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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BASIC & PRIMUS C90 V 3.0 english / 10.04.2012
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