts or water is not permitted and is not regarded
as use as agreed.
5.4.1.Pump rotation check
On top 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.
5.4.2.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!

Manual of instructions TT-390 19/35
6. Operations
The unit is controlled by the temperature controller MP-888.
The temperature controller MP-888 is a universal controller for all TOOL-TEMP units.
6.1. Overview MP-888
1
Display of set value
2
Display of actual value
3
Flow control (Feature not available)
Display of the current flow in litres/min, English or American gallons/min.
4
Up arrow Raise of set value
5
Down arrow Reduction of set value
6
Program button
7
Flow control (Feature not available)
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 temperature is too high
12
LED Maximum temperature
Lights up when the maximum temperature has been reached
13
LED External temperature control
Lights up when the set value is applied from extern

Manual of instructions TT-390 20/35
1
Possible supply voltages (factory adjusted)
2
Possible temperature sensor (factory adjusted)
3
Version of the controller
4
Temperature sensor connection
21+23 Temperature sensor –note + / -
22 Pt-100 compensation
5
Flow control –encoder signal
6
Connection external set point
26+28 Analog input 4 - 20mA
27+28 Analog input 0 - 10 V
7
Connection actual value - output
29+30 Analog output 0 - 10V
8
Power supply
1 230V AC
2 Neutral
3 PE
9
Flow control (alarm)
10
Temperature monitoring, temperature deviation alarm
11
Cooling (command)
12
Heating (command)