thermal regulation of the dies in the die-casting industry ... - Aluplanet

THERMAL
REGULATION
OF THE DIES IN THE
DIE-CASTING
INDUSTRY

CONTROL OF THE DIE TEMPERATURE
THE STATE OF TECHNOLOGY
THE PRODUCTS
COMPANY PROFILE
IECI
INDUSTRIAL THERMAL REGULATORS
Via P.L. Nervi, 13
25050 PASSIRANO (BRESCIA) - ITALY
Tel. +39 - 030 68 50 370 r.a.
Fax +39 - 030 68 50 511
e-mail ieci@iol.it
www.iecionline.com

CONTROL
OF
THE DIE
TEMPERATURE

In the casting, the temperature of the die has
a notable influence on the quality of the pieces
and on the work cycle.
Working with a die temperature which is too
low, you can encounter the following problems:
• Rapid degrading of the die;
• Difficult expulsion;
• Contraction of the piece around the pins;
• Welding between the metal and the die;
• Reduction in the efficiency of the lubroseparators;
• Dimensional instability;
• Incomplete filling.
Operating in the other way, with a die
temperature which is too high can result in the
following problems:
• Difficult expulsion of the cast (deformations,
seams);
• Rapid degrading of the lubro-separant;
• Lengthening of the cycle time;
• Dimensional piece instability;
• Air bubble formation;
• Presence of withdrawal porousness
and cavities;
• Increased wear of the die.
It seems clear that the correct checking of the
die temperature, takes on a vital importance
to attain a high and constant production quality
alongside an optimization of the productive
cycle.
The thermal regulators are electro-mechanical
pieces of equipment which have the role of
thermically regulating the dies used during
the die-casting process.
The thermal regulation comes by heating
and/or cooling a fliud (diathermic oil or
pressurised water), which is then sent, by means
of an electric pump, inside the channels
extracted in the die; the heat transmission to
the cast surface then makes for the convection
between the fluid and the channel surfaces
and for conduction through the material of the
die itself.
With the use of thermal regulation exchange,
you are able to highlight the main advantages
indicated in the following four points:
1) IMPROVEMENT IN THE MECHANICAL
CHARACTERISTICS AND OF THE CAST
HOLDING;
2) POSSIBILITY OF INCREASING THE
PRODUCTIVITY OF THE PRESSES
THROUGH THE REDUCTION OF THE
CYCLE TIME ;
3) INCREASE IN DIE LIFE-SPAN;
6
4) REDUCTION IN INITIAL REJECTS.

THERMAL REGULATORS
FOR IMPROVING
THE QUALITY OF THE
CASTING
The mechanical characteristics of die-casting
are closely correlated to the structural
morphology of the alloy and its granulometry.
In particular, one encounters an improvement
of the following values:
elongation %,
mechanical resistance to traction,
hardness,
with the increase of the number of grains per
unit of volume, that is with a fine crystalline
structure.
The size of the crystals in die-casting is
undoubtedly linked to the local cooling time of
the casting:
• Short cooling time (small thicknesses) =>
FINE STRUCTURE => improved mechanical and
sealing characteristics;
• Improved cooling time (large thicknesses)
=> COURSE STRUCTURE => limited mechanical
and sealing characteristics.
7
Utilising thermal regulators, a very high
cooling velocity is obtained and therefore the
mechanical and sealing properties of the part
are improved.
With parts that have different thicknesses, it is
possible to adjust the mechanical and sealing
properties, making the solidification time
constant in the various zones of the casting,
heating the zones that are too cold (of small
thickness) and cooling the zones that are too
hot (of large thickness).

THERMAL REGULATORS
FOR INCREASING
PRODUCTIVITY
With the use of thermal regulators it is
possible to obtain an improvement of
company productivity.
Increasing the castings/h we have an
increment of the quantity of heat transferred
from the alloy to the printer surface (for the
alloy UNI 5076 Q= 798 Kj/Kg), from which
an increase of the temperature of the
impression is produced, leading to an increase
in the solidification time.
With the help of thermal regulation systems
it is possible to maintain a high number of
moulds as this thermal increment is eliminated,
increasing the cooling.
THERMAL REGULATORS
FOR INCREASING THE
LIFE OF THE DIE
The dies that are normally used in the diecasting
process have physical and mechanical
characteristics which var y with the temperature,
as in the following graph.
Curve showing heat resistance of steel
for dies “W300”
Rp=Resistence and limit of weakening 0.2 in N/mm 2
1800
1600
1400
1200
1000
800
600
400
200
0
20
Rm
Rp0,2
Z
200 400 600
Test temperature in C
80
60
40
20
0
Z=Contraction in %
8
Rm= mechanical attraction resistance

With thermal regulators it is possible to obtain
suitable pre-heating of the die in order to:
• Surpass the Fragile/Ductile transition
temperature of the steel (around 150 C),
under which there is a high probability that
structural damage due to thermal fatigue will
be brought to light.
• Reduce the thermal gradient between the
die and the molten metal in both the prepressing
phase and during machine standstill,
notably limiting the thermal tensions in the
steel.
Operating in the way described it is possible
to obtain an increment of die duration of even
27-30% (*).
THERMAL REGULATORS
FOR DECREASING INITIAL
REJECTS
The heating of the die at the beginning of the
cycle and therefore during machine standstill,
as well as increasing the life of the dies by
diminishing thermal shocks, allows the reduction
of the number of shots necessary to bring the
figure to temperature.
9
Consequently, it has been verified that in some
cases the reduction of rejects has reached
values of approximately 65% (*).

THE STATE
OF
TECHNOLOGY

Today’s technology provides the user with a
choice of thermal regulators which are generally
subdivided according to the type of thermal
carrier fluid used (diathermic oil or water)
and the type of heating system used (electrical
energy or gas).
The optimum characteristics for a thermal
carrier fluid are:
· High boiling point;
· High thermal conductivity;
· High point of inflammability (for oily fluids);
· Inoxibility;
· Non corrosiveness;
· Non toxicity.
Normally, water or diathermic oils are used
as thermal regulating fluids.
Water has a coefficient of heat transmission
by convection and conduction which is about
double that of oil.
However, on the negative side it has a low
boiling point, is susceptible to forming calcareous
deposits and to triggering corrosive
phenomena.
These three problems can be solved by pressurising
the circuit so that the water is always
in the liquid state even at high temperatures,
utilising suitable components in anticorrosive
material (inox steel AISI 304, 316 etc.) and if
necessary treating the water by process, if the
hardness is greater than 20 F.
Oils and synthetic fluids do not have constant
thermal conduction characteristics like water:
on the increase of the temperature the internal
conductivity diminishes and the specific heat
increases. Also, these fluids are both expensive
to buy and to dispose of, pollutant and inflammable
once the critical temperature has been
reached.
Oily fluids, in certain environmental conditions
(temperature >60 and contemporary presence
of oxygen) or in direct contact with the heating
elements, also give rise to the phenomenon of
cracking which is revealed by a great diminution
of fluidity that jeopardises the thermal
exchange.
For the heating system one can opt for electrical
energy or methane gas (IECI patent). When
the heating system is entrusted to electrical
energy, the resistences can be immersed directly
in contact with the oil, or externally to the
system, with indirect heating ( IECI-IHCS System
on the Climat PF-Z Series Thermal Regulator).
12

DIATHERMIC OIL THERMAL
REGULATORS
With this type of thermal regulation, the die is
brought to the desired temperature by circulating
diathermic oil in the conditioning channels.
It is necessary to distinguish between mineral
oils, deriving from the distillation of crude oil,
and synthetic fluids, both composed for the
greater part by hydrocarbons, but with the
latter having the advantage of a greater durability
to ageing.
In fact, the decomposition of the fluid generally
gives rise to the formation of volatile substances,
denominated “low boilers” as well as high
viscosity polymers “high boilers”: the former,
in both cases, must be periodically bled from
the system in order to avoid pump cavitations,
vapour blockages or mechanical damage,
whilst the latter are only soluble in synthetic
fluids, up to a certain quantity (10-15%).
Diathermic synthetic fluid also has the
advantage of a high boiling point which
therefore allows the preheating of the die to
temperatures of up to 300 C.
EXAMPLE OF VARIATIONS OF THE PROPERTIES OF
DIATHERMIC OIL IN RELATION TO THE TEMPERATURE
Temperature Density Heat specified Thermic conductivity
C kg/mc kJ/(kg K) (W/mK)
0 1021,5 1,495 0,118
10 1014,9 1,529 0,118
20 1008,4 1,562 0,118
30 1001,8 1,596 0,117
40 995,2 1,630 0,117
50 988,6 1,665 0,116
60 981,9 1,699 0,116
70 975,2 1,733 0,115
80 968,5 1,768 0,115
90 961,8 1,803 0,114
100 955,0 1,837 0,114
110 948,2 1,873 0,113
120 941,4 1,908 0,112
130 934,5 1,943 0,111
140 927,6 1,978 0,111
150 920,6 2,014 0,110
160 913,6 2,05 0,109
170 906,6 2,086 0,108
180 899,5 2,122 0,107
190 892,3 2,158 0,107
200 885,1 2,195 0,106
210 877,8 2,231 0,105
220 870,4 2,268 0,104
230 863,0 2,305 0,103
240 855,5 3,342 0,102
250 847,9 2,379 0,100
260 840,3 2,417 0,099
270 832,5 2,455 0,098
280 824,6 2,492 0,097
290 816,6 2,531 0,096
300 808,5 2,569 0,095
On the other hand, it becomes clear that with
the increase of the temperature, the thermal
conductivity (W/m* K) diminishes and the
specific heat (Kcal/Kg* K) increases, making
the transmission of heat more difficult.
13

METHANE GAS OR
ELECTRICAL ENERGY
HEATING SYSTEMS
THE GAS THERMAL REGULATORS, utilising the
energy of the gas for the heating of the
diathermic oil, allow the temperature of the
thermal carrier oil to reach a max value of
300 C.
A sophisticated flame system powered by
methane gas or G.P.L. is utilised for the heating
of the oil.
The main advantages derived from the use of
this system are to be found
- in the enormous economic saving (up to 80%
with respect to traditional electrical energy
systems) and
- in the elimination of plant engineering
restraints deriving from requests to the supplying
body for energy (important example
transformer rooms).
With practical combustion tests it can be
concluded that 1m 3 of methane produces heat
equal to 9,44 Kw of electrical energy and in
relation to the costs (variable however according
to zone and contract) a large economic saving
is obtained.
Heating Cost
Electric energy
Gas
Results deriving from an experimental comparison
between the energy consumption of a traditional electrical
energy thermal regulator and that of an IECI PF-GAS
THE ELECTRICAL ENERGY HEATING SYSTEMS
foresee the use of electrical resistences. These
systems have the advantage of being very fast
and efficient, but on the negative side, when
the heating elements are in direct contact with
the fluid, they violently stress its physical
characteristics leading to its rapid deterioration.
14

WATER FOR THE THERMAL
REGULATION
Under precise pressure (760 mm of mercury),
pure water remains in the liquid state between
temperatures of 0 and 100 centigrade; at
0 it solidifies; at 100 it boils.
It is necessary to maintain the water in the
liquid state even at high temperatures, in
order to obtain effective and efficient thermal
regulation and to avoid the formation of
limestone.
The precipitation of calcium carbonate and
magnesium carbonate (principal components
of the deposits commonly called LIMESTONE),
is directly proportional to the increase of temperature
and is maximum in correspondence
to vaporisation.
Pressurised water thermal regulation apparatus
must therefore be equipped with particularly
reliable devices in order to guarantee the
minimum pressurisation in relation to the maximum
temperature that can be reached.
P
217.7
atm
0.006
atm
Solid
Phase
0.0098 C
Liquid
Phase
Gaseous Phase
374 C
Critical
point
T
15
Amongst the most notable physical chemical
properties of water for thermal regulation, let
us remember:
• the highest specific heat amongst the
common substances (1 Kcal/Kg/ C) constant
at various temperatures;
• the coefficient of heat transmission by
convection which is about twice that of oily
fluids;
• the best coefficient of heat transmission by
conduction, with respect to oily fluids;
• thermal transfer characteristics that are
constant within a wide of interval of
temperatures (as opposed to oily fluids which
present, on the increase of the temperature,
an increase of the specific heat and a diminution
of the thermal conductivity);
• inflammability;
• economy: the water to be used does not
have to have special chemical characteristics
apart from a total hardness of between 10
and 20 F (medium hardness). It is therefore
possible to utilise water from cooling towers,
wells, closed refrigerated circuits, opportunely
filtered.

THE PRODUCTS

CLIMAT PF Z Series
THERMAL REGULATOR
PF Z 300 series single or double zone
industrial thermal regulators regulate the
temperature of dies by means of diathermic
oil being pushed into the conditioning channels
and heated with external resistance.
The maximum temperature that can be
reached by the thermal carrier oil is 300 C,
whilst the minimum temperature is determined
by the parameters ( pressure, delivery,
temperature) of the grid water connected
to the thermal regulator.
THE I.H.C.S. SYSTEM
The I.H.C.S. device ( Indirect Heating - Cooling
System) is an exclusive exchanger which consists
of an special geometry of pipes in 316 inox
steel, where the heating elements are found
on the exterior and not immersed in the oil.
The passage of water for cooling takes place
in special cavities and determines a thermal
exchange in countercurrent with the thermal
carrier fluid. The main advantages of the
I.H.C.S. system are:
• Greater resistance of the oil to cracking
• Greater thermal yield in heating and cooling
phases thanks to the raised exchange suface.
• Attenuation of calcareous deposits or impurities
in the cooling water thanks to the raised
cut-and-fill and the turbulent flow in the
avities;
• Reduced dimensions even for high power.
• Extremely long duration and constant yield
of heating elements over time as they are
not immersed in oil.
18

FUNCTIONALITY
An electronic device handles the automatic
sequence between the pre-heating
temperature and working temperature which
are differentiated between themselves.
With this technical equipment the die is heated
with the press at a standstill (for example prior
to beginning work) so that it is already hot,
ready for the injection, from the first minute,
at a higher temperature than the working
temperature.
The self-cooling controlled by the oil when
the unit is switching off allows the oil to remain
in the circuit every time after switching off until
a temperature of 60 is reached. In this way,
the diathermic quality and the physical
characteristics of the thermal-vector oil are
preserved for as long as possible.
The particular equipment described, put
together with the daily and weekly
programmer used to switch on and switch off
the equipment, allow the operator to manage
the production in a simple and automated way.
- Fluid: diathermic oil
- Max temperature: 300
- Available versions: single or double zone
- Heating system: by external resitence IHCS
- Heating power: from 15 to 48 Kw
- Cooling system: by indirect exchange
- Cooling power: 80,000 Kcal/h
- Max. pump pressure: 90 l/min
- Max. pump load: 10 bar
- Dimensions in mm: h1330x500x1000
- Weight: 150 kg
STANDARD EQUIPMENT
This is completed by: alarm pressure switches
for low or high circuit pressure, circuit pressure
signalling manometer; visual alarms of the
principal functions, circuit emptying device for
die exchange, anti-disturbance protection on
entry of the signal originating from the
temperature probe, automatic ignition and
switching off in relation to the oil level, automatic
by-pass, digital clock for automatic ignition
and switching off, controlled self-cooling of
the oil, differentiated management of the
preheating and working temperatures.
OPTIONAL
• Serial interface predisposition;
• Visualisation of the temperature on return;
• Increase of the die inputs and outputs.
19

CLIMAT PF-GAS Series
THERMAL REGULATORS
CLIMAT PF GAS 300 Series industrial thermal
regulators, modular for single zones, regulate
the temperature of dies by means of diathermic
oil which is pushed into the conditioning channels.
The maximum temperature that can be reached
by the thermal carrier oil is 300 C, whilst the
minimum temperature is determined by the
parameters (pressure, delivery , temperature)
of the grid water connected to the thermal
regulator.
The exceptional new feature is the use, for
the heating of the oil, of a sophisticated flame
system, reliable and safe, powered by methane
GAS or G.P.L..
MAXIMUM SAFETY AND RELIABILITY
Every machine is composed of safety pressure
switches which intervene in the case of
irregularities: mistaken connections to the die,
clogged passages, closed taps or when water
is present in the oil.
In fact, when irregular pressure is detected,
heating is immediately interrupted and over 4
bar automatic by-pass takes place.
This system safeguards the smooth operation
of the thermal regulator, the chemical-physical
properties of the oil and the operator himself.
The exchange is also subjected to the tests
foreseen by the laws in force.
THE ADVANTAGES
As well as the normal advantages of thermal
regulation, through the use of this modern
system (patented) one obtains an enormous
economic saving (up to 80% with respect to
traditional electrical energy systems) and the
elimination of plant engineering restraints
deriving from requests to the supplying body
for energy (important example transformer
rooms).
With practical combustion tests one can conclude
that 1m3 of methane produces heat
equal to 9.44 Kw of electrical energy and in
relation to the costs (variable however according
to zone and contract) a large economic saving
is obtained.
20

FUNCTIONALITY
An electronic device handles the automatic
sequence between the pre-heating
temperature and working temperature which
are differentiated between themselves.
With this technical equipment the die is heated
with the press at a standstill (for example prior
to beginning work) so that it is already hot,
ready for the injection, from the first minute,
at a higher temperature than the working
temperature.
The self-cooling controlled by the oil when
the unit is switching off allows the oil to remain
in the circuit every time after switching off until
a temperature of 60 is reached. In this way,
the diathermic quality and the physical
characteristics of the thermal-vector oil are
preserved for as long as possible.
The particular equipment described, put
together with the daily and weekly
programmer used to switch on and switch off
the equipment, allow the operator to manage
the production in a simple and automated way.
- Fluid: diathermic oil
- Max temperature: 300
- Heating system: by Methane Gas or GPL
- Max. heating power: 28,000 Kcal/h
- Cooling system: by indirect exchange
- Cooling power: standard 80,000 Kcal/h
- Max. pump pressure: 70 l/min
- Max pump laod: 6 bar
- Pump motor: 2.2 kw
- Dimensions in mm: h1330x500x1000
- Weight: 150 kg
STANDARD EQUIPMENT
• Visual alarm of the principal functions;
• Circuit emptying device for die exchange;
• Safety pressure switches (high and low
pressure);
• Automatic ignition and switching off in
relation to the oil level;
• Digital clock for automatic ignition and
switching off;
• Controlled self-cooling of the oil;
• Differentiated management of the preheating
and working temperatures;
• Automatic by-pass calibrated to 4 bar;
• Combustion fumes recuperation system for a
maximum yield of heating power.
21
OPTIONAL
• Serial interface predisposition.
• Visual return temperature indicator.
• Increase of die inputs and outputs.

CLIMAT PF- ZH Series
THERMAL REGULATORS
The CLIMAT PF ZH Series modular single zone
industrial thermal regulator, an absolute first
in the die-casting sector, is a mobile electrohydraulic
apparatus designed for the regulation
of die temperatures through the use of
PRESSURISED WATER pushed into the
conditioning channels.
The maximum temperature that can be reached
by the thermal carrier water is 200 C, whilst
the minimum temperature is determined by the
temperature of the mains water connected to
the thermal regulator.
THE ADVANTAGES
• High velocity in the thermal exchange, due
to a coefficient of transmission of the heat by
convection and conduction which is about
double with respect to oil, and thermal transfer
characteristics that remain constant over a
wide interval of time.
• Notable savings with regards to costs
inherent to the use and elimination of the
fluid (water rather than diathermic oil).
• Absolute cleanliness of the conditioning
channels inside the die that remain free from
impurities that would form were oil to be used.
• Non-flammability of the thermal carrier fluid.
The components and the circuit produced
entirely in inoxidizable AISI 316 steel and the
innovative water pressurisation system, have
allowed problems related to corrosion and the
formation of limestone to be avoided.
X
Oil
2 x
Water
The coefficient of heat transmission for convention in water
is equal to around double that of the oily fluids
22

PUMP FOR HIGH TEMPERATURES
Great attention has been paid to the choice of
the pump, entirely in anticorrosive material for
the recycling of the water at high temperatures.
The special characteristics allow an optimum
efficiency in the ratio between the delivery and
pressure values, which while being high, do
not implicate any fluid leakage problems.
- Fluid: water (average hardness

CLIMAT PF-GH SERIES
THERMAL REGULATORS
The CLIMAT PF-GH Series modular single zone
industrial thermal regulator, an absolute first
in the die-casting sector, is a mobile electrohydraulic
apparatus designed for the regulation
of die temperatures by means of PRESSURISED
WATER being pushed into the conditioning
channels.
The maximum temperature that can be reached
by the thermal carrier water of the various
models is 140 - 180 - 200 C, whilst the
minimum temperature is determined by the
temperature of the grid water connected to the
thermal regulator.
The exceptional new feature is the coupling
of the use of water as a thermal carrier fluid
with the use of methane gas for the powering
of the heating system.
The components and the circuit, entirely in AISI
316 inoxidizable steel and the innovative water
pressurisation system, have allowed possible
problems related to corrosion and limestone
formation to be avoided.
ADVANTAGES
Other than the normal advantages from
thermoregulation, through the use of this
modern system you can attain:
• ENORMOUS ENERGY SAVING (up to 80%
with respect to a traditional electrical system);
• High velocity in the thermal exchange, due
to a coefficient of transmission of the heat by
convection and conduction which is about
double with respect to oil, and thermal transfer
characteristics that remain constant over a
wide interval of time;
• Notable savings with regards to costs inherent
to the use and elimination of the fluid (water
rather than diathermic oil);
• Absolute cleanliness of the conditioning
channels inside the die that remain free from
impurities that would form were oil to be used;
• Economy, since the water to be used does
not need to have special chemical characteristics
(medium hardness between 10 and 20 F);
• Non-flammability of the thermal carrier fluid.
PUMP FOR HIGH TEMPERATURES
Great attention has been paid to the design
and construction of the pump, entirely in anticorrosive
material for the ricircolo of water at
high temperatures.
Its special characteristics allow excellent efficiency
in the ratio between the delivery and
pressure values, which while being high do
not implicate any fluid leakage problem.
24

MAXIMUM SAFETY
Each apparatus is subjected to tests so that it
conforms to all laws in force.
Also, the apparatus is equipped with several
levels of safety which cross the automatic control
of all functions, and is capable of shutting
down immediately when the slightest
abnormality is detected.
The minimum and maximum pressure of the
circuit is controlled by means of an extremely
precise digital system in order to avoid the
vaporisation of the fluid due to high
temperatures.
- Fluid: water (average hardness

CLIMAT PF N Series
THERMAL REGULATORS
The PF N series industrial thermal regulator,
available in single or double zone with max
temperature of 200 - 250 - 300 C, is a
mobile electro-hydraulic apparatus suitable
for the heating, cooling and maintaining of
the desired working temperature for dies,
containers or cylinders, by means of diathermic
oil being pushed into the conditioning channels
and heated with immersed heating elements.
The maximum temperature that can be reached
by the thermal carrier oil is 200 - 250 -
300 C, whilst the minimum temperature is
determined by the parameters (pressure, delivery,
temperature) of the grid water connected
to the thermal regulator.
MAXIMUM SAFETY AND RELIABILITY
Each apparatus is composed of safety pressure
switches which intervene in the case of irregularities:
mistaken connections to the die, clogged
passages, closed taps or when water is present
in the oil. In fact, when a pressure irregularity
is detected, heating is immediately interrupted
and above 4 bar an automatic by-pass takes
place. This system safeguards the smooth
operation of the thermal regulator, the chemicalphysical
properties of the oil and the operator.
The exchange is also subjected to the tests
foreseen by the laws in force.
26
PUMP FOR HIGH TEMPERATURES
Great attention has been paid to the design
and construction of the motor pump for the
recycling of the thermal carrier oil. The pump
is able to adapt to any type of circuit, thanks
to the high delivery and head. Also, the material
and type of construction guarantee resistance
to very high temperatures.

FUNCTIONALITY
The apparatus is constructed with modular
components which facilitate maintenance and
use (heating unit, heat exchanger and pump
unit).
The heating elements are immersed in fluid
and positioned along the hydraulic circuit in
order to avoid the oil lingering and thus creating
tar.
It is a closed circuit system with an expansion
tank, calculated to compensate for the increase
of oil volume due to the raising of the temperature.
Further care of the oil is provided by:
• Controlled auto-cooling on switching off,
which allows it to remain in circulation until a
temperature of 60 C is reached;
• Safety pressure switches which operate,
blocking the heating in case of irregularities
(presence of water, obstructed passages, etc);
• Automatic by-pass which opens gradually
above 4 bar and prevents the interruption of
the oil circulation.
Maximum temperature: 200 250 300
Circuit fluid:
Diathermic oil
Heating system:
by immersed
Cooling system:
indirect exchange
Max.heating power: from 12 to 48 Kw
Cooling power:
55,000 Kcal/h
Electro-pump:
centrifuge
Max. pump capacity:
70 l/min
Max. pump pressure:
6 bar
Pump motor:
2.2 Kw
Dimensions in mm: h 920x510x1,000
Weight:
100 Kg
STANDARD EQUIPMENT
is completed by: safety pressure switches; circuit
pressure signalling manometers; visual alarm
of the principal functions; anti-disturbance
protection on input of the signal originating
from the temperature probe; automatic starting
and switching off in relation to the oil level;
automatic by-pass; controlled oil auto-cooling.
OPTIONAL
• Serial interface predisposition.
• Visual return temperature indicator.
• Increase of die inputs and outputs.
• Increase of heating power up to 48 Kw
per zone.
• Digital programming clock.
• Emptying of the circuit.
• Electronic device which automatically
manages the transition between the
preheating temperature and the working
temperature.
27

REFRIGERATORS AND
COOLERS
For the correct treatment of water for industrial
refrigeration, IECI suggests some models of
refrigerators and coolers with technical
characteristics which are particularly suitable
for use in die-casting, such as:
THE REFRIGERATOR CIRCUIT
Realised in copper tube with connections welded
in silver alloy, with high action dehydrating
and filtering mechanical dehydrator filter,
thermostatic valve with external equaliser.
MODULARITY
Possibility to connect several machines in
parallel, also using other brands of modular
refrigerator.
COAXIAL TYPE SELF-CLEANING
EVAPORATOR OF TURBULENCED
Realised in thick copper tubes mm. 10/10
direct expansion of new water/gas conception,
immersed in the accumulation tank, thermally
isolated, crossed gas-water fluids in countercurrent.
THE HYDRAULIC CIRCUIT
Realised with entirely galvanised pipe fittings,
with circulation motor pump, accumulation
tank in which the coaxial type evaporator is
immersed, air valve, by-pass for protection of
the motor pump, flowstate for control of the
water flow, automatic external by-pass,
antifreeze resistences.
28
VERTICAL DEVELOPMENT AIR COOLERS
FOR WATER
Vertical development cooling is designed to
diminish cluttered spaces at the base and
maximise the thermal exchange, thanks to the
high number of ventilators distributed on the
whole exchange surface.

SYSTEMS
OF CONNECTION
TO THE DIES
The design and realisation of systems for the
distribution of diametric fluid (oil or water)
represents a distinct sign and an adequate
completion of the thermal regulation service.
Careful attention is placed also on the choice
of materials used, that must guarantee the
safety of the operator and the good functioning
of the system.
The use of steel connections and taps
for high temperatures is a distinctive
element in IECI’s systems.
IECI Thermal regulators technicians have
accumulated a notable experience over the
years, installing hundreds of systems in different
conditions and are now able to supply
a range of solutions capable of satisfying
any technical requirements.
The connection of thermal regulation apparatus
to the application can be carried out in
two ways:
• flexible system;
• fixed system.
In the first instance, one carries out the installation
using flexible inox steel piping,
accurately insulated to avoid heat dispertion.
In the second instance, the majority of the
flexible piping is replaced by rigid pipes,
insulated and protected by zinc-coated
channels.
The system can be carried out, where possible,
with the use of pre-assembled modules (standard
length), but in the majority of cases,
given the variable structures of the applications,
a custom-made system is necessary, to
best exploit the optimal ruotes.
29

COMPANY
PROFILE

THE COMPANY
IECI Thermoregulators was founded in 1972
as an electrical-plumbing plant engineering
company.
Following this, specialising in the production
of thermal regulators for the plastic and metal
casting industry.
The technological research and the
experimentation have always been at the centre
of IECI’s policy that through continuous evolution
of its products, the elaboration of numerous
international patents is added.
Alongside the validity of the machines, the
company has created a detailed and efficient
technical assistance service, which has
gathered notable agreements between the final
users.
Commercially, IECI manages every contact
with its customer from within the company,
offering a precise and transparent service.
Recently, the process in order to achieve the
ISO9001 certification has been started,
corresponding to the will of IECI Thermal
regulators to constantly improve the service
offered to its customers.
THE PATENTS
"Dual zone pressurised water thermal
regulation system"
Nr. BS2002A000003 registered 22.01.2002
"Pressurised water thermal regulation system"
Nr. BS2001A000009 registered 13.02.2001
"Pressurised water thermal regulation system"
Nr. BS2000A000081 registered 04.08.2000
"Thermal regulation system with integrated
heating and cooling sections (IHCS external
resistance heating)"
Nr. BS99A000012 registered 17.02.1999
"Gas heating thermal regulation system"
Nr. BS95A000073 registered 25.07.1995
32
"Continuous vacuum thermal regulation
system"
Nr. BS84A5177 registered 10.071984

FAIRS AND
CONVENTIONS
DIECASTING DAY International convention
about Die-casting Technology.
November 2001 - Engineering faculty
University of Brescia - Inn.Tec.
METEF 2002
International Aluminium Trade Fair - Foundry
from May 8 to 11 2002
Garda Exhibition Centre - Montichiari (Brescia)
HIGH TECH DIECASTING (Al and Mg alloys)
February 22 2002
International conference about the high
technology in die-casting (aluminium and
magnesium alloys) organised by AIM
(Associazione Italiana di Metallurgia) in
cooperation with the University of Padua and
with Metef 2002
CREDITS
Centre of competence on die-casting at the
Engineering faculty of the University of Brescia.
Research centre BÜHLER, Uzwil (Switzerland)
INN.TEC. srl
Syndicate for Technological Innovation at the
Engineering faculty of the University of Brescia
GIFA 2003
International trade fair of the Dusseldorf foundry
from June 16 to 23 2003
Internet portal on the world of aluminium
Industrial metamarket
33

CATALOGUE
IECI-DIE-CASTING
March 2002
With modifications reserved.
The data and the characteristics of the
equipment described in this catalogue may vary
due to technical or aesthetic improvements
without notice and, therefore, are not binding
to any possible supply.
(*) Certified technical data by qualified client,
available for possible verification.
34

IECI
INDUSTRIAL THERMAL REGULATORS
Via P.L. Nervi, 13
25050 PASSIRANO (BRESCIA) - ITALY
Tel. +39 - 030 68 50 370 r.a.
Fax +39 - 030 68 50 511
e-mail ieci@iol.it
www.iecionline.com