tool heaters and temperature controllers

Tool Heaters and Temperature Controllers

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 14001 accreditations providing our customers with a high level of performance and quality. To view or download our ISO certificates please visit www.tricool.com

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.

Tricool ThermalAdvanced Engineering

Built on Experience19841983 19851975 1980

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

Tricool Engineering was formed

First temperature controller developed

and sold

2

Tricool Thermal Explained page 2

Case Studies

Experience Counts

Glass and rubber industry page 4Automotive 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: Pump capacity and schematics Page 12

The HTF Range page 14

HTF: About the units page 15

HTF: Technical data page 16

HTF: Pump capacity and schematics page 17

The P140 Range page 19

P140: About the units page 20

P140: Technical data page 21

P140: Pump capacity and schematics page 22

Tailor-Made Options page 23

Contents

19971991 2007 20122008

Relocation to new factory in Fareham

Hampshire (20,000ft2)

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

(50,550ft2)

Tricool Thermal is now the manufacturing

division of a £40 million organisation

supplying temperature control equipment all

over the world

P14

0m

3

Experience Counts

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.

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 3000oC 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 260oC. 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.

4

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

C7 Advanced

C7 Advanced

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.

6

Taking Control

C7 Controllers

The C7 advanced controller has been developed for our thermoregulators to provide innovative technological temperature analysis.

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 Controller

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 ü

Security codesOperator, engineer and manufacturer access to ensure no unauthorised access: these can be configured on the advanced model

ü

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 ü ü

Selectable languages English, French, German, Spanish, Dutch, Swedish and Danish ü ü

Ethernet interface Information can be sent via ethernet connection if required üAnalogue interfaces (external temperature input/output)

Information can be sent via 4-20mA signals ü ü

Recipe controlRecipes can be created and saved for time, dwell and temperature set points ü

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

Automatic phase swap Ensures correct rotation of phases üData logging and trending on flow temperature and alarms

Data is logged on micro SD card for evaluation of process when required ü

Energy display Real time energy consumption can be displayed on screen ü

Options

Modbus RS485 Option for information to be sent via Modbus ü

Profibus DP Option for information to be sent via Profibus ü

Features and Benefits

Safety:

Sensor failure monitorHose rupture and leakage monitorTriple safety cut out for heating

7

TheT90 Range

8

T90 Range T90e • T90s • T90m

- Water up to 90oC

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 advantagesinclude:

- Minimal rejection rates for improved production start-ups

- Continuous high-quality production

- Improved cavity-filling performance

- Closer tolerances

9

T90About the units

Available Options:

- Connections for various analogue and digital electric interfaces

- Remote probe for cascade control

- Stainless steel panels

- Increased cooling

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 non- ferrous 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 T90s and T90m - see page 6

10

11

Technical Data T90

Technical Data T90e T90e T90s T90s T90s T90m T90m T90m

Outlet temperature: oC 90 90 90 90 90 90 90 90

Heat transfer fluid: Water Water Water Water Water Water Water Water

Nominal capacity: Litres 17 17 17 17 17 47 47 47

Filling quantity: Litres 15 15 15 15 15 43 43 43

Expansion volume: Litres 2* 2* 2* 2* 2* 4* 4* 4*

Maximum external volume:

Litres 66 66 66 66 66 150 150 150

Heating capacity: kW 9 12 9 12 18 24 32 48

Cooling capacity: kW 40 40 80 80 80 150 150 150

At outlet temperature with 20oC cooling water inlet temperature

oC 90 90 90 90 90 90 90 90

Pumping capacity data:

Flow rate: lpm 60 60 70 70 70 150 150 150

Pressure: bar 4 4 5.8 5.8 5.8 5 5 5

Control: Solid State Relay

Measuring mode: (std.) PT100

Operating voltage: (std.) v-ph-Hz 400-3-50+E

Connections:

Process flow return: - G½” G¾” G¾” G¾” G¾” G1” G1” G1”

Coolant inlet/outlet: - G¼” G¼” G½” G½” G½” G½” G½” G½”

Dimensions:

Length: mm 575 575 865 865 865 985 985 985

Width: mm 300 300 340 340 340 400 400 400

Height: mm 600 600 745 745 745 900 900 900

Weight: kgs 40 40 50 60 70 140 150 160

Colour: RAL7035/RAL3020

Ambient temperature: oC 40

Noise level: dB(A) <70

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 15oC to 90oC

Equipment T90e T90s T90m

Control system C7 ü - -

Control system C7 advanced - ü üSolid state relay ü ü üElectronic flow measurement - ü üBypass for regulation of the flow rate in the process

- ü üLeak-free pump ü ü üWater circuit of non-ferrous materials ü ü üAutomatic water refill ü ü üUnit in IP54 protection degree ü ü ü

0 0 10

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T90e - 9T90e - 12

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T90 Schematics

T90e T90s & T90m

T90 Pump Capacity

T90m - 24T90m - 32T90m - 48

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T90s - 9T90s - 12T90s - 18

12

TheHTFRange

13

HTF RangeHTF150 • HTF250 • HTF350

- Oil heaters from 150oC to 350oC

- Plastics Extrusion

- Die Casting

- Injection Moulding

- Food Production

- Chemical and Pharmaceutical

- High Temp Jacketed Vessels

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:

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

HTFAbout the units

• C7 basic with diagnostic control for HTFe models

• C7 advanced standard on HTFs and HTFm - see page 6

• Non-ferrous parts - All components exposed to water are made of non- ferrous 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 (except for HTF150e) - 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 HTF350, optional HTF250 units. Eliminates thermal shocking of the heat exchanger, ensuring a long service life

Available Options:

- Connections for various analogue and digital electric interfaces



- Increased cooling

- 3-way valve bypass on the temperature control side fitted on HTF250 (standard on HTF350)

15

Technical Data HTF

Technical Data HTF150e HTF250e HTF250s HTF350s HTF250m HTF350m

Outlet temperature: oC 150 250 250 350 250 250

Heat transfer fluid: Oil Oil Oil Oil Oil Oil

Nominal capacity: Ltrs 17 18 18 36 36 63

Filling quantity: Ltrs 8 6 6 9 9 12

Expansion volume: Ltrs 9 12* 12* 27** 27** 51**

Maximum external volume:

Ltrs 66 41 41 92 133 175

Heating capacity: kW 9/12 9 9 12 9 12 18 24 36 48 24 36 48

Cooling capacity: kW 60 110 110 110 110 110/220 110/220


oC 150 250 250 250 250 250 250


Maximum flow rate: lpm 60 70 70 100 70 100 160 200 100 200

Maximum delivery head:

bar 4 6 6 6.5 6 6.5 3.6 7 6.5 7



Operating voltage:v-ph-Hz

400-3-50+E

Connections:

Process flow return: - G½” G1” G1” G1” DN32 *** DN50 *** DN50 ***

Coolant inlet/outlet: - G½” G½” G½” G½” G½” G½”/G¾” G½”/G¾”

Dimensions:

Length: mm 630 755 755 1055 1055 1400

Width: mm 305 360 360 500 500 610

Height: mm 670 920 920 1185 1185 1400

Weight: kgs 50 60 60 90 150 170 190 210 210 280


Operating temperature: oC 40


Notes: *The expansion volume allowed within the tank design has been based on the stated ‘Maximum External Volume’ and assuming the ‘Process Fluid’ is being heated from 20oC to 250oC.

**The expansion volume allowed within the tank design has been based on the stated ‘Maximum External Volume’ and assuming the ‘Process Fluid’ is being heated from 20oC to 350oC.

Equipment HTF150 HTF250 HTF350

Control system C7 ü - -

Control system C7 advanced - ü ü

Solid state relay ü ü ü3-way valve on temperature control side

- Optional ü

Electronic flow measurement - Optional ü

Mag Drive Pump - ü ü

16

17

HTF Pump Capacity

HTF Schematics

HTF250s - 9 & HTF250s - 12HTF350s - 9 & HTF350s - 12

HTF250e - 9

HTF250s - 18 & HTF250s - 24HTF350s - 18 & HTF350s - 24

HTF150e - 9 HTF150e - 12

HTF250m - 48 & HTF350m - 48 HTF250m - 24

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HTF250 HTF350

TheP140Range

18

P140 Range

- Plastics/Injection Moulding

- Food Production Processes

- Chemical and Pharmaceutical

These pressurised units deliver high temperature water heating with limited need for maintenance and offer increased energy efficiency.

Capacities range from 9-48kW, with water temperatures reaching up to 140oC.

P140e • P140s • P140m

- Water up to 140oC

The unit features an air bottle, stainless steel heat exchanger, pressure sustaining accumulator, non- ferrous internal parts, low tank volume and solid state relays. The unit also features an auto shutdown system to prevent any leaks.

19

C7 Controllers

P140About the units

Available Options:

- Direct cool

- Increased cooling



- Connections for various anologue inputs & outputs

• C7 basic with diagnostic control for P140e models

• C7 advanced standard on P140s and P140m - see page 6

• Non-ferrous parts - All components exposed to water are made of non- ferrous 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

20

Technical Data P140

Technical Data P140e P140s P140s P140m

Outlet temperature: oC 140 140 140 140

Heat transfer fluid: Water Water Water Water

Heating capacity: kW 9/12 9/12 18/24 24/36/48

Cooling capacity: kW 40 80 100 150


oC 140 140 140 140


Flow rate: lpm 40 40 70 130

Pressure: bar 3.8 3.8 4 3



Operating voltage: (std.) v-ph-Hz 400-3-50+E

Connections:

Process flow return: - G½” G½” G1” G1¼”

Coolant inlet/outlet: - G½” G½” G½” G½”

Dimensions:

Length: mm 630 755 755 1055

Width: mm 305 360 360 500

Height: mm 670 920 920 1.185

Weight: kgs 50 60 70 80


Ambient temperature: oC 40


Equipment P140e P140s P140m

Control system C7 ü ü -

Control system C7 advanced - ü üSolid state relay ü ü üElectronic flow measurement - ü üDisplay of outlet pressure - ü üLeak-free pump - Optional Optional

Pressure gauge for outlet pressure ü ü ü

21

P140 Pump Capacity

P14

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P14

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P140 Schematics

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P140e - 9 & P140e - 12P140s - 9 & P140s - 12

P140s - 18 & P140s - 24

P140m - 24 & P140m - 36 & P140m - 48

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.

OEM Manufacturing

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 dimensions2 - Voltages and temperatures3 - Flow rates and pressures4 - 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.

23

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.

Contact us

ICS Service • 24/7 Nationwide Support • Emergency Breakdown • 0800 169 3861

www.tricool.com

Group Companies

Head Office SouthICS HouseStephenson RoadCalmore Industrial EstateTotton, Southampton SO40 3RYFREEPHONE 0800 169 3861T +44 (0)23 8052 7300F +44 (0)23 8042 8366

London

T +44 (0)208 200 2404

Midlands

T +44 (0)121 326 7771F +44 (0)121 327 4114

North

T +44 (0)1274 740877F +44 (0)1274 391708

Scotland

T +44 (0)1698 723308F +44 (0)1698 723309

Ireland

T +353 (0)46 92 52934M +353 (0)87 279 2024

tool heaters and temperature controllers

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