Tool Heaters and Temperature Controller Units

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Duane Neal
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1 Tool Heaters and Temperature Controller Units

Tricool Thermal Advanced Engineering Tricool Thermal have been manufacturing high quality temperature control equipment for over 30 years.

2 Tricool Thermal Advanced Engineering Tricool Thermal have been manufacturing high quality temperature control equipment for over 30 years. This amount of manufacturing experience has allowed us to grow in the UK and internationally; with distributors located throughout Europe and Asia. Our large production facility is based in Southampton, UK providing standard units for stock as well as fully customised solutions for all site requirements. Our experienced engineers utilise the latest 3D CAD technology to design the units which are manufactured in-house using the latest cellular production methods. With our flexible yet reliable approach, we have the ability to provide temperature control equipment to a wide variety of industries: Plastics Food & Beverage Medical Pharmaceutical Manufacturing & Process Chemical Cosmetic Printing & Laminating All our temperature control units are manufactured to ISO 9001 and ISO accreditations providing our customers with a high level of performance and quality. To view or download our ISO certificates please visit In addition to this, our Southampton production facility has a fully fitted test rig. We are one of the few companies in the UK to provide this facility and where required, customers are welcome to schedule a visit to view this in action. The test rig provides customers with reassurance that their equipment meets all performance ratings stated in Tricool literature. Built on Experience Tricool Engineering was formed First temperature controller developed and sold Tricool Engineering purchased UTAC Engineering to form the largest UK temperature controller manufacturer First temperature controller sold by international distributor Launched complete range of temperature controllers 2

Contents Tricool Thermal Explained page 2 Case Studies Experience Counts Glass and rubber industry page 4 Automotive and food industry page 5 Taking Control page 6 Features

HTF: Technical data page 16 HTF: Schematics page 17 The P140/P120 Range page 19 P140/P120: About the units page 20 P140/P120: Technical data page 21 P140/P120: Schematics page

areas for temperature control systems ICS Temperature Control Group acquired Tricool Engineering to combine their sales and marketing with Tricool s engineering Relocation to

3 Contents Tricool Thermal Explained page 2 Case Studies Experience Counts Glass and rubber industry page 4 Automotive and food industry page 5 Taking Control page 6 Features and Benefits page 7 The T90 Range page 9 T90: About the units Page 10 T90: Technical data page 11 T90: Schematics Page 12 The HTF Range page 14 HTF: About the units page 15 HTF: Technical data page 16 HTF: Schematics page 17 The P140/P120 Range page 19 P140/P120: About the units page 20 P140/P120: Technical data page 21 P140/P120: Schematics page 22 Tailor-Made Options page Relocation to new factory in Fareham Hampshire (20,000ft 2 ) Company moved into food market and explores other new areas for temperature control systems ICS Temperature Control Group acquired Tricool Engineering to combine their sales and marketing with Tricool s engineering Relocation to new site in Totton, Southampton (50,550ft 2 ) Tricool Thermal is now the manufacturing division of a 40 million organisation supplying temperature control equipment all over the world 3

Experience Counts The Glass Industry Requirement: To provide continuous and accurate temperature control for the process of float glass production for solar panels using line beams to maintain

This is then run along a continuous belt in which line beams maintain its temperature; gradually cooling as it goes.

The dual circuit ensured continuous productivity even if a fault occured; allowing the line beams to maintain their exact temperature.

18 different probes were fitted on the units to communicate with the customer s central computer system; monitoring for any faults 24/7.

4 Experience Counts The Glass Industry Requirement: To provide continuous and accurate temperature control for the process of float glass production for solar panels using line beams to maintain temperature levels. Raw materials are melted down together in a furnace at temperatures of up to 3000 o C producing a liquid compound. This is then run along a continuous belt in which line beams maintain its temperature; gradually cooling as it goes. Solution: We provided bespoke built dual circuit oil heaters with capacities of 200kW-400kW reaching temperatures of up to 260 o C. The dual circuit ensured continuous productivity even if a fault occured; allowing the line beams to maintain their exact temperature. These units were specifically designed to deliver consistently, very high temperatures with improved reliability. 18 different probes were fitted on the units to communicate with the customer s central computer system; monitoring for any faults 24/7. The Rubber Industry Requirement: To provide a packaged multi zone temperature control solution for the manufacture of tyres. Located overseas, the project required essential temperature control of a Banbury type mixer for the production and extrusion of rubber. Varied yet accurate temperatures were needed at each stage of the manufacturing process in order to produce the exact rubber compound. Solution: Having worked with the customer previously we had an understanding of their current process requirements, we were able to manufacture and supply 8 off 3-zone TCU s (temperature control units) and 4 off 4-zone TCU s. These compact, bespoke built multi zone T90 s with capacities of 9-96kW carry out the temperature control of 3-zones in one. They provide a more cost effective and practical solution whilst interfacing with the customer s main control panel using Profibus. With non-ferrous internal parts and self cleaning solenoid valves, maintenance and cleaning needs are reduced. The 4-zone TCU was adapted for temperature control of a larger extrusion machine, meeting all the particular design specifications. 4

Experience Counts The Automotive Industry Requirement: To provide temperature control equipment to a large car

Heating and cooling equipment was required to simulate the temperatures of diesel fuel to ensure the engine worked

Solution: Having worked closely with the customer we had a clear understanding of their requirements.

company based in High Wycombe Buckinghamshire.

vessels (BS550) jacketed vessels, blenders, dispensers and clean room equipment.

5 Experience Counts The Automotive Industry Requirement: To provide temperature control equipment to a large car manufacturer in order to test the car engines. Heating and cooling equipment was required to simulate the temperatures of diesel fuel to ensure the engine worked safely at extreme conditions. Solution: Having worked closely with the customer we had a clear understanding of their requirements. Special HTF150 units were provided, which allowed the customer to set specific flow rates to match the diesel in order to gain accurate test readings. The Food Industry Requirement: To provide precision temperature control equipment to a large project-led engineering company based in High Wycombe Buckinghamshire. The company specialise in the manufacture of a wide range of finely tuned products that includes mixers, pressure vessels (BS550) jacketed vessels, blenders, dispensers and clean room equipment. Solution: Following an extensive brief, we designed and manufactured a custom-built 5kW thermoregulator to provide accurate temperature control. The unit circulates water through a closed circuit that maintains the temperature of the jacketed vessel s contents within a very tight tolerance. So far, we have supplied the customer with 45 systems and are confident that whatever the application we can be relied upon to provide the best solution to meet the customer s requirements. 5

Taking Control C7 Controllers Tricool Thermal units are

process temperatures and ensure maximum productivity with no

The C7 basic controller is featured on our range of e units;

C7 Advanced Controller The C7 advanced controller has been

to provide the users with a more advanced system which is easy

6 Taking Control C7 Controllers Tricool Thermal units are available with C7 basic and C7 advanced controllers to manage process temperatures and ensure maximum productivity with no downtime. The C7 basic controller is featured on our range of e units; all other units are available with the C7 advanced controller. C7 Advanced Controller The C7 advanced controller has been developed for our thermoregulators to provide innovative technological temperature analysis. C7 Advanced Design development has been re-evaluated in order to provide the users with a more advanced system which is easy to navigate and can analyse processes in great detail; ensuring every aspect of the temperature and control is working to maximum productivity. C7 Advanced 6

Number of running hours ü 7 day timer Switching on and off can be controlled via internal clock optional ü Security codes Operator, engineer and manufacturer access to ensure no unauthorised access:

7 Features and Benefits Features Benefits Basic Advanced Touch screen display Simple mobile smartphone navigation ü Full colour 3.5 TFT display Clear and easy to understand ü Text display No symbols or codes, clear text for alarms ü ü Modular Easily expandable ü Service due alarm Simple maintenance reminder ü Operating hours Number of running hours ü 7 day timer Switching on and off can be controlled via internal clock optional ü Security codes Operator, engineer and manufacturer access to ensure no unauthorised access: these can be configured on the advanced model Temperature limit values Programmable temperature alarms high and low ü ü Auto-tune cascade control Control of process using both remote and local probes ü Remote probe Sensing temperature from remote probe in process optional ü Selectable languages English, French, German, Spanish, Dutch, Swedish and Danish ü ü Ethernet interface Information can be sent via ethernet connection if required ü Analogue interfaces (external temperature input/output) Recipe control Information can be sent via 4-20mA signals ü ü Recipes can be created and saved for time, dwell and temperature set points Fully programmable Adjustable for all processes ü Flow monitoring The flow rate can be measured and displayed with limits and alarms ü Pressure monitoring The pressure can be measured and displayed with limits and alarms ü ü ü Automatic phase swap Ensures correct rotation of phases optional Data logging and trending on flow temperature and alarms Data is logged on micro SD card for evaluation of process when required Energy display Real time energy consumption can be displayed on screen ü ü Options Modbus RS485 Option for information to be sent via Modbus optional Profibus DP Option for information to be sent via Profibus optional Safety: Sensor failure monitor Hose rupture and leakage monitor Triple safety cut out for heating 7

8 8 The T90 Range

9 T90 Range T90e T90t - Water up to 90 o C This range of modern temperature control equipment ensures temperatures are accurately managed within applications such as injection moulding, extrusion, rollers and vessels. These non-pressurised units deliver highly effective water heating with maximum reliability for long-life productivity. Additional advantages include: - Minimal rejection rates for improved production start-ups - Continuous high-quality production - Improved cavity-filling performance - Closer tolerances 9

T90 About the units Mechanical Direct acting self cleaning solenoid valves - Low maintenance due to minimal cleaning required Non-ferrous parts - All components exposed to water are made of

10 T90 About the units Mechanical Direct acting self cleaning solenoid valves - Low maintenance due to minimal cleaning required Non-ferrous parts - All components exposed to water are made of nonferrous materials. Ensuring a long service life Stainless steel heat exchanger - More efficient with large gaps between plates which reduces the risk of blocking due to contamination Automatic and manual filling Castors Heating elements - Made of heat resistant alloy incoloy for high corrosion resistance and long service life High quality pump materials (no seal) Flow meter as standard (except for T90e-9/12) Pressure sensors (except for T90e-9/12) Inlet/outlet temperature sensors (except for T90e-9/12) Leak stopper Tank made of stainless steel - Ensuring a long service life Electric and control equipment Solid state relays - Energy savings due to pulsing every 0.3 seconds (contactors generally every 16 seconds) proving increased accuracy Diagnostic controller - Improves maintenance by showing knowledge of any faults that occur C7 basic with diagnostic control for T90e models C7 advanced standard on T90t - see page 6 Available Options: - Connections for various analogue and digital electric interfaces - Remote probe for cascade control - Stainless steel panels - Increased cooling 10

11 Technical Data T90 Technical Data T90e-9 T90e-12 T90e-18 T90t-9 T90t-18 T90t-24 T90t-32 T90t-48 Temperature max o C: Heat transfer fluid: Heating capacity kw: Water Water Water Water Water Water Water Water Cooling indirect indirect indirect indirect indirect indirect indirect indirect Cooling capacity kw*: Weight kg Process connections Cooling connections ¼ ¼ Pump capacity max (l/min/ bar) 60 lpm/ 60 lpm/ 70 lpm/ 6 bar 70 lpm/ 6 bar 70 lpm/ 6 bar 150 lpm/ 5 bar 150 lpm/ 5 bar 150 lpm/ 5 bar Operating voltage: 400V-3ph-50Hz Measuring mode: PT1000 PT100 C7 Basic controller C7 Advanced controller **Additional fill line Leakstopper Mould drain Return temperature indication Auto fill Castors Measuring indication and monitoring of flow rate Acoustic alarm Pressure indication Anti flood back kit Connection for remote sensor Optional Optional optional optional Dimensions: Length mm Width mm Height mm Notes: *The expansion volume allowed within the tank design has been based on the stated Maximum External Volume and the process fluid is being heated from 15 o C to 90 o C ** Additional fill line 11

12 T90 Schematics T90e T90e Schematics T90t 12

13 TheHTFRange 13

HTF Range HTF150e HTF200e HTF250e HTF300t - Oil heaters from 150 o C to 300 o C

9-48kW providing consistent high temperatures without pressurisation.

the following processes: - Plastics Extrusion - Die Casting - Injection Moulding

the production of die casting, temperature control units can reduce reject rates

14 HTF Range HTF150e HTF200e HTF250e HTF300t - Oil heaters from 150 o C to 300 o C This range of robust heater units work at a wide variety of capacities from 9-48kW providing consistent high temperatures without pressurisation. Units within this range provide the perfect temperature control consistency for the following processes: - Plastics Extrusion - Die Casting - Injection Moulding - Food Production - Chemical and Pharmaceutical - High Temp Jacketed Vessels In the production of die casting, temperature control units can reduce reject rates up to 80% and make the die last up to three times longer; reducing heat up time by as much as 30%. 14

HTF About the units C7 basic with diagnostic control for HTFe models C7 advanced standard on HTFt - see page 6 Non-ferrous parts - All components exposed to water are made of nonferrous materials

Offers increased accuracy and with no moving parts eliminates wear and tear Stainless steel heat exchanger - Gaps between the plates reduce the risk of blocking Direct acting self cleaning solenoid

drive pump as standard (on HTF300t & HTF250e) - Seal-less so low maintenance alleviates any leaks Bypass for internal circulation of the oil - In case of insufficient flow.

15 HTF About the units C7 basic with diagnostic control for HTFe models C7 advanced standard on HTFt - see page 6 Non-ferrous parts - All components exposed to water are made of nonferrous materials ensuring a long service life Solid state relays - Reduces energy usage due to pulsing every 0.3 seconds (contactors generally every 16 seconds). Offers increased accuracy and with no moving parts eliminates wear and tear Stainless steel heat exchanger - Gaps between the plates reduce the risk of blocking Direct acting self cleaning solenoid valves - With no diaphragm this helps reduce the maintenance needed, due to the minimal manual cleaning required Large volume tank on the HTF150 s - More stable temperatures can be achieved Magnetic drive pump as standard (on HTF300t & HTF250e) - Seal-less so low maintenance alleviates any leaks Bypass for internal circulation of the oil - In case of insufficient flow. Avoids thermal overloading of the oil Seperate expansion vessel - Reduces oxidation as the circulating oil is seperated from the atmosphere by the stationery oil in the expansion tank 3-way valve - On temperature control side, standard on units HTF300t. Eliminates thermal shocking of the heat exchanger, ensuring a long service life Available Options: - Connections for various analogue and digital electric interfaces - Remote probe for cascade control - Stainless steel panels - Increased cooling - 3-way valve bypass on the temperature control side fitted on HTF300t 15

Technical Data HTF HTF150 HTF200 HTF250e/HTF300t Technical Data e-6 e-12 e-6 e-9 e-12 e-18 e-24 t-9 t-12 t-18 t-24 t-36 t-48 Temperature max o C: Heat transfer fluid: Heating capacity kw: 150 150 200

16 Technical Data HTF HTF150 HTF200 HTF250e/HTF300t Technical Data e-6 e-12 e-6 e-9 e-12 e-18 e-24 t-9 t-12 t-18 t-24 t-36 t-48 Temperature max o C: Heat transfer fluid: Heating capacity kw: *250/300 *250/300 *250/300 *250/300 *250/300 *250/300 Oil Oil Oil Oil Oil Oil Oil Oil Oil Oil Oil Oil Oil Cooling indirect indirect indirect indirect indirect indirect indirect indirect indirect indirect indirect indirect indirect Cooling capacity kw: Weight kg Process connections Male Male Male BSP PN16 Flanged BSP PN16 Flanged BSP PN16 Flanged BSP PN16 Flanged 1 ¼ BSP PN16 Flanged 1 ¼ BSP PN16 Flanged Cooling connections ¼ Male ¼ Male ¼ Male BSP BSP Pump capacity max (l/min/ bar) 60 lpm/ 60 lpm/ 60 lpm/ 50 lpm/ 3 bar 50 lpm/ 3 bar 100 lpm/ 2.6 bar 100 lpm/ 2.6 bar 55 lpm/ 6.5 bar 55 lpm/ 6.5 bar 100 lpm/ 7.8 bar 100 lpm/ 7.8 bar 200 lpm/ 8.5 bar 200 lpm/ 8.5 bar Operating voltage: 400V-3ph-50Hz Measuring mode: PT1000 *PT1000/PT100 C7 Basic controller on 250e on 250e on 250e on 250e on 250e on 250e C7 Advanced controller way valve bypass Return temperature indication Castors Measuring indication and monitoring of flow rate Acoustic alarm Pressure indication Connection for remote sensor optional Dimensions: Length mm Width mm Height mm Notes: *Depending on model 16

17 HTF Schematics HTF300t T90e Schematics HTF200e/ HTF250e 17

18 18 The P140/P120Range

P140/P120 Range P140e P120e - Water up to 140 o C These pressurised units

o C. - Plastics/Injection Moulding - Food Production Processes - Chemical

exchanger, pressure sustaining accumulator, nonferrous internal parts,

19 P140/P120 Range P140e P120e - Water up to 140 o C These pressurised units deliver high temperature water heating with limited need for maintenance and offer increased energy efficiency. Capacities range from 9-36kW, with water temperatures reaching up to 140 o C. - Plastics/Injection Moulding - Food Production Processes - Chemical and Pharmaceutical The unit features an air bottle, stainless steel heat exchanger, pressure sustaining accumulator, nonferrous internal parts, low tank volume and solid state relays. The unit also features an auto shutdown system to prevent any leaks. 19

P140/P120 About the units C7 basic with diagnostic control for P140/P120 models C7 advanced is optional on all P140/P120 models - see page 6 Non-ferrous parts - All

cooling water pressure - flexible operation Direct acting self cleaning solenoid valves - Low maintenance due to minimal cleaning required (no diaphragm) Heating

lock the supply water system down to prevent any leaks Air release bottle - Protects the heating elements and pump where large amounts of air could be present in the

20 P140/P120 About the units C7 basic with diagnostic control for P140/P120 models C7 advanced is optional on all P140/P120 models - see page 6 Non-ferrous parts - All components exposed to water are made of nonferrous materials ensuring a long service life Pressure sustaining accumulator - Operating temperature independent of cooling water pressure - flexible operation Direct acting self cleaning solenoid valves - Low maintenance due to minimal cleaning required (no diaphragm) Heating elements - Made of heat resistant alloy incoloy for high corrosion resistance and long service life Auto shutdown system - If a pipe breaks the machine will stop and lock the supply water system down to prevent any leaks Air release bottle - Protects the heating elements and pump where large amounts of air could be present in the process Available Options: - Direct cool - Increased cooling - Stainless steel panels - Remote probe for cascade control - Connections for various anologue inputs & outputs 20

21 Technical Data P140/P120 P140 P120 Technical Data e-9 e-12 e-18 e-24 e-36 e-9 e-12 e-18 e-24 e-36 Temperature max o C: Heat transfer fluid: Heating capacity kw: Water Water Water Water Water Water Water Water Water Water Cooling indirect indirect indirect indirect indirect direct direct direct direct direct Cooling capacity kw*: max max max max max Weight kg Process connections BSPT Male BSPT Male 1 ¼ BSPT Male BSPT Male 1 ¼ Cooling connections BSP Pump capacity max (l/min/ bar) 38 lpm/ 38 lpm/ 80 lpm/ 80 lpm/ 130 lpm/ 3 bar 38 lpm/ 38 lpm/ 80 lpm/ 80 lpm/ 130 lpm/ 3 bar Operating voltage: Measuring mode: C7 Basic controller C7 Advanced controller Additional fill line Mould drain with compressed air Return temperature indication Auto fill Castors Measuring indication and monitoring of flow rate Acoustic alarm Connection for remote sensor 400V-3ph-50Hz PT1000 Optional Optional - - Optional Optional Optional Optional Optional Optional Optional Optional Optional Optional Optional Dimensions: Length mm Width mm Height mm

22 P140e/P120e Schematics P140e T90e Schematics P120e 22

Tailor-Made Options Having carried out numerous projects for a variety of applications around the world our engineering team are experienced in a wide variety of applications.

technology for challenging and complex tasks. We can provide tailor-made special systems and system solutions with a keen price/ performance ratio.

customised equipment to suit specific requirements and provide a variety of control options.

Units are available with or without a controller which allows integration into the customers own control specific environment.

control systems. These systems are for integration into the OEM s machinery and equipment is configured to meet the customer s application requirements.

Market specific temperature controllers Major injection moulding and other industrial suppliers often operate with modular, multi circuit temperature control systems.

23 Tailor-Made Options Having carried out numerous projects for a variety of applications around the world our engineering team are experienced in a wide variety of applications. Exclusively dealing with customer specific systems our engineering team is a competent partner in the design, development, configuration and implementation of customised technology for challenging and complex tasks. We can provide tailor-made special systems and system solutions with a keen price/ performance ratio. 1 - Special construction and dimensions 2 - Voltages and temperatures 3 - Flow rates and pressures 4 - Controller specific special applications and function We can manufacture customised equipment to suit specific requirements and provide a variety of control options. Our systems can communicate with higher level machines or line controls via a wide range of different electronic interfaces. Units are available with or without a controller which allows integration into the customers own control specific environment. OEM Manufacturing We are a preferred partner of many machine manufacturers and processors providing solutions for temperature control systems and compact integrated temperature control systems. These systems are for integration into the OEM s machinery and equipment is configured to meet the customer s application requirements. Temperature control technology is integrated as a system component into machinery for plastics, food and pharmaceutical processing in plant engineering applications. Market specific temperature controllers Major injection moulding and other industrial suppliers often operate with modular, multi circuit temperature control systems. Our units feature a particularly small footprint which can be configured to suit customer specific special components or customer specific flow rates and cooling/heating conditions. In the food and pharmaceutical industry, stainless steel panels are often required with suitable IP rated controllers as well as chart recorders and trending. With a wealth of experience in this area, we offer standard stainless steel panels with suitable PLCs. 23

Contact us Group Companies Head Office South ICS House Stephenson Road Calmore Industrial Estate Totton, Southampton SO40 3RY FREEPHONE 0800 169 3861 T +44 (0)23 8052 7300 F +44 (0)23 8042 8366

24 Contact us Group Companies Head Office South ICS House Stephenson Road Calmore Industrial Estate Totton, Southampton SO40 3RY FREEPHONE T +44 (0) F +44 (0) London T +44 (0) North T +44 (0) F +44 (0) Scotland T +44 (0) F +44 (0) Midlands T F Ireland T +353 (0) M +353 (0) ICS Service 24/7 Nationwide Support Emergency Breakdown Tricool Thermal Brochure V2 Nov 013

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