Microgel Mould Temperature Control Unit · 2020. 3. 26. · MicrogelTM for injection molding Single and dual zone temperature control units with inte-gral water-cooled chiller and

MicrogelTM for injection molding

Single and dual zone temperature control units with inte-gral water-cooled chiller and booster pumps.

Microgel is a super-compact mold cooling unit specifically designed for “cycle cooling time reduction”. Combines a water-cooled chiller with one or two high flow booster pump temperature controllers with heating elements and a free-cooling valve.

Digitally-synchronized with the molding machine, allows for researching and recording the best setting of flow rate and temperature for each zone, optimizing product quality with the minimum cycle cooling time.

Range available in 11 models for the dual zone version and 14 models for the single zone version with cooling capacity from 4 to 180 kW, with heating capacity from 6 to 48 kW.

Available with two versions of process pumps (see page 8):

SP = standard pressure, high flow pumps

HP = high pressure, high flow pumps

The choice of components, the assembly procedures and the rigorous final testing of 100% of the production gua-rantee continuous operation with maximum reliability, even in the most difficult conditions.

Main advantages

Synchronization with the process Cycle time reduction up to 50% Intelligent use of energy consumption High energy savings with automatic free-cooling

Available mold drain kits Web-monitoring interface Temperature, flow and pressure digital readings (IN/

OUT)

Microgel for plastic

injection molding

Summit TPC: Vanguard Tame Park, Tamworth, Staffordshire B77 5DY T: +44(0)1827 213401 | www.totalprocesscooling.co.uk

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Microgel - RCD/RCM

Mold temperature control

The mold temperature has a considerable influence onthe quality of the molded piece and on the work cycle

Optimization of the production process

Production capacity (cycle reduction, waste and deadtime)

Product quality (better aesthetics and consistent dimen-sional stability)

Reduction in operating costs (reduction of scrap andenergy savings)

Benefits for the process

Perfect repeatability and high productivity Possibility of searching and storing the best cooling con-

ditions Complete independence in setting work parameters Pressure - flow - temperature control of each indivi-

dual process Precision in process temperature control Permanently stable and controlled cooling conditions High cooling efficiency and minimal temperature dif-

ferencial on the mold High reliability Maximum flexibility to eliminate the known problems of

process cooling (condensation, appearance of the piece,respect for the dimensional aspects)

Maximum integration between Microgel, machine andoperator

Benefits for the user Low energy consumption and fast start-up Low pump energy consumption Low losses related to thermal losses in the environment Reduction of dead times for mold changeover and

preheating Low maintenance costs (simple and fast) Minimum environmental impact, having up to 80% less

refrigerant than a centralized system High energy savings with the "INDIVIDUAL FREE-

COOLING" function

Automotive

Packaging

Medical

Technical Molding

Dual zone

RCD Microgel


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Microgel - RCD/RCM

Standard functions

7" backlit touchscreen interface (HMI)

Multilingual interface

Instructions and troubleshooting guide integrated in the multilingual display

Representation through graphical synoptics of the main operating variables

Complete views of all water and refrigeration parameters for easy understanding of operating principles

Readout of % of compressor usage

Delivery temperature reading (for each zone)

Reading of delivery and return pressure (for each zone)

Water flow reading (for each zone)

Calculation of pressure and flow differential

Metric/IP system selectable from standard user panel

Automatic operation in Free-Cooling mode

Remote start/stop function

High/low pressure differential protection

Probe protection (interrupted and/or short-circuited)

Anti-ice protection

Prolonged signaling of set point deviation

Recording 50 alarms and 1000 in memory on SD card

Automatic start-up venting and filling sequence

Cooling control with motorized modulating valve (one for each zone)

High efficiency process pump for each zone

High efficiency recirculation pumps

Filter on cooling water inlet

Filter on water return from the process

By-pass for standard pressure regulation from the RC18 to 170-L (included)

Acoustic alarm

Heavy duty caster for pivot handling

Options and accessories

Serial interface: Different serial interface protocolsavailable to manage the product with centralized elec-tronic devices

Visual alarm: In addition to the acoustic alarm fittedas standard, a visual alarm is also available on request

Separate circuit versions: For particular applicationsit is possible to supply on request also the CT or SCversion which is made in such a way as to separate theuser circuit from the cooling circuit

Tower kit: It is usually used to avoid fouling or con-tamination problems in the condenser with open circuitcooling systems (evaporative tower or well)

Flowmeters and external temperature sensors

Insulation kit for low operating temperatures

Typical connection scheme

Microgel RCD with drain kit


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Microgel - RCD/RCM

DIGITAL CONTROL examples of pages on the display

Main user screen

All unit variables are displayed, including water-side and refrige-rant-side temperatures and pressures

Color coding indicates which parameters are out of range andwhich components are active, including compressors, heaters,pumps, 3-way valves and filling/free cooling valves

Touching on “Chiller Refrigerant Side” of the main user screen

All refrigerant temperatures and pressures are indicated,including subcooling and superheat values

Touching on “Zone 1” or “Zone 2” of the main user screen

All pump values are indicated, including supply and return pres-sures, ΔP, calculated flow rates (actual values with optional flowmeters) and pump & heating kW values

Graphical representations of pump performance and tempera-tures are included

Chiller performance screen

A graphical representation of chiller performance versusset point over a 60 minute time frame is displayed

Compressor loading is depicted graphically

Cooling capacity, absorbed power and COP (coefficient ofperformance) are indicated

Historical alarm log screen

Additional information for each alarm can be viewed by pres-sing and holding the alarm bar

Full language alarm descriptions are supplied along with recom-mendations and possible causes (troubleshooting)


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Microgel - RCD/RCM

Main features

Refrigeration equipment

High efficiency and low noise hermetic Scroll compressors Stainless steel brazed plate evaporator and condenser Continual condensing pressure control by means of a pressure valve Double high pressure gas alarm (via software and mechanical) Ecological gas, in compliance with European environmental protection directives

Water distribution equipment

Designed to provide constant pressure and flow both to the process and to the evaporator One or two process pumps with special high-performance mechanical seal in terms of flow rate and durability Wide range of capacities from 20 to 450 m3/h Recirculation pump to guarantee constant flow to the evaporator Low surface load Incoloy heating elements Safety thermostat for resistances Temperature control system with proportional modulating valve for each zone, for precise temperature control Automatic start-up venting and filling sequence Stainless pipes and fittings Insulated stainless steel buffer tank

Electrical and control equipment

Electrical panel complete with door interlock switch Protection of electrical circuits of compressors and pumps Microprocessor controller developed according to Frigel specifications Control panel with 7" touch screen display (HMI) Possibility of installing the most well-known interface systems for communication with production machines and

centralized supervision Complete monitoring of the refrigeration and hydraulic circuit using pressure and temperature sensors Complete display on the message display, in selected language, with precise instructions on procedures, faults and

possible solutions Proportional-integral control logic for temperature control with error lower than ±1°C Procedures for loading and emptying the mold circuit Standard acoustic alarm

Provision for installation of optical alarms, also remotable

Frame

Made of steel and painted with epoxy powder Removable panels Compact design and fitted with casters


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Microgel - RCD/RCM

Technical and dimensional data RCD - 50Hz

(*) Cooling capacities are based on supply to process/condenser inlet water temperatures and process water delta T = 2°C

(**) See pump performance curves on page 8.

Available supply voltage: 400V±10%/3/50Hz; 460V±10%/3/60Hz; 380V±10%/3/60Hz; On request: UL electrical panel for 60 Hz versions

Microgel - RCD

Model 40/12 60/12 80/12 100/24 130/24 170/24-L 170/24 210/24 300/48 350/48 450/48

Power supply voltage and frequency 400V±10%/3/50Hz

Cooling capacity (*) 10°C/35°C kW 7,3 10,5 16,1 20,4 26,7 34,2 34,2 41,9 55,8 69,8 89,1

Heating capacity kW 6+6 12+12 24+24

Compressor

HP 3 4 6 8,5 10 13,5 13,5 15 20 25 30

Type Scroll

Recirculation pump kW 0,37 0,55 1,10 1,10 1,50

SP process pump (**) kW 0,75 1,50 1,80 3,00 5,50

HP process pump (**) kW 1,50 2,20 5,50 7,50

Total max. electrical load and FLA

SP pro-cess

pump

kW 15 16 16 29 29 30 34 36 61 64 69

A 24 27 30 47 49 51 55 60 96 105 115

HP pro-cess

pump

kW 16 16 16 30 30 32 39 41 65 68 73

A 27 27 30 49 51 54 65 70 104 113 123

Compressed air (min. 4 - max 7.5 bar) - Yes

Sound level dB(A) @ 10 m 39 40 41

Net weight kg 210 215 235 360 370 395 600 650 950 980 1.015

Process connections in G 1" G 1 ½” G 2" 3" Victaulic

Cooling connections in G 1" G 1 ½” 2" Victaulic

Compressed Air Connections

mm - 6

Machine dimension

Model 40/12 60/12 80/12 100/24 130/24 170/24-L 170/24 210/24 300/48 350/48 450/48

A mm 450 450 450 540 540 540 630 630 950 950 950

B mm 910 910 910 1.210 1.210 1.210 1.790 1.790 1.850 1.850 1.850

C mm 1.110 1.110 1.110 1.420 1.420 1.420 1.470 1.470 1.470 1.470 1.470

Weights and dimensions refer to units in basic configuration, without added options


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Microgel - RCD/RCM

Technical and dimensional data RCM - 50Hz



Available supply voltage: 400V±10%/3/50Hz; 460V±10%/3/60Hz; 380V±10%/3/60Hz On request: UL electrical panel for 60 Hz versions

Machine dimension

Model 18/6 40/6 60/6 80/6 100/12 130/12 170/12-L 170/12 210/12 300/24 350/24 450/24 700 900

A mm 390 450 450 450 540 540 540 630 630 950 950 950 950 950

B mm 590 910 910 910 1.210 1.210 1.210 1.790 1.790 1.850 1.850 1.850 2.380 2.380

C mm 840 1.110 1.110 1.110 1.420 1.420 1.420 1.470 1.470 1.470 1.470 1.470 1.500 1.500


Microgel - RCM

Model 18/6 40/6 60/6 80/6 100/12 130/12 170/12-L 170/12 210/12 300/24 350/24 450/24 700 900

Power supply voltage and frequency 400V±10%/3/50Hz

Cooling capacity (*) 10°C/35°C kW 3,8 7,3 10,5 16,1 20,4 26,7 34,2 34,2 41,9 55,8 69,8 89,1 140,0 178,0

Heating capacity kW 6 6 12 24 --

Compressor

HP 1,5 3 4 6 8,5 10 13,5 13,5 15 20 25 30 2 x 25 2 x 30

Type recipr. Scroll Multiscroll

Recirculation pump kW - 0,37 0,55 1,10 1,10 1,50 4,00

SP process pump (**) kW 0,45 0,75 1,50 1,80 3,00 5,50 11,00

HP process pump (**) kW - 1,50 2,20 5,50 7,50 22,0


SP process pump

kW 7 8 9 9 15 15 16 19 21 32 35 40 69 80

A 11 13 15 18 25 27 29 32 37 51 60 69 117 135

HP process pump

kW - 9 9 9 16 16 17 21 24 34 37 42 80 91

A - 15 15 18 26 28 31 37 42 55 64 73 136 154

Compressed air (min. 4 - max 7.5 bar)

- Si


Net weight kg 120 180 185 195 295 300 340 500 550 770 810 880 1.380 1.445

Process connections in G ½" G 1" G 1 ½” G 2" 3" Victaulic 4" Victaulic

Cooling connections in G ½" G 1" G 1 ½” 2" Victaulic 3" Victaulic


mm - 6


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Microgel - RCD/RCM

Process pumps curves 50Hz RCM 18 Process pumps

RCM single zone

single pump

RCD dual zone

two pumps

RC_40 RC_60-80

RC_100-130-170L RC_170-210

RC_300-350-450 RC_700-900

HP - HIGH PRESS

SP - STD PRESS


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Microgel - RCD/RCM

Technical and dimensional data RCD - 60Hz




Microgel - RCD

Model 40/12 60/12 80/12 100/24 130/24 170/24-L 170/24 210/24 300/48 350/48 450/48

Power supply voltage and frequency 460±10%/3/60Hz

Cooling capacity (*) 10°C/35°C kW 8,8 12,5 19,8 24,8 31,0 41,4 41,4 51,3 67,1 83,3 106,0

Heating capacity kW 6+6 12+12 24+24

Compressor

HP 3 4 6 7,5 10 13,5 13,5 15 20 25 30

Type Scroll

Recirculation pump kW 0,55 0,75 1,10 1,50 1,50

SP process pump (**) kW 1,10 1,50 2,20 3,00 5,50

HP process pump (**) kW 1,50 3,00 5,50 7,50 2,20


SP process pump

kW 16 16 18 30 31 34 36 40 63 70 77

A 380V 25 27 28 48 52 57 62 68 105 106 116

A 460V 21 25 27 42 46 49 53 58 94 103 113

HP pro-cess pump

kW 16 17 19 32 33 37 41 45 67 74 81

A 380V 27 29 30 52 56 63 74 77 113 114 124

A 460V 24 26 28 44 49 53 60 65 102 111 121


- Yes


Net weight kg 210 215 235 360 370 395 600 650 950 980 1.015

Process connections in G 1" G 1 ½” G 2" 3" Victaulic

Cooling connections in G 1" G 1 ½” 2" Victaulic

Compressed Air Con-nections

mm - 6

Machine dimension

Model 40/12 60/12 80/12 100/24 130/24 170/24-L 170/24 210/24 300/48 350/48 450/48

A mm 450 450 450 540 540 540 630 630 950 950 950

B mm 910 910 910 1.210 1.210 1.210 1.790 1.790 1.850 1.850 1.850

C mm 1.110 1.110 1.110 1.420 1.420 1.420 1.470 1.470 1.470 1.470 1.470



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Microgel - RCD/RCM

Technical and dimensional data RCM - 60Hz




Machine dimension

Model 18/6 40/6 60/6 80/6 100/12 130/12 170/12-L 170/12 210/12 300/24 350/24 450/24 700 900

A mm 390 450 450 450 540 540 540 630 630 950 950 950 950 950

B mm 590 910 910 910 1.210 1.210 1.210 1.790 1.790 1.850 1.850 1.850 2.380 2.380

C mm 840 1.110 1.110 1.110 1.420 1.420 1.420 1.470 1.470 1.470 1.470 1.470 1.500 1.500


Microgel - RCM

Model 18/6 40/6 60/6 80/6 100/12 130/12 170/12-L 170/12 210/12 300/24 350/24 450/24 700 900

Power supply voltage and frequency 460±10%/3/60Hz

Cooling capacity (*) 10°C/35°C kW 4,5 8,8 12,5 19,8 24,8 31,0 41,4 41,4 51,3 67,1 83,3 106,0 167,0 212,0

Heating capacity kW 6 6 12 24 --

Compressor

HP 1,5 3 4 6 7,5 10 13,5 13,5 15 20 25 30 2 x 25 2 x 30

Type Re-cipr. Scroll Multiscroll

Recirculation pump kW - 0,55 0,75 1,10 1,50 1,50 4,00

SP process pump (**) kW 0,45 1,10 1,50 2,20 3,00 5,50 11,00

HP process pump (**) kW - 1,50 3,00 5,50 7,50 22,00 2,20


SP process pump

kW 7 8 9 10 16 16 20 21 25 34 41 47 81 94

A 380V 11 14 15 15 26 30 34 38 44 60 62 72 121 141

A 460V 10 12 14 16 23 27 29 32 37 51 60 70 117 137

HP process pump

kW - 9 10 11 17 17 21 24 27 36 43 49 92 105

A 380V - 15 16 16 27 31 37 42 48 64 66 76 141 161

A 460V - 13 14 16 24 28 31 36 41 55 64 74 133 153


- Yes

Sound level dB(A) @10 m 39 40 41

Net weight kg 120 180 185 195 295 300 340 500 550 770 810 880 1.380 1.445

Process connections in G ½" G 1" G 1 ½” G 2" 3" Victaulic 4" Victaulic

Cooling connections in G ½" G 1" G 1 ½” 2" Victaulic 3" Victaulic


mm - 6


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Microgel - RCD/RCM

Process pumps curves 60Hz RCM 18 Process pumps

RCM single zone

single pump

RCD dual zone

two pumps

RC_40 RC_60-80

RC_100-130-170L RC_170-210

RC_300-350-450 RCM 700-900

HP - HIGH PRESS

SP - STD PRESS


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Microgel - RCD/RCM

Connection example

Order code

Typical scheme of an injection molding coo-

ling system (Ecodry System)

with

Microgel

for each mold

Typical connection diagram of a

RCD Series Microgel

to the injection molding and to the

centralized circuit


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Microgel - RCD/RCM

Documents

Microgel Mould Temperature Control Unit · 2020. 3. 26. · MicrogelTM for injection molding Single and dual zone temperature control units with inte-gral water-cooled chiller and