Piovan WTC Thw9

THP6 - THP12
THW9 - THW12
THO6
Service Book KG001904 - ENGLISH
1. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1. Output of heat exchangers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2. Pump performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3. Water specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3. Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1. Positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2. Hydraulic connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3. Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5. Start the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1. Preliminary checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2. First start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2.a. First start-up of models THP - THW. . . . . . . . . . . . . . . . . . . . . 21
5.2.b. First start-up of models THO. . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3. Normal start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.4. Operation of electric pump in reversible mode. . . . . . . . . . . . . . . . . . 24
6. Stopping the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7. Alarm signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8.1. Scheduled maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1.a. Every month. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1.b. Periodically. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.2. Assembly of float (models THW - THO). . . . . . . . . . . . . . . . . . . . . . . 29
Non original instructions obtained by translating the original manual written in Italian
8.3. Disassembling and reassembling heating elements and exchanger. 30
9. Instructions for automatic rapid drainage (optional). . . . . . . . . . . . . . . 31
9.1. Models THP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.2. Models THW - THO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10. Connection in serial line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11. Decommissioning the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
12. Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
TABLES OF SPARE PARTS
WIRING DIAGRAM
I ENGLISH
Safety rules
1. Failure to observe the basic rules of accident prevention and safety is one of
the main causes of accidents when using and servicing industrial machinery.
2. Before performing any operation on the machine you must carefully read
this manual, the safety rules below and the information given on the warning
notices affixed to the machine. Do not allow unauthorised personnel to use,
adjust or repair the machine.
3. In the design and manufacture of the machine and the writing of the instruction
manual, all attempts have been made to eliminate or reduce the hazards for
those who install, use or repair the machine. If you come across any further
potentially hazardous conditions, please inform the manufacturer, who will take
measures to remedy the problem.
4. When required, all persons working on the machine must wear protective
clothing (helmets, safety footwear, gloves, earplugs or hearing protection,
safety goggles etc.) in accordance with international workplace safety
standards.
5. Only persons with adequate technical training, who have a complete
working knowledge of the machine, who have the necessary physical and
psychological requirements for working safely on the machine and who have
fully read the documentation supplied are allowed to operate the machine and
perform routine maintenance tasks on it.
6. Set up footboards or platforms (in accordance with the safety regulations in
force) when installing parts that cannot be reached from ground level.
7. When interfacing with other processing machines, strictly observe the
instructions given by the manufacturers of the other machines.
8. Check that the safety systems (guards, microswitches, sensors) are in
perfect working order before starting work. Any parts that are not in perfect
working order must be repaired before proceeding. It is strictly forbidden to
remove safety devices, or to tamper with the electrical system or any of the
mechanisms.
9. This machine must be used for the purpose for which it was designed.
Improper use of the machine is strictly prohibited.
10. Do not touch the machine with your hands or any other parts of the body if
they are wet or damp.
The manufacturer cannot be held responsible for any injury to persons or
damage to property resulting from the non-observance of the above safety
prescriptions.
These prescriptions supplement but do not replace the statutory industrial
accident prevention regulations in force in the country where the machine
is installed.
ENGLISH 2
Graphic safety symbols
DANGER
Refers to procedures or practices which, if not performed
correctly, cause serious harm to health, injury or death.
DANGER
Electric shock!
DANGER
Hot surface!
WARNING
correctly, may cause serious harm to health, injury or death.
WARNING
Protective footwear must be worn!
WARNING
Protective gloves must be worn!
WARNING
Head protection must be worn!
WARNING
Face guard must be used!
WARNING
Respiratory protection must be used!
CAUTION
correctly, may cause serious damage to the system or
Ingranaggi
_01
individual components thereof.
ATTENTION
Refers to possible hazardous situations that may cause
serious damage to the system or individual components
thereof.
3 ENGLISH
1. Description
A temperature controller is a device for maintaining a constant temperature in a
fluid, called a process fluid. This fluid, conveyed by appropriate means, is used in
turn to maintain the temperature of liquids or solids constant (particularly utilities
for plastic materials).
This manual refers to the following models of temperature controllers:
• THP..., in which pressurised water is used as a process fluid.
• THW..., in which non pressurised water is used as a process fluid.
• THO..., in which diathermic oil is used as a process fluid.
Fig. 1
DANGER
Risk of serious damage to health, injury or death.
►►All uses of the machine are excluded in environments
with a potentially explosive atmosphere, caused by
powders or gas.
ENGLISH 4
2. Technical data
GENERAL TECHNICAL DATA THP6 THP12
Electric part
230/50 - 400/50
Supply voltage and frequency V/Hz
220/60 - 380/60 - 460/60
Heating element power kW 6 12
Cooling section
Cooling fluid water
Maximum temperature °C 15
recommended (°F) (59)
Hourly capacity l/min 15 ÷ 20
kPa 350 ÷ 450
Pressure
(bar) (3.5 ÷ 4.5)
Performance
Process fluid water
°C 140
Maximum temperature of fluid
(°F) (284)
Cooling power* kW 28 70
Filling volume l 6
Notes:
Cooling water capacity l/min 15
Temperature of cooling 10
* water °C (50)
Temperature of process (°F) 120
fluid (248)
Various
Equivalent sound pressure level dB(A) 72
kPa 600 ÷ 800
Rapid drainage air pressure
(bar) (6 ÷ 8)
Total weight kg 60
5 ENGLISH
GENERAL TECHNICAL DATA THW9 THW12
Electric part
400/50 400/50
230/50 230/50
Supply voltage and frequency V/Hz 380/60 380/60
220/60 220/60
460/60 460/60
Heating element power kW 6 9 11 12
Cooling section
Cooling fluid water
kPa 200 ÷ 700
Pressure
(bar) (2 ÷ 7)
Performance
Process fluid water
°C 90
(°F) (194)
Cooling power* kW 21 38
Filling volume l 10.5
Notes:
* water °C (50)
fluid (176)
Various
kPa 600 ÷ 800
(bar) (6 ÷ 8)
Total weight kg 55
ENGLISH 6
GENERAL TECHNICAL DATA THO6
230/50 - 400/50
220/60 - 380/60 - 460/60
Heating element power kW 6
Cooling section
Cooling fluid water
kPa 200 ÷ 700
Pressure
(bar) (2 ÷ 7)
Performance
Process fluid oil*
°C 160
(°F) (320)
Cooling power** kW 13
Filling volume l 10.5
Notes:
Use diathermic oil for heating systems.
*
We advise using Mobil MOBILTHERM 605 oil.
** water °C (50)
fluid (302)
Various
kPa 600 ÷ 800
(bar) (6 ÷ 8)
Total weight kg 55
7 ENGLISH
Electric pump THP6 THP12
230/50 - 400/50
220/60 - 380/60 - 460/60
Power kW 0.75
Maximum capacity l/min 40
Maximum head m 60
Electric pump THW9 THW12
230/50 - 400/50
220/60 - 380/60 - 460/60
Power kW 0.75
Maximum head m 40
Electric pump THO6
230/50 - 400/50
220/60 - 380/60 - 460/60
Power kW 0.75
Maximum head m 40
ENGLISH 8
Working environment
°C 5 ÷ 40
Ambient temperature
(°F) (41 ÷ 104)
Altitude m Max 2000
°C -25 ÷ 55 (-13 ÷ 131)
Transport and storage temperature
(°F) 70 (158) < 24h
679
250
686
THP6 - THP12 THW9 - THW12 THO6
80 45 80 75 50
80 75 50
f e
h e f h e f
225
225
73 g 90 g 90
476
i
g k k
65
h 35
505
505
235
235
j/k
257
j j
150
130
130
Fig. 2
For the meaning of the symbols located on the rear panel of the machine, see
Par. 4. 2. - Page 17.
d8e962f2-c899-4594-a9bb-ac8e06b75b42
9 ENGLISH
04a_tptwto
2.1. Output of heat exchangers
04c_tptwto
THP6 THP12
kW
THP6 90
80
kW
70
35
60 kW
30 14
25 50
12
20 40 10
30 8
15
6
10
5
04c_tptwto 20
10
4
2
0 20 40 60 80 100 120 ∆Τ °C 0 10 20 30 0 40 50
30 60 6070 8090 90 120100 110150
120 130 °C
180 ∆Τ °C
0 36 72 108 144 180 216 ∆Τ °F 0 18 36 54 0 72 90
54 108108126 144
162 162 216
180 198270
216 234 °C
324 ∆Τ °F
THW9
kW
kW kW 14
25 50 12
20 40 10
8
15 30
6
10 20
4
5 10 2
0 20 40 60 80 ∆Τ °C 0 20 40 60 80 ∆Τ °C 0 30 60 90 120 150 180 ∆Τ °C

0 36 72 108 144 ∆Τ °F 0 36 72 108 144 ∆Τ °F 0 54 108 162 216 270 324 ∆Τ °F
Fig. 3
ΔT = ifference between temperature of process fluid leaving the machine
d
and temperature of cooling fluid entering the heat exchanger.
06b_tptwto
06b_tptwto
2.2. Pump performance
THP6 - THP12
m
70
60
m
m
50 50
50
40 40
40
30 30
30
20 20
20
10 10
10
0 10 20 30 40 50 l/min 0 10 20 30 40 50 60 l/min
0 10 20 30 40 50 60 l/min
Fig. 4
ENGLISH 10
2.3. Water specifications
Check that the water used by the temperature controller respects the indications
below, which comply with data obtained from experience and with the provisions
of Standards UNI/CTI 8884 and UNI/CTI 8065.
Water specifications
Clear, colourless, odourless,
Appearance free from sediment and
suspended solids
pH >7
µS/cm
Electric conductivity < 1500
(at 20°C)
< 80
Hardness mg/l
(< 8)
CaCO3
Hardness <5
(°Fr)
(pressurised water circuits) (< 0.5)
Chlorides mg/l Cl < 100

Sulphates mg/l SO4 < 50
Iron mg/l Fe < 0.2
Copper mg/l Cu < 0.05
Organic substances mg/l O2 Absent
Dissolved gases:
● hydrogen sulphide;
Absent
● ammonia;
mg/l (oxygen within solubility limits)
● methane;
● oxygen.
Mineral oils Absent
11 ENGLISH
3. Handling
Safety rules for handling, lifting, packing, and unpacking
1. The machine must be handled by expert personnel in accordance with
statutory health and safety regulations.
2. Use handling equipment that conforms to the safety requirements stated in
"Machinery Directive" in force. The handling equipment must be accompanied
by documentation certifying its conformity to the above requirements and
must be capable of bearing the weight of the machine plus its packing and
any accessories installed before the final positioning of the machine. Carefully
follow any instructions marked on the machine packing (the weight is given on
the outside of the pack). Do not use ropes or chains to harness the pack.
3. All handling operations must be performed with the machine completely
empty, i.e. with no process materials or fluids inside it, and with any external
support structures removed.
4. All the machine parts involved in the lifting operation are sized for handling
solely the machine with no accessories installed (unless otherwise indicated).
5. If the machine is lifted with steel cables, make sure that its weight is evenly
distributed over all the lifting points and that the strain on the cables is uniform.
The angle between each cable and the horizontal plane must not be less than
45°.
6. Fasten any loose parts. Make sure that the load is properly balanced and
securely fastened to the handling equipment. Always proceed with the utmost
caution to avoid injuring persons or damaging the machine.
7. All persons not involved in operating the means of transport must be kept at a
safe distance from the moving load.
8. Position the machine on a perfectly flat and level surface of suitable size and
construction in relation to the weight and dimensions of the machine.
9. After removing the packing, check that all parts of the machine are present
and in good condition. If you have any doubts, do not use the machine:
contact the PIOVAN Technical Service Department or an authorised service
centre. The packing materials must be disposed of in accordance with
statutory waste disposal regulations.
ENGLISH 12
WARNING
Risk of machine falling during handling procedures.
►►Pay special attention and always wear suitable personal
protective equipment!
►►Do not approach the machine in movement.
►►The sizing of the lifting equipment and their use for
handling the machine is the responsibility of the
customer and must be carried out in compliance with
the regulations in force.
►►Do not use slings to hoist the machine: use only a
forklift or pallet conveyor.
►►Before moving the machine lift it slowly a few
centimetres with the forklift or pallet conveyor to find the
centre of gravity.
Fig. 5
After removing the packing, it is possible to move the temperature controller by

hand (for short distances and on a completely flat and level surface) with the aid
of the 4 wheels, 2 of which are directional and fitted with a brake.
If the machine has to be moved after a period of operation, it is indispensable to
ensure that it is switched off, disconnected from the power, pneumatic and water
supply lines, that it has cooled down to room temperature and there are no liquids
inside it.
ENGLISH 14
4. Installation
Safety rules for installation
1. The machine must be installed by skilled personnel in compliance with
statutory health and safety regulations and in accordance with the instructions
in this manual.
2. Make sure the installation work is performed in conditions of adequate visibility
that remain constant through time; install supplementary lighting if necessary.
3. Mark off the work zones with tape and display suitable danger notices in the
areas where the installation work is taking place.
4. Install the machine in a place that is protected from aggressive chemicals and
the weather.
5. Check that the supply voltage and frequency stated on the machine data plate
correspond to those of the electrical mains and check that the mains circuit is
suitably sized in relation to the machine's maximum power input (refer to the
"technical data" table and the wiring diagram).
6. The machine must be connected to an efficient earthing point (as specified in
statutory electrical safety regulations). You must make sure that this essential
safety requirement is complied with. If you have any doubts, have the circuit
thoroughly checked by a qualified electrician. Electrical protection devices,
suitably sized for the total power of the machine, must be installed at the point
of connection to the electrical power feeding line (see wiring diagram).
WARNING
►►It is strictly forbidden to remove or modify the safety
devices and guards fitted by the manufacturer.
WARNING
►►Before performing the electrical connections, verify that
all the devices and the accessories provided have been
installed.
15 ENGLISH
4.1. Positioning
1. Position the machine on a perfectly flat surface, making sure it is suitably
constructed and sized in relation to the weight and dimensions of the machine
and the connected structures.
2. Observe the minimum positioning clearances as indicated below (see Fig. 6 -
Page 16).
Failure to respect these distances could hinder operations of maintenance and
proper ventilation of the electric pump and control panel.
3. The chosen installation site must offer sufficient ventilation for the machine.
>300mm
>1000mm >1000mm
B D
>300mm
Fig. 6
ENGLISH 16
4.2. Hydraulic connection
WARNING
Burning hazard.
►►Convey the safety drain into a separate circuit (models
THP), and overflow (models THW and THO) , so as
to prevent the hot fluid, which could escape due to
malfunctions on the temperature controller, from coming
in to contact with persons accidentally.
►►Use pipes with diameter the same as or larger than that
of the drain.
CAUTION
Danger of damage to the machine.
►►When connecting the pipes, prevent the connections
from turning with a special locking wrench.
CAUTION
Danger of damage to the machine.
►►The pipes connecting the circuit with the utility and
those in the circuit coming from the utility should not be
bent or crushed.
►►Do not install flow controls on the process fluid that
are in contact with the environment or any other
accessories that could represent an obstacle or create a
depression in the circuit on its way to or from the utility.
17 ENGLISH
30_tptwto
_01
Ref. Symbol Description Connection Notes

31_tptwto Use pipes with an internal
_01 Exit of fluid diameter larger than 12 mm
e
toward utility able to resist a pressure of
at least 1000kPa (10bar)
1/2"Gas and a temperature at least
Entrance of fluid female 30°C (54°F) higher than the
f
from utility (including maximum temperature of the
mesh filter) process fluid (*).
Cooling fluid
g -
intake
Use pipes with an internal

diameter larger than 12 mm
able to resist a pressure of
Cooling fluid 1/2"Gas at least 1000kPa (10bar)
h 34_tptwto outlet female and a temperature at least
_01 30°C (54°F) higher than the
maximum temperature of the
process fluid (*).
35_tptwto
_01 Filling of
i temperature - Only on THO models.
controller
36_tptwto Emptying of Dispose of process fluid

according to the rules in
j _01 temperature
effect where the machine is
controller
installed.
3/8"Gas
For THP models, this drain
female
is also used for manual
Safety drain or
k emptying of machine.
Overflow
The drain should never be
plugged.
(*) Read the characteristics of the coolant (see Chap. 2. - Page 5).
ENGLISH 18
4.3. Electrical connections
WARNING
Electric shock hazard.
►►To remove the connector from the socket, never pull the
cable.
►►The power cable must be suitably protected against
crushing, sharp edges, sources of heat or chemical
aggression.
►►If it should be necessary to change the machine’s power
cable, use an electric cable with a suitable section for
the total installed power.
Ingranaggi
_01
ATTENTION
Suitable protection for the total power of the machine must be
installed at the point of connection to the electric mains.
It is advised to use protection fuses: follow the indications in the
enclosed wiring diagram.
In addition, install a main circuit breaker switch between the
electricity line and the machine power supply lead; it must be
installed in an easily accessible position.
The connection between the machine and the main power panel must be done
following the indications given on the wiring diagram.
19 ENGLISH
5. Start the machine
5.1. Preliminary checks

Make the preliminary checks before each start of the machine.
1. Make sure the pipelines for the process fluid are connected correctly and that
there are no leaks at the joints.
2. Make sure the cooling water pipelines are connected and that the pressure is
correct (see Chap. 2. - Page 5).
Once the preliminary checks have been performed it is possible to start the
machine.
5.2. First start-up

Ingranaggi
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ATTENTION
The procedure for “first start-up” should be carried out when the
machine is started for the first time or after a prolonged period
of disuse for maintenance.
The machine can be started only after checking that the voltage
and frequency of the mains correspond to the values shown on
the machine identification plate.
Only for THP models: make sure the pump shaft rotates freely
performing a small rotation by hand, inserting an Allen wrench
in the hole in the ventilation grating on the back of the electric
motor.
ENGLISH 20
5.2.a. First start-up of models THP - THW
1. Power the electric panel by turning the main circuit breaker QS1 to position 1
[ON]: the machine performs some internal checks on the electronic circuit and
the display shows the main menu.
2. Press key for more than two seconds: the machine goes into waiting
status for filling with the process fluid (water) and the light is lit on the
control panel (see respective manual).

3. When the required level is reached the warning light goes out and the
electric pump is switched on to pump the process fluid into the circuit.
4. Check the state of the [ Operation ] parameter (see respective manual).
5. Stop the machine by pressing key .
6. Check, by looking through the inspection slits, that:

-- the electric pump rotates clockwise if Operation = Nor;
-- the electric pump rotates counterclockwise if Operation = Rev.
If the direction of rotation is incorrect, turning the main circuit breaker QS1 to
position 0 [OFF], disconnect the machine from the electric power line and invert
the positions of two of the leads on the terminals of the circuit breaker QS1 (see
wiring diagram).
WARNING
►►These operations must be performed by a skilled
operator with the electrical power disconnected!
7. Power the machine, turn the main circuit breaker QS1 and press the key
again: the work cycle begins.
The machine may fill with additional process fluid depending on the size of the
circuit.
21 ENGLISH
5.2.b. First start-up of models THO
WARNING
Burning hazard.
►►Failure to follow the described procedure could cause
sudden, dangerous outbursts of boiling oil under
pressure from the back of the temperature controller.
Ingranaggi
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ATTENTION
To reach the desired process temperature, it is advisable to
proceed gradually: increase the value at regular intervals of
15°C (27°F) and wait about 10 minutes after each increase to
allow the temperature to stabilize. Upon reaching 95°C (203°F),
maintain the process temperature constant for long enough for
all traces of water and moisture in the oil to evaporate.
[ON]: the machine performs some internal checks on the electronic circuit and
the display shows the main menu.
2. Press key for more than two seconds: the machine goes into waiting
status for filling with the process fluid (oil) and the light is lit on the
control panel (see respective manual).

3. Fill with oil manually. Unscrew the cap on the filling tube i on the rear panel of
the machine and use a funnel to fill with oil until the activation of the electric
pump that sends the process fluid into the circuit (the warning light
goes off) (see Fig. 2 - Page 9).

4. Check the state of the [ Operation ] parameter (see respective manual).
5. Stop the machine by pressing key .
6. Check, by looking through the inspection slits, that:

-- the electric pump rotates clockwise if [ Operation ]= Nor;
-- the electric pump rotates counterclockwise if [ Operation ]= Rev.
ENGLISH 22
If the direction of rotation is incorrect, turning the main circuit breaker QS1 to
position 0 [OFF], disconnect the machine from the electric power line and invert
the positions of two of the leads on the terminals of the circuit breaker QS1 (see
wiring diagram).
WARNING
►►These operations must be performed by a skilled
operator with the electrical power disconnected!
7. Power the machine, turn the main circuit breaker QS1 and press the key
again: the work cycle begins.
8. Depending on the capacity of the process cycle, the oil level in the tank could
decrease: in this case the warning light comes on again and the
electric pump stops. Manually restore the oil level in the tank until the electric
pump that sends the process fluid into the circuit is reactivated and the
warning light goes off.
WARNING
Burning hazard.
►►The cap on the filling tube i on the rear panel of the
machine may reach high temperatures (see Fig. 2 - Page
9).
Use the appropriate personal protective equipment.
5.3. Normal start-up

[ON].
2. Set the desired operating parameters (see respective manual).
3. Check that the warning light is off, press the key , until the
same warning light reappears in fixed mode.
23 ENGLISH
5.4. Operation of electric pump in reversible mode
The electric pump installed on the temperature controller can operate temporarily
with contrary rotation (reversible mode).
This makes it possible to create a depression in the utility and thus reduce or
eliminate losses of process fluid in case of breakage and/or cracking of the utility.
It is advisable to use this mode only for as long as strictly necessary to terminate
the production batch in progress, before dismantling and repairing the utility.
On models THP, the maximum temperature that can be set in this mode is 80°C
(176°F).
In this mode the display of the flow rate value of the process fluid (if the detecting
sensor is installed), is not available (the display shows the value [ 0.0 l/min ]).
ENGLISH 24
6. Stopping the machine
WARNING
To stop the machine in an emergency, turn the main switch
QS1: use this procedure only when strictly necessary and
not as a routine operation.
►►Wait until the machine has cooled down to room
temperature before working on internal parts.
To stop the machine under safe conditions and start the forced cooling
procedure, proceed as follows:
1. Press key with light on, until it goes off or starts blinking. The
machine stops automatically (light will go out upon reaching the safe
temperature setting in parameter [ Cooling temp. ]) (see respective

manual).
2. Switch off the power supply to the electric panel.
7. Alarm signals
Any alarms are shown on the display of the electronic control circuit, the lighting
of which becomes red and the alarm light blinks.
Acquire the alarm that has intervened (see respective manual).
Remedy the causes of the alarm (see respective manual).
Alarms can be of two types:
-- : Blocking (interrupt machine operation).
-- : Non blocking (do not interrupt machine operation).
25 ENGLISH
8. Maintenance
Adjusting, servicing and troubleshooting safety rules
1. All adjustment, maintenance and troubleshooting work must be performed by
specialised personnel. Specialised personnel are those who, because of their
education, experience, training, specific knowledge of accident prevention
regulations and first aid, have been authorised to carry out work related to
checking and preventive measures. These personnel must be equipped with
all the tools and equipment specified in both local and international accident
prevention regulations.
2. Thorough inspections, performed at regular intervals, are required to prevent
breakdowns and guarantee that the machine works at maximum efficiency
over time.
3. Unless expressly stated otherwise, all maintenance and adjustment work on
the machine, or parts of it, must be performed with the machine completely
isolated from the electricity, compressed air and water supply sources.
4. Mark off the work zone with tape and put up notices warning of the hazards
in the areas where the adjustment, maintenance or troubleshooting work is
taking place.
5. Wait until the machine and the parts that have to be approached have cooled
down to room temperature before performing any maintenance tasks. Drain off
and remove any liquids inside the machine to prevent them from coming into
contact with live parts during the maintenance work.
6. To avoid injuring persons or damaging objects, make sure that no solids,
liquids or gases are discharged or disposed of in the environment. Have these
substances removed in suitable containers, in accordance with the binding
waste disposal regulations in the place of installation.
7. If any breakdowns occur that the operator is unable to remedy, switch off
the machine and contact the PIOVAN Technical Service Department or an
authorised service centre.
8. On completing the maintenance work, switch on the machine and do the
operational checks, taking all the necessary precautions. Do not stop
taking the precautions described above until the maintenance work is fully
completed.
9. Take special care to ensure that the maintenance work does not involve other
nearby machines, as this may be a potential hazard.
Scheduled maintenance must be carried out to guarantee optimum machine
performance.
ENGLISH 26
The inside of the machine is accessible by unscrewing the fastening screws on
each side panel. To remove the cover from the machine unscrew the screws on
the rear panel and slide it toward the back of the machine far enough to release it
from its slot.
Stopping the machine (see Chap. 6. - Page 25).
Disconnect the machine from the coolant supply and from the utility.
Wait until the machine has cooled down to room temperature.
Empty the machine through the discharge j and, only for THP models, operate
also on the ball valve 05 (see Fig. 2 - Page 9, Table 1 / 1 and Table 2 / 1).
db495edf-a94f-4bb8-afb8-885f4d0b54e0 db495edf-a94f-4bb8-afb8-885f4d0b54e0 3c090cfb-3f73-4c18-b0c9-5eb2998199ba 3c090cfb-3f73-4c18-b0c9-5eb2998199ba
8.1. Scheduled maintenance
WARNING
►►Except where otherwise indicated, all maintenance jobs
must be performed with the machine switched off and
completely isolated from the electricity, compressed air
and water supply sources (if present).
8.1.a. Every month

For all models
• Inspect the cleanliness of the filters on the connecting pipes to the process
and cooling circuits (e - f - g) and replace if necessary (see Fig. 2 - Page 9).
• Check the electrical connections of the machine’s internal components.
• Check for any leaks in the process circuit, inside or outside the machine.
• Check the cleaning of the openings for uptake of the ventilation air for the
electric pump.
• Check the operation of the solenoid valves.
27 ENGLISH
8.1.b. Periodically
For models with water as process fluid
• Extract the heat exchanger and heating elements to remove any calcium scale
that may have formed (see Par. 8. 3. - Page 30).
4fcb1564-4a85-4a32-90d5-b79b431dcf44
Do not use substances that could corrode copper when cleaning the heat
exchanger. Do not use substances that could corrode nickel-iron-chromium
alloys (Incoloy) when cleaning the heating elements.
For models with oil as process fluid
• Extract the heat exchanger and heating elements and remove any residues of
carbon and rubber that could form in the oil.
Check also the condition of the oil: draw a small amount from the discharge
cap j on the rear panel of the machine (see Fig. 2 - Page 9).
If it contains carbon or rubber residues, it should be completely changed.
Clean the tank, heating element and heat exchanger when changing the oil.
The frequency of performing scheduled maintenance indicated here is not

absolute.
The correct times depend on the hours of use of the materials processed; they
must be defined by means of repeated initial tests.
ENGLISH 28
8.2. Assembly of float (models THW - THO)
Ingranaggi
_01
ATTENTION
The following operations must be carried out after every
periodical cleaning cycle that involves removal of the float in the
tank.
Fig. 7
Insert the float rod in the special holder on the lid of the tank and pass it through
the small driver arm on the microswitch (see Fig. 7 - Page 29).
Fasten the float at a height where it will block the stopper on the rod below the
microswitch driver arm. Close the lid on the tank and proceed as follows.
1. Lift the float rod so that it is at less than maximum height.
2. Position the stop so that the microswitch driver arm is at the maximum height,
without forcing it.
3. Block the stop using the screws provided.
29 ENGLISH
8.3. Disassembling and reassembling heating elements
and exchanger
To disassemble the heating elements and the heat exchanger (only for THP
models) proceed as follows.
1. Unscrew the retaining screws of the panel positioned on the rear of the
machine.
2. Remove the panel and unscrew the retaining nuts of the heating elements and
of the heat exchanger.
3. Extract the heat exchanger and the heating elements to clean them.
4. After cleaning, reassemble the components proceeding in inverse order to the
procedure described above.
ENGLISH 30
9. Instructions for automatic rapid drainage
(optional)
The rapid drainage system can be used to empty the utility quickly with all the
pipelines for connection of the process fluid.
The system is installed on request of the client.
The system uses the machine’s own pump to empty the utility.
Activate the procedure (see respective manual).
Ingranaggi
_01
ATTENTION
The procedure is started only if the process temperature is
lower than the value set in the parameter [Cooling temp.]
(see respective manual).
Otherwise the forced cooling procedure will be started.
31 ENGLISH
9.1. Models THP
During the utility drainage phase, the duration of which can be set in the
parameter [Mould drainage], the pump works in reversible mode, sucking
up the fluid from the utility and conveying it into the coolant output pipe h (see
respective manual and Fig. 2 - Page 9).
The temperature controller stops once the drainage phase is concluded.
To activate rapid discharge it is necessary to connect the compressed air pipe to
the special coupling m (see Table 5 / 1).
49e8eef3-6339-4e07-af3e-5779df7d385b 49e8eef3-6339-4e07-af3e-5779df7d385b
Respect the indicated characteristics of the compressed air (see Chap. 2. - Page
5).
9.2. Models THW - THO

During the utility drainage phase, the duration of which can be set in the
parameter [Mould drainage], the pump works in reversible mode, sucking
up the fluid from the utility and conveying it into the tank inside the temperature
controller (see respective manual).
The temperature controller stops once the drainage phase is concluded.
The capacity of the internal tank is about 2.5 l.
If the amount of fluid in the utility and in the pipes exceeds the maximum capacity,
the excess fluid will flow out through the overflow drain k (see Fig. 2 - Page 9).
In this case it is necessary to convey the outlet of the overflow towards an
adequate drain or a container with suitable dimensions.
ENGLISH 32
10. Connection in serial line
Ingranaggi
_01
ATTENTION
For all information on the subject, consult the manual supplied
with the serial connection option.
By connection in serial line we mean an electrical connection between two

or more machines controlled by electronic devices: this connection is used to
exchange information between them.
Temperature controllers, on request, can be equipped with this option whereby it
is possible to control the main machine functions by remote control, for example,
directly by control of the press.
33 ENGLISH
11. Decommissioning the machine
When the machine’s life cycle comes to an end, it must be disconnected from
the electrical, pneumatic and water (if present) supply sources and uninstalled
from its work station. The machine must be disposed of in full compliance with
statutory laws in the country where it is installed.
Ingranaggi
_01
ATTENTION
After having removed the machine from its working position,
permanently affix to it a notice with the message: “MACHINE
TO BE SCRAPPED: DO NOT USE”.
12. Spare parts

To reduce machine downtimes caused by worn or broken parts to a minimum, we
advise you to keep a reserve stock of all the spare parts marked * in the spare
parts list.
The following data must be given when ordering spare parts.
1. All the data on the identification plate affixed to the machine.
2. The reference number and part number of the requested part, if present (see
tables of spare parts).
3. A description of the requested part.
4. The quantity required.
5. The exact address and requested forwarding method.
PIOVAN S.p.A. declines all liability for incorrect consignments resulting from
inaccurate or incomplete information.
The components, which are not referred to in the machine maintenance
procedures described, can be replaced only by the PIOVAN Technical Assistance
Service.
ENGLISH 34
TABLES OF SPARE PARTS
Table 1 / 1 Tables of spare parts
BP2
BP3
BT1
BT2
A1
03
YV2 01
08
02 SL1
V2
ST1
07
06
04
02
YV3 EH1
V3
YV1 02
V1
05 09
M1
THP6
# Description THP6
01 Safety valve
-
02 Non-return valve
03* Exchanger gasket 633D0870
04 Heat exchanger 6109730
05 Ball valve -
06* Heating element gasket 633A0920
07* Copper sealing ring 645A2280
08 Pressure gauge
-
09 Mechanical seal
A1 Electronic control board 968G006A1
BP2
Flow rate sensor
BP3
-
BT1
Temperature probe
BT2
Electric heating elements
650A0310
220/3/60 - 230/3/50 - 380/3/60 - 400/3/50
EH1*
4650612
460/3/60
M1 Electric pump -
SL1* Level switch 4151067
# Description THP6
ST1 Safety thermostat
V1 Water filling valve
YV1* Water filling coil
V2 Vent valve -
YV2* Vent coil
V3 Cooling water valve
YV3* Cooling water coil
BP2
BP3
BT1
A1
BT2
10
YV2
01
08
SL1
02
ST1
V2
11
06
12
02
04
YV3
EH1
V3
02
YV1
11
V1
05
09
M1
THP12
# Description THP12
01 Safety valve
-
02 Non-return valve
03
04 Heat exchanger 4280815
05 Ball valve -
07
08 Pressure gauge
09 Mechanical seal
10 Hose 500 mm -
11 Hose 400 mm
12 Hose 300 mm
BP2
Flow rate sensor
BP3
-
BT1
Temperature probe
BT2
650A0310
220/3/60 - 230/3/50 - 380/3/60 - 400/3/50
EH1*
4650612
460/3/60
M1 Electric pump -
# Description THP12
YV1* Water filling coil
V2 Vent valve -
YV2* Vent coil
BP2
BT1
BT2 A1
YV3 M1
V3
YV1
V1
SL1 01
07
02
05
03
04
06
EH1
ST1
THW9 - THW12
# Description THW9 THW12

01 Electric pump gasket
-
02 Tank gasket
03 Heat exchanger 610A4460 610A4480
04 Loading pipe gasket
-
05 Return pipe gasket
06 Float 637A0320
BP2 Flow rate sensor
BT1 -
Temperature probe
BT2
650A0250 650A0410
220/3/60 - 230/3/50
EH1* 650A0340 650A0390
380/3/60 - 400/3/50
4650608 4650605
460/3/60
M1 Electric pump -
# Description THW9 THW12

YV1* Water filling coil -
BP2
BT1
A1
BT2
M1
YV3
V3
SL1
07
01
05
02
04
03
06
EH1
ST1
THO6
# Description THO6
01 Electric pump gasket
-
02 Tank gasket
03 Heat exchanger 610A4460
04 Cap gasket
-
05 Return pipe gasket
06 Float 637A0320
BP2 Flow rate sensor
BT1 -
Temperature probe
BT2
650A0250
220/3/60 - 230/3/50
EH1* 650A0260
380/3/60 - 400/3/50
4650606
460/3/60
M1 Electric pump -
V3 Cooling water valve -
THP6 - THP12 THW9 - THW12 - THO6
V6 YV6
01
V5
02 YV5
V6
YV6
V5
m
YV5
THW9 - THW12
# Description THP6 - THP12
THO6
01 3-way electropneumatic valve
02 Non-return valve
V5 Utility drainage valve
-
YV5 Utility drainage coil
V6 By-pass valve
YV6 By-pass coil

Piovan WTC Thw9

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THP6 - THP12

0 20 40 60 80 ∆Τ °C 0 20 40 60 80 ∆Τ °C 0 30 60 90 120 150 180 ∆Τ °C

Chlorides mg/l Cl < 100

After removing the packing, it is possible to move the temperature controller by

Ref. Symbol Description Connection Notes

Use pipes with an internal

36_tptwto Emptying of Dispose of process fluid

5.1. Preliminary checks

5.2. First start-up

control panel (see respective manual).

5. Stop the machine by pressing key .

6. Check, by looking through the inspection slits, that:

again: the work cycle begins.

control panel (see respective manual).

goes off) (see Fig. 2 - Page 9).

5. Stop the machine by pressing key .

6. Check, by looking through the inspection slits, that:

again: the work cycle begins.

5.3. Normal start-up

same warning light reappears in fixed mode.

temperature setting in parameter [ Cooling temp. ]) (see respective

-- : Non blocking (do not interrupt machine operation).

8.1. Scheduled maintenance

8.1.a. Every month

The frequency of performing scheduled maintenance indicated here is not

9.2. Models THW - THO

By connection in serial line we mean an electrical connection between two

12. Spare parts

# Description THW9 THW12

# Description THW9 THW12

THP6 - THP12 THW9 - THW12 - THO6

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