Wittmann Tempro basic C 90 Operation manual

Tempro basic C 90 & Tempro primus C 90 Page 1
BASIC & PRIMUS C90 V 3.0 english / 10.04.2012
Tempro basic C 90
&
Tempro primus C 90
V 3.0
Translation of Original
Operating Manual

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TABLE OF CONTENTS
1 GENERAL........................................................................................................6
1.1 Symbols highlighting instructions in the operating manual.............................6
1.2 Definition of Terms.........................................................................................7
1.3 Safety Instructions.........................................................................................7
1.4 Notes about process safety of the device......................................................9
2 COMPLETENESS OF THE DELIVERY, WARRANTY..................................10
2.1 Transport Damage.......................................................................................10
2.2 Warranty......................................................................................................10
3 ASSEMBLY INSTRUCTIONS .......................................................................11
3.1 Transport and Preparation for Assembly .....................................................11
3.2 Requirement on the Installation Location.....................................................13
3.3 Electrical Connection...................................................................................14
3.4 Safety Temperature Cutout of the Electric Heating......................................14
4 LAYOUT AND FUNCTION............................................................................15
5 INSTALLATION.............................................................................................17
5.1 Cooling Water Connection...........................................................................17
5.2 Connection of the Tool Circuits....................................................................17
5.3 Electrical Connection...................................................................................17
5.4 Connections on the rear side.......................................................................18
6 START UP.....................................................................................................20
6.1 Switching the device on with the main switch ..............................................20
6.2 Filling ...........................................................................................................20
6.3 Leakage monitoring.....................................................................................20
6.4 Operation mode...........................................................................................21
6.4.1 Pressurized stabilizing:..........................................................................21
6.4.2 Suction temperature control:..................................................................21
6.4.3 Evacuating:............................................................................................21
6.5 Procedure for exchanging tools Tempro basic C 90....................................22
6.6 Procedure for exchanging tools Tempro primus C 90..................................22
7 OPERATION..................................................................................................23
7.1 Changing values..........................................................................................23
7.2 Short overview of operation and settings.....................................................24
7.2.1 Input and Displaymode..........................................................................24
7.2.2 Status display........................................................................................24

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7.3 Display of actual value and status (ACT).....................................................25
7.3.1 Display of internal temperature..............................................................25
7.3.2 Display of heating / cooling performance...............................................25
7.3.3 Display of version number (only at ACT – Display) ...............................25
7.4 Adjustment of set point value (SET1)...........................................................25
7.5 Adjustment of set point value for cooling down function (SET2).................26
7.6 Adjustment of tolerance limits (TOL)............................................................26
7.7 Display of operating hours...........................................................................27
7.8 Display of current flow rate ..........................................................................28
7.9 ON- and OFF switching of the temperature stabilizing circuit......................28
7.10 Code Input.................................................................................................28
7.11 Cooling down function button.....................................................................29
7.12 Error messages..........................................................................................29
7.13 Safety temperature limiter..........................................................................30
7.14 Switching to degree Fahrenheit or degree centigrade...............................32
7.15 Code – Menu: ............................................................................................32
7.15.1 Configuration menu (Code 120)..........................................................32
7.16 Code-Menu only for Option „Flow indication“:............................................33
7.16.1 Operatinghour menu (Code 101).........................................................33
7.16.2 Service-Menu (Code 111) display of actual pressure..........................34
7.17 Interface – menu (Code 130 .....................................................................34
8 MAINTENANCE.............................................................................................35
8.1 Cleaning, Notices, Storage and Disposal.....................................................37
8.2 Warranty......................................................................................................37
8.3 Maintenance schedule.................................................................................38
9 REPAIR INSTRUCTIONS..............................................................................39
9.1 Prior to opening the unit...............................................................................39
9.2 Remove side panels ....................................................................................39
9.2.1 Demount of lateral parts........................................................................39
9.2.2 Re-assembling of lateral parts...............................................................39
9.3 Structure of mechanic system Tempro basic C 90.......................................40
9.4 Structure of mechanic system Tempro primus C 90....................................41
9.5 Change the heater element .........................................................................42
9.6 Pump exchange for Tempro basic C90:.......................................................42
9.7 Setting the Motor Protection Relay..............................................................42
9.7.1 Possible causes for tripping the Motor Protection Relay........................43
9.8 Structure of electric system:.........................................................................44

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9.9 The electronic system..................................................................................45
9.9.1 Exchange of the electronic part.............................................................45
9.10 Circuit board ..............................................................................................46
9.10.1 Plug connection of Circuit board..........................................................46
10 TECHNICAL DATA .....................................................................................47
10.1 Technical Data Tempro basic C90 and primus C90...................................47
10.2 Heat Transfer Medium...............................................................................48
11 OPTIONS.....................................................................................................50
11.1 External sensor PT100.............................................................................50
11.1.1 Accessories.........................................................................................51
11.2 Serial Interface:..........................................................................................51
11.2.1 Interface RS232, RS485, TTY/CL (20mA) T500001393......................51
11.3 Analog Interface:........................................................................................51
11.3.1 Interface Basic C / analog T500001553...............................................51
11.4 Interface cables..........................................................................................51
11.4.1 Engel RS232 .......................................................................................52
11.4.2 Engel 20mA.........................................................................................52
11.4.3 Demag 20mA.......................................................................................52
11.4.4 Arburg 20mA (plug SubD 3 pol)...........................................................52
11.4.5 Arburg 20mA (plug SubD 9 pol)...........................................................52
11.4.6 Ferromatik 20mA.................................................................................53
11.4.7 Krauss Maffei 20mA ............................................................................53
11.4.8 Battenfeld 20mA..................................................................................53
11.5 Connection cables.....................................................................................54
11.5.1 Series interfacing RS232.....................................................................54
11.5.2 Series interfacing 20mA (identical with Engel 20mA) ..........................54
11.6 Pressure Measurement with Flow Indication .............................................54
11.6.1 Flow rate measuring:...........................................................................54
11.6.2 Parameters for flow rate calculation:....................................................55
11.6.3 Description – Menus for flow indication: ..............................................56
11.6.3.1 Display – current flow value:......................................................56
11.6.3.2 Procedure..................................................................................57
12 SPARE PARTS............................................................................................58
12.1 Spare parts mechanical system Tempro basic C 90 / primus C90.............58
12.2 Valves........................................................................................................60
12.2.1 Spare parts for valves..........................................................................60
12.3 Spare parts of electric system....................................................................61
13 SERVICE DEPARMENTS ...........................................................................62
14 WIRING DIAGRAMS ...................................................................................66

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1 General
The safety of our customers is the first consideration of all technical solutions.
Wittmann plastics devices are subjected to high quality requirements. Our
objective is the safety of operating personnel and users.
In order to achieve this objective, several rules are necessary.
This operating manual is to be used by every person who is authorized for
activities on this device.
Ensure that the operators are familiar with the operating manual and the device.
Instruct all persons in the working area of the device about the indirect and direct
dangers emanating from it.
The operating manual contains detailed descriptions of the unit and the
components included in the scope of delivery. We reserve the right to make
technical modifications to the products without prior notice.
The operating manual must only be used internally. It must not be made available
to third parties. The reproduction of the content of this manual, in part or in whole,
is only permitted with the explicit permission of the author.
1.1 Symbols highlighting instructions in the operating manual
Safety instructions in this operating manual that must be adhered to in order to
prevent personal injury are highlighted with the general warning symbol
(safety symbol according to DIN 4844-W9)
Dangers in connection with electric voltage are highlighted with the warning
symbol
(safety symbol according to DIN 4844-W8)
Dangers in connection with explosion protection are highlighted with the warning
symbol
Safety instructions that must be adhered to in order to prevent damage to the
device and its functions are highlighted with the warning CAUTION

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1.2 Definition of Terms
This operating manual always uses recurring terms and designations, that are
explained here for better understanding:
Device
The term „Device“ can describe both an individual device, a tool, a machine, as
well as an installation.
Operator
The operator is that person who operates the device at his own responsibility or
when instructed to do so.
User
The user of a device is the person responsible for all procedures (e.g. production
foreman, shop foreman, etc.). The user instructs the operators to execute a task.
Work Instruction
The work instruction (not to be confused with operating manual) describes the
interplay between several devices, sequences or production processes. The work
instruction is to be prepared by the user of the device.
Machinist
If several operators work on one device, then the machinist coordinates the
sequences. The machinist must be nominated by the user.
Specialist Personnel
Persons who are qualified, based on their training, to perform work professionally
are regarded as specialist personnel.
1.3 Safety Instructions
Read through the operating manual carefully before setting into operation for
the first time. Observe all points, ask questions if anything is unclear.
Observe the local regulations and requirements.
Compare the specifications for the energy supply of the device with the local
energy supply.
Have all work on the device performed by specialist personnel.
Take note, that the device can be hot and that the danger of burning exists.
For all work on the device, wear regulation work clothes.

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With the help of the operating manual, prepare a precise work instruction for
the work sequence with this device. Nominate a machinist responsible for the
device. The operators of the device must be at least 16 years old.
Regularly inspect all lines, hoses and screw couplings for leaks, damage
and firm seating. Have defects that occur eliminated immediately.
Observe and take note of the warning signs.
In the event of malfunctions, immediately shut down the machine using the
main switch.
If the device has been shut down for safety reasons or while mechanical
work on the device is being completed, you must secure it against unauthorised
switching on. To do this, disconnect the power supply by pulling the mains plug.
Before carrying out any work on the device, disconnect it from the power
supply.
Do not undertake any modifications of any kind on the device without the
written approval of the manufacturer.
Before beginning maintenance work, nominate a supervisor and notify the
operating personnel responsible.
This device must not be operated if certain parts are not mounted or if the
protective covers or side panels have been removed. RISK OF INJURY FROM
BURNS!
Observe the safety instructions / operating manual of the connected
devices.
Keep this operating manual safe, so that it is available at any time at the
place where the device is operated.

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1.4 Notes about process safety of the device
This device is designed exclusively for the heating of water as described in
chapter 13.2 “Heat transfer fluid“.
CAUTION The permissible storage temperature of the device is +5°C – +40°C
(+41°F – 104°F)
When the device is set into operation for the first time, all electrical
connections are to be checked.
Check the rotational direction of the pump.
CAUTION Keep a record of maintenance and repair work.
CAUTION Use only Wittmann original replacement parts.
To shut down the device in the event or an emergency (EMERGENCY-
STOP), operate the main switch or disconnect the mains plug from the socket (if
device is equipped with a socket).
In the event of a power failure, do not manipulate or disconnect the
tempering medium hoses, as the entire tempering system is pressurised. RISK OF
INJURY FROM BURNS!
In the event of a power failure of EMERGENCY-STOP, do not manipulate or
disconnect the hoses filled with tempering medium! The entire tempering system is
pressurised and the device is automatically restarted as soon as the power
returns. An EMERGENCY-STOP of the machine does not automatically result in
an EMERGENCY-STOP of the tempering device! RISK OF INJURY FROM
BURNS!
Do not operate the device when the switch cabinet or the terminal box door
is open.
Never operate the heater, if its protective covers or side panels are removed.
RISK OF INJURY FROM BURNS!

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Certain accessible parts at the connecting points of the device are very hot
(temperature of over 70°C)! RISK OF INJURY FROM BURNS!
In the event of a control system failure that makes it impossible to control the
device, immediately contact the manufacturer. Do not take any action unless
instructed by the manufacturer! RISK OF INJURY FROM BURNS!
2 Completeness of the Delivery, Warranty
Wittmann devices are packed with great care, in order to protect them during
transport. For assembly, all packaging is to be removed.
CAUTION Remove the packaging and the protective foil of the devices with great
care. The use of sharp objects can cause damage to the painted surfaces and the
devices.
Verify the completeness of the delivery.
2.1 Transport Damage
The commissioned transport organizations must ensure that the devices are
delivered in an undamaged condition.
Inspect the device for visible transport damage immediately after it arrives.
Report any visible transport damage to the commissioned transport organization
immediately.
In the event of any transport damage, discuss a solution to rectify the damage
directly with the transport organization.
2.2 Warranty
For delivered products, we undertake the warranty for defects that result due to a
fault in construction, the material or the workmanship for a period of 12 months
after acceptance of the goods by the customer.
The defect notification must take place immediately and in writing.
We are not liable for damage occurring as a consequence of natural wear and
tear, excessive loading, faulty handling, unsuitable operating materials, defective
maintenance and the like.
For further details, refer to the Sales and Delivery Conditions.
In the event of transport damage, do not return the device, but instead
notify our nearest customer service center without delay.
You will find this in chapter Customer Service Centers

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3 Assembly Instructions
The assembly and commissioning may only be undertaken by persons authorized
for this purpose, in order to avoid damage to devices, equipment and persons.
These assembly instructions presume knowledge about the regulations for the
prevention of accidents, working conditions, as well as safety regulations and their
implementation.
These assembly instructions presume knowledge in the fields of electricity and
mechanics, that have been acquired based on their training, experience and
instruction.
Ensure that all persons working with and on the device have the necessary
skills. Observe the safety instructions for the operation of transport and lifting gear.
All assembly work must be carried out while the machine is not powered and not
pressurised.
Our trained fitters are happy to assist you with this work.
3.1 Transport and Preparation for Assembly
The device and the accessories are delivered on pallets. At transport temperatures
of 0°C or below, the device should be left for 1 hour in a heated room before
starting it to allow it to return to room temperature.
To protect the device during transport and assembly, it is wrapped in protective
foil. Remove all foil before commissioning the device.
To transport the device (packing unit) on site, use only suitable lifting and transport
gear (e.g. forklift truck, pallet truck, etc.).
All transport and lifting gear must be operated by suitably qualified
personnel.
To transport and lift the device, proceed as shown in the pictures below. Secure
the device (packing unit) against toppling over/slipping from the forklift truck.
The transport of the device on rollers is only permitted for short distances on site.

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Small pallet truck Fork lift truck
Large pallet truck
To lift the device from the packaging use
eyelet bolts according DIN 580.

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3.2 Requirement on the Installation Location
Location of installation ......................Closed room
Air humidity.......................................15% - 85%
Height above sea level......................max. 1000 m
Horizontal alignment .........................max. deviation +/-3° (uneven floor)
Floor .................................................Non-slip surface, dry, no trip hazards
Ambient temperature.........................+5°C to +40°C
Load-bearing capacity / device..........Observe weight and dimensions
MODEL DESIGN
Weight
[kg]
Width
[mm]
Height
[mm]
Depth
[mm]
Tempro basic C 90 Standard 31 235 660 590
Tempro primus C 90 Standard 31 235 660 590
Ensure that all parts of the machine are easily accessible for maintenance
and repair. Keep the workplace clean and uncluttered!
Take into account that the device releases heat and humid air during
operation.
Ensure that there is sufficient ventilation at the location of installation.
If the units are to be installed on platforms, you must provide additional
safety devices (e.g. strips) to prevent the heaters from rolling off (alternatively,
order rollers with locking mechanism available from Wittmann).
The device must not be operated in explosive atmospheres.

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3.3 Electrical Connection
Connect the device to a power supply system that conforms to the
specifications on the type plate. Always adhere to the instructions and regulations
of your electricity supply company. All electrical connections must be completed by
an authorised specialist technician or under his/her supervision.
There is provided a main fuse (see indicated current consumption on
nameplate) which interrupts the electrical energy supply to the unit in case of
overload.
For safety reasons, in particular the function of the protective conductor terminal is
to be checked.
Install the energy supply with an appropriate safety distance to hot parts.
Lay all cables of the device, so that no faults can occur through other
electrical devices. Thereby in particular control lines and data transmission cables
are to be isolated from power conducting lines.
For BASIC units, check the pump rotational direction. The unit uses a right-hand
field of rotation.
The entire unit will have to be specially grounded if you work with materials that
cause strong electrostatic discharges as they are conveyed.
For all work, disconnect the device from the electrical energy supply. This is the
most secure protection against electrical accidents.
If work on the electrics cannot be completed, then secure the device against
unintentional setting into operation.
For this purpose disconnect the power supply system by releasing the main plug
from the power socket.
Check all electrical terminal- and screw connections of the load current circuit
regularly for firm seating.
3.4 Safety Temperature Cutout of the Electric Heating
During transport, the device can be exposed to low temperatures.
The safety temperature cutout trips at temperatures below –5°C. For
troubleshooting, bring the device to room temperature and reset the safety
temperature cutout of the heater concerned with the reset button.
(See chapter 7.12)
.

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4 Layout and Function
The tempering devices Tempro basic C90 and Tempro primus C90 are used for
tempering injection molding tools on injection molding machines, as well as other
tempering circuits on plastics processing machines.
This temperature stabilizer of the basic / primus C90 integrates modern design,
compact structure and simple handling.
The temperature stabilizer has a temperature stabilizing circuit with a mould connection.
Diagram of temperature stabilizing circuit: Tempro basic C 90
Nr.
Description
Nr.
Description
1 Heat exchanger 9 Heater element
2 Filling solenoid valve 10 Cooling solenoid valve
3 Cooling-water inlet 11 Cooling coil
4 Cooling-water outlet 12 Temperature sensor
5 Level switch 13 Microprocessor controller
6 Pump 14 Safety temperature cutout
7 Mould connection-FEED 15 Ventilation valve
8 Mould connection-RETURN 16 Drain plug

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Diagram of temperature stabilizing circuit: Tempro primus C 90
Nr.
Description
Nr.
Description
1 Heat exchanger 9 Heater element
2 Filling solenoid valve 10 Cooling solenoid valve
3 Cooling-water inlet 11 Cooling coil
4 Cooling-water outlet 12 Temperature sensor
5 Level switch 13 Microprocessor controller
6 Pump 14 Safety temperature cutout
7 Mould connection-FEED 15
8 Mould connection-RETURN 16 Drain plug
The temperature stabilizing circuit includes a heat exchanger (1). The heat exchanger is
filled with water automatically through a solenoid valve (2). (Capacity approx. 9 litres
Tempro basic / primus C90).
Joint water feed for filling (2) and cooling (10) solenoid valves through coarse filter. The
filling height is controlled by the level switch (5).
The temperature stabilizing medium is driven by the pump (6) in an open circuit through
the mould circuit and runs back into the heat exchanger. Mould connections feed and
return (7,8).
The water is heated by the heating element (9) inside the heat exchanger. When the
cooling solenoid valve (10) is opened the cooling water flows through the cooling spiral
(11) and cools the temperature stabilizing medium (indirect cooling).
Cooling water feed and return (3,4).
The medium temperature is monitored by the temperature sensor (12) and closely
controlled by an advanced microprocessor controller (13).
The measuring accuracy is 0.1 degrees and therefore allows for a constant temperature of
+/- 0,5 degrees in the injection mould.
Please read thoroughly the following chapters which contain important
information about installation, start-up, operation, and maintenance.

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5 Installation
With obvious transport damage, do not send the device back, instead notify the
nearest customer service center immediately.
5.1 Cooling Water Connection
Use only suitable pressure- and temperature-resistant hoses.
Depending on the cooling or heating cycle, high return flow temperatures of max.
95°C can occur in the drain hose!
Fit a shut-off device (e.g. ball valve) in the incoming supply.
Water pressure (differential pressure between forward and return flow) of more
than 6 bar can lead to functional faults of the cooling valve.
5.2 Connection of the Tool Circuits
CAUTION We recommend not reducing the cross-section at the connections for
the tool circuit as this could result in an increased operating pressure and excess
wear of the pump! The connections to the tool should be established with hoses of
minimum 13 mm in diameter that are not longer than 4 metres!
Use only suitable pressure- and temperature-resistant hoses and screwed
connection couplings.
Minimum Pressure and Temperature Resistance of the Hoses:
Type max. pressure (bar) max. Temperature
Tempro basic C 90
Tempro primus C 90 6 95°C
5.3 Electrical Connection
For all devices, the mains connection is to be fuse-protected externally by the
user according to the power of the device (circuit-breaker + observance of the
local protective measures).
Connected load:
Voltage heating cap. max. current fuse
3x400V AC max. 6 kW 10A 16A
3x480V AC max. 9 kW 12,5A 16A

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The mains connection cable (4 m) is already mounted on all stabilizers and
provided with a plug (CEE 16A). (Special voltage without plug).
The wiring of the temperature stabilizer is designed for a right-hand 3-phase
network.
In main switch position 1 the pump is running in pressurized operation. (Right-
hand orientation)
Check: Fan wheel of pump motor is running in the arrow direction.
If this is not the case, two phases in the plug of the main connection must be
interchanged.
For safety reasons, the proper function of the protective conductor terminal
should be examined thoroughly.
5.4 Connections on the rear side
High temperatures (above 70°C) occur at the exposed parts at the
connection locations of the stabilizer !
RISK OF BURNS!!
(1) COOLING WATER – INLET (2) COOLING WATER – OUTLET
(3) MOULD CONNECTION – FEED (4) MOULD CONNEECTION – RETURN

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Tempro basic C 90 & Tempro primus C 90
1 Cooling water – Inlet (G ¼“)
2 Cooling water – Outlet (G ¼“)
3 Mold connection – Feed (G ¾“)
4 Mold connection – Return (G ½“)
E MAIN CONNECTION

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6 Start up
Before switching the stabilizer on, please read the entire Chapters Startup
and Operation to avoid false operation which may cause injuries to persons and
damage the stabilizer!
6.1 Switching the device on with the main switch
A self-test with simultaneous activation of all displays (display test) occurs at first –
the horn sounds briefly. Then, the current actual value will be displayed.
Entries are now expected.
The device is only switched on and off by way of the main switch.
6.2 Filling
The stabilizer is equipped with an automatic filling and refilling system. That
means that the current filling level is reported to the controller via the level
monitoring and the controller then switches on the solenoid filling valve.
6.3 Leakage monitoring
Excessive water loss in the forming circuit (hose loose, burst, etc.) will trigger the
leakage monitoring device and the filler valve will be closed or may no longer be
opened. In addition, a fault signal will be emitted (alarm contact and blinking LED
on the display and error message E03).
Primus C90:(horn and blinking LED on display and error message E03)
The monitoring system is divided into the following steps:
System-pipe pressure
§Initial filling time 6 min at 4 bar approx. ca. 20 l
§Refilling time (contin. filling) 30 sec at 4 bar approx. ca. 1.6 l
§Sum of refilling times 1 - 60min (adjustable)*
*The total refilling time over the last 10 hours is monitored. An error message is
generated, if the set time is exceeded. The totals counter can be deactivated
(value "0"). The factory-set total refilling time is 10 minutes. This value can only be
adjusted in the configuration menu ("con").