Tool-Temp TT-181 Manual

Manual of instruction
Temperature control unit TT-181
with Temperature Controller MP-888
01/2019
Version: 04

Manual of instructions TT-181 2/33
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 2019 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. 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 - Filling (Water operation)........................................................................................................................ 16
5.4.1. Pump rotation check............................................................................................................................................... 17
5.4.2. Display of pump pressure....................................................................................................................................... 17
5.5. Initial operation with heat transfer oil (Oil operation)......................................................................................................... 18
5.5.1. Close the automatic filling....................................................................................................................................... 18
5.5.2. Change stage switching (according to the electrical diagram)................................................................................. 18
5.5.3. Switching of the heating stages (according to the electrical diagram) ..................................................................... 18
6. Operations.................................................................................................................................... 19
6.1. Overview MP-888............................................................................................................................................................ 19
6.2. Parameter settings MP-888 –without flow control............................................................................................................ 21
6.3. Setting of the temperature –Heating / Cooling................................................................................................................. 23
6.4. Mould drainage –Changing the consumer....................................................................................................................... 23
6.5. Leak prevention operation................................................................................................................................................ 23
7. Safety and monitoring devices................................................................................................... 24

Manual of instructions TT-181 3/33
7.1. Pump............................................................................................................................................................................... 24
7.2. Heating –Temperature monitoring................................................................................................................................... 24
7.3. Level control.................................................................................................................................................................... 24
7.4. Temperature deviation control ......................................................................................................................................... 24
7.5. Acoustic indication of faults (horn) ................................................................................................................................... 25
8. Maintenance................................................................................................................................. 26
8.1. Inspection........................................................................................................................................................................ 26
8.2. Cleaning.......................................................................................................................................................................... 26
8.3. Repair.............................................................................................................................................................................. 26
9. Out-of-service / transport............................................................................................................ 27
10. Disposal........................................................................................................................................ 27
11. Failure corrective action ............................................................................................................. 28
12. Components and spare parts..................................................................................................... 29
12.1. Overview components and spare parts............................................................................................................................ 29
12.2. Liste Komponenten und Ersatzteile.................................................................................................................................. 31
Attachments:
•Electrical diagram MP-888 EL-000017

Manual of instructions TT-181 4/33
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-181 5/33
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.
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-181 6/33
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-181 7/33
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-181 8/33
2. Overview temperature control unit
2.1. Front view

Manual of instructions TT-181 9/33
1
Temperature Controller MP-888
2
ON/OFF-Switch unit (green)
3
ON/OFF-Switch heating (green)
Water: Switchable in stages 3 kW + 6 kW = 9 kW
Oil: 3 kW (OR-circuit)
4
ON/OFF-Switch horn (green)
5
Temperature monitoring internal left (red)
The maximum temperature of the unit is exceeded. The unit switches off.
Control lamp Temperature deviation control right (red)
Difference between desired and actual temperature is too big. Unit continues to run.
6
Control lamp thermal relay pump (red)
Thermal relay of the pump motor has responded.
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 lamp pre-warning (yellow)
lights + horn Unit continues to run, level has to be corrected
10
Level control lamp (yellow)
lights + horn unit switches off
11
Main switch
Emergency stop
12
Name plate with following details:
13
Switch cabinet –safety device
14
Coverage –safety device

Manual of instructions TT-181 10/33
2.2. Rear view
15
From mould
½“ BSP female thread
16
Manometer pump pressure
17
To mould
½“ BSP female thread
18
Cooling water inlet with water filter
⅜“ BSP female thread
19
Cooling water outlet
⅜“ BSP male thread
20
Manually refill with overflow
1“ BSP male thread
21
Overflow
22
Drainage
⅜“ BSP female thread

Manual of instructions TT-181 11/33
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!

Manual of instructions TT-181 12/33
3. Technical Specifications
Temperature range
up to 90°C with water / up to 150°C with oil
Temperature control
self-optimizing, electronic microprocessor controller MP-888
Heating capacity
Water operation: 9 kW, with manual stage switching 3/6
Oil operation: 3 kW
Pump capacity
motor 0,75 kW
Pressure mode: 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
½“ BSP female thread
from mould
½“ BSP female thread
cooling water inlet with water filter
⅜“ BSP female thread
cooling water outlet
⅜“ 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 cabinet, easily accessible from the front
Colour
silver-grey RAL 7001
Heat exchanger
low-maintenance
Noise level(dBA)
< 70 dBA (distance 3 m)

Manual of instructions TT-181 13/33
4. EU –Declaration of conformity

Manual of instructions TT-181 14/33
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

Manual of instructions TT-181 15/33
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 feets
(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!
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“
10 mm
1/2“
15 mm
3/4“
20 mm
1“
25 mm
DN32
32 mm
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-181 16/33
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 +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 / 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!
5.4. Initial operation - Filling (Water operation)
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.

Manual of instructions TT-181 17/33
5.4.1.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.
5.4.2.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-181 18/33
5.5. Initial operation with heat transfer oil (Oil operation)
The temperature control unit can also be operated with heat transfer oil. The unit must be prepared
accordingly for this operation and after this the unit can be filled manually through the filler neck. A
guideline for the required filling amount can be taken from the technical data.
WARNING
The unit may only be changed by a competent electrician.
The unit hast o be disconnected from the power supply!
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. 29).
Wasser
Öl
5.5.2.Change stage switching (according to the electrical diagram)
The heat stages has to be reduced to 1 x 3kW by rewiring the terminal block on the inside of the
door. The two switches for the heater are new wired in OR-circuit.
Water
Oil
5.5.3.Switching of the heating stages (according to the electrical diagram)
The heater must be wired in star on the contactors.
Water
Schütz
contactor
contacteur
contattore
K3
Schütz
contactor
contacteur
contattore
K4
2 4 6
2 4 6
T1 T2 T3
T1 T2 T3
R1
R2
R3
R1
R2
R3
Oil

Manual of instructions TT-181 19/33
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
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
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-181 20/33
1
Technical specifications
2
Temperature sensor connection
21+23 Temperature sensor –note + / -
22 Pt-100 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)