Pressurised Water Chillers

Pressurised water temperature control units up to 160°C

Pressurised water temperature control units from Tool-Temp distinguish themselves through the ability to regulate water temperature at values above 100 °C. Tool-Temp divides its pressurised water systems into two temperature groups: units with a maximum temperature up to 140 °C and units with a maximum operating temperature of up to 160 °C.

TT-1398 N

  • Maximum temperature 140°C
  • Heating capacity 6 kW
  • Cooling capacity 20 kW @ 140°C
  • Cooling system indirect
  • Pump capacity 110 l/min;
    max. 5.0 bar
  • Medium water

For injection moulding applications, small moulds

TT-142 N

  • Maximum temperature 140°C
  • Heating capacity 12 kW
  • Cooling capacity 60 kW @ 140 °C
  • Cooling system indirect
  • Pump capacity 110 l/min;
    max. 5.0 bar
  • Medium water

Tool moulds, injection moulds, small rollers, extruders

TT-137 N

  • Maximum temperature 140°C
  • Heating capacity 12 kW
  • Cooling system indirect / direct
  • 90 kW @ 140°C indirect
  • 60 kW @ 50°C direct
  • Pump capacity 110 l/min;
    max. 5.0 bar
  • Medium water

Moulds, temperature control system with wide temperature range

TT-137 B/BP

  • Maximum temperature 160°C
  • Heating capacity 12 kW
  • Cooling system indirect / direct
  • 90 kW @ 160°C indirect
  • 60 kW @ 50°C direct
  • Pump capacity 75 l/min;
    max. 6.5 bar
  • Medium water

Moulds, temperature control system with wide temperature range

TT-138 N

  • Maximum temperature 140°C
  • Heating capacity 18 kW I 24 kW
  • Cooling system indirect / direct
  • 85 kW @ 160°C indirect
  • 60 kW @ 60°C direct
  • Pump capacity 110 l/min;
    max. 5.0 bar
  • Medium water

Moulds, double-walled containers, temperature control system with wide temperature range

TT-138 B/BP

  • Maximal temperature 160°C
  • Heating capacity 18 kW I 24 kW
  • Cooling system indirect / direct
  • 85 kW @ 160°C indirect
  • 60 kW @ 60°C direct
  • Pump capacity 75 l/min;
    max. 6.5 bar
  • Medium water

Moulds, double-walled containers, temperature control system with wide temperature range

TT-DW160

  • Maximum temperature 160°C
  • Heating capacity 9 kW I 18 kW
  • Cooling capacity 40 kW @ 150°C
  • Cooling system indirect
  • Pump capacity 36 l/min;
    max. 5.0 bar
  • Medium water

Small moulds, compact, powerful pressurised water system

TT-1358 W

  • Maximum temperature 130°C
  • Heating capacity 24 kW I 48 kW
  • 180 kW @ 130°C indirect
  • 400 kW @ 70° direct
  • Cooling system indirect
  • Pump capacity 250-350 l/min;
    max. 4.5 bar
  • Medium water

 

rollers, plates, temperature control system with very high cooling capacity

Product range overview -pressurised water temperature control units

Pressurised water temperature control units from Tool-Temp. Ideal for temperatures up to 160 °C - using water as the medium

In order to bring temperatures above the boiling point, the system must be pressurised. This means that the prevailing static pressure in the temperature control circuit is increased accordingly. The static pressure in units that operate up to 140 °C is directly increased using the mains water pressure. In order to achieve temperatures up to 160 °C, all pressurised water systems from Tool-Temp use booster pumps to increase the pressure. These ensure that the units operate properly, regardless of the mains water pressure, and can be used up to the maximum intended temperature. The nature of the system means that pressurised water units must be connected to the mains water supply. This is because the units generate the required pressure using the mains pressure.

Practically all Tool-Temp pressurised water units feature a dome-shaped water tank. At a circulation temperature of 80 °C, the solenoid valve closes the air vent so that the system is closed off from the atmosphere. This ensures that the static pressure in the system remains higher than the saturation pressure due to the temperature. This is necessary so that the pump on the intake side does not experience cavitation. To prevent an excessive increase in the static pressure inside the unit, the pressurised water units from Tool-Temp feature an expansion tank with a pretensioned membrane. This moderates the speed at which the pressure increases in relation to the vapour pressure curve. The pressure generated from the mains water supply or from the booster pump is partially absorbed by the expansion tank. This feature of Tool-Temp units means that they also have the advantage of being able to hold up against the pressure increase that results of expansion of the circulation water. This allows large consumers to be connected without the units going into an emergency shut-off due to overpressure.

The units have an automatic refill feature. When the temperature is below 80 °C, a solenoid valve opens to refill the unit from either mains water pressure or the booster pump. The filling pump allows refilling to happen even if the mains pressure is lower than the system pressure as determined by the inlet temperature. The water now flows through the check valve and into the system. All pressurised water units from Tool-Temp have a mould evacuation feature that makes handling the units easier and allows the mould to be changed more quickly. In some models, this feature makes use of an active evacuation using compressed air. This guarantees complete drainage without any residual water remaining.

All elements required for control and automatic monitoring such as push buttons, contactors, thermal relays for the pump motor, circuit breakers as well as the temperature controller are housed in the unit’s switch box. Temperature control uses a PID controller with heat-neutral-cool settings. The electronics are so designed that heating and cooling signals cannot be activated at the same time. This makes the controller extremely energy efficient.

When using semi-conductor contactors, the automatic safety devices and/or fuses cut the power supply in the event of an overload or short circuit within the protected component (e.g. heater).

Thanks to its high thermal capacity and environmentally-friendly nature (uncomplicated disposal), water is popular for use as a heat transport medium. The thermal capacity of water is around 4.2 kJ/kg, double that of heat transport oils. This means that significantly more energy can be transported and a more stable mould temperature achieved at a lower flow rate. Water also has a much lower viscosity compared to oil at around 1 mm²/s below 250 °C. This allows for more turbulent flows to be achieved at lower flow speeds. Turbulent flow is needed to ensure a faster exchange of heat between the heat transport medium and the relevant surfaces (heating elements, coolers, mould channels, inside surfaces of rollers, reactor walls, etc.)

As one of just a few heat transport mediums, water also has the advantage that its heat transfer properties are almost entirely independent of the temperature. This allows water to be used with a large range of temperatures. Water quality plays an especially important role in pressurised water units. Dissolved salts, chlorine content that is too high, a pH value that is too low, or the use of copper pipes and cavities can lead to corrosion, limescale or material fatigue. Chemically treated water is often essential when using it in industrial processes. In using this, it is critical that the additives used are suitable for high temperatures and that they do not decompose or split into acids at temperatures above 100 °C and do not form explosive vapours.

Tool-Temp places great value on ensuring robust construction. Pressurised water systems exclusively make use of permanent pipe joints. These are made using highly automated bending machines at the plant in Sulgen. The housing is fully enclosed so that zero contamination can take place. Heaters are placed under minimal load and the ratio of load on the heating surface to flow rate is optimised. Critical components such as coolers and flow rate sensors are produced in our own facilities. Starting with the design phase, special attention is given to the materials used. Without exception, stainless steel is used at every single point that will come into contact with water.

The following safety elements are integrated into all pressurised water units from Tool-Temp:

  • The check valve prevents water from flowing backwards if the pressure in the circuit is higher than the mains supply pressure.
  • Two safety valves monitor the rising pressure. The first valve switches off the heating, the second opens the circuit when the pressure is too high to force a drop in pressure.
  • The manometers show both the system and pump pressures.
  • The flow rate sensor monitors circulation of the circulation medium to the consumer.
  • The pressure release ensures that the temperature control circuit is depressurised before the unit is decoupled from the consumer. When the unit is unpressurised (solenoid valve open) and the temperature is below 80 °C, the consumer can be emptied using suction.

Alongside the maximum temperature, the pressurised water series from Tool-Temp can also be divided into two groups in relation to cooling. All units feature indirect cooling as standard. There is an additional group of units which also feature direct cooling alongside the indirect cooling. Below 80 °C, the models with two cooling systems can be switched over from indirect cooling using a pipe bundle heat exchanger to direct cooling. A solenoid valve opens, allowing cooling water to flow directly into the water tank. This form of cooling mixes the cooling water with the process water. Excess water leaves the unit via the cooling water outlet. These pressurised water units can be used in a variety of applications due to their excellent cooling power across their entire operational range.

The primary advantage of pressurised water units lies in the high heat carrying capacity and excellent heat transfer properties of water. Compared to oil heat transfer mediums, water can transport much more energy. The wide range of operating temperatures achieved by Tool-Temp pressurised water units, as well as the direct cooling function, makes these units suitable for a wide range of applications. They are used for heating tool moulds in the plastic industry, controlling the temperature of rollers in the printing industry, and temperature control for extruders in the chemical, pharmaceutical and food processing industries.