Microgel - RCD/RCM

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 Microgel for plastic
8):
injection molding
 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  Available mold drain kits
 Cycle time reduction up to 50%  Web-monitoring interface
 Intelligent use of energy consumption  Temperature, flow and pressure digital readings (IN/
 High energy savings with automatic free-cooling OUT)

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Microgel - RCD/RCM
Mold temperature control
 The mold temperature has a considerable influence on
the quality of the molded piece and on the work cycle Automotive

Optimization of the production process

 Production capacity (cycle reduction, waste and dead
time)
 Product quality (better aesthetics and consistent dimen-
sional stability)
 Reduction in operating costs (reduction of scrap and
energy savings)

Benefits for the process Packaging

 Perfect repeatability and high productivity
 Possibility of searching and storing the best cooling con-
ditions
 Complete independence in setting work parameters
Medical
 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 and
operator

Benefits for the user Technical Molding

 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
Dual zone
RCD Microgel

Summit TPC: Vanguard Tame Park, Tamworth, Staffordshire B77 5DY

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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 protocols
available to manage the product with centralized elec-
tronic devices

 Visual alarm: In addition to the acoustic alarm fitted

as standard, a visual alarm is also available on request

 Separate circuit versions: For particular applications

it is possible to supply on request also the CT or SC
version which is made in such a way as to separate the
user circuit from the cooling circuit

 Tower kit: It is usually used to avoid fouling or con-

tamination problems in the condenser with open circuit
cooling systems (evaporative tower or well)

 Flowmeters and external temperature sensors

 Insulation kit for low operating temperatures

Typical connection scheme
Microgel RCD with drain kit

Summit TPC: Vanguard Tame Park, Tamworth, Staffordshire B77 5DY

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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 and
which 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 flow
meters) and pump & heating kW values
 Graphical representations of pump performance and tempera-
tures are included

Chiller performance screen

 A graphical representation of chiller performance versus
set point over a 60 minute time frame is displayed
 Compressor loading is depicted graphically
 Cooling capacity, absorbed power and COP (coefficient of
performance) 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)

Summit TPC: Vanguard Tame Park, Tamworth, Staffordshire B77 5DY

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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

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
Technical and dimensional data RCD - 50Hz
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

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

Compressor
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
(**)
SP pro- kW 15 16 16 29 29 30 34 36 61 64 69
cess
Total max. electrical pump A 24 27 30 47 49 51 55 60 96 105 115
load and FLA HP pro- kW 16 16 16 30 30 32 39 41 65 68 73
cess
pump A 27 27 30 49 51 54 65 70 104 113 123
Compressed air
- Yes
(min. 4 - max 7.5 bar)
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
mm - 6
Connections
(*) Cooling capacities are based on supply to process/condenser inlet water Available supply voltage: 400V±10%/3/50Hz; 460V±10%/3/60Hz; 380V±10%/3/60Hz;
temperatures and process water delta T = 2°C On request: UL electrical panel for 60 Hz versions
(**) See pump performance curves on page 8.

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

Summit TPC: Vanguard Tame Park, Tamworth, Staffordshire B77 5DY

T: +44(0)1827 213401 | www.totalprocesscooling.co.uk
sales@summit-tpc.co.uk
Microgel - RCD/RCM
Technical and dimensional data RCM - 50Hz
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 --

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

Compressor
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

kW 7 8 9 9 15 15 16 19 21 32 35 40 69 80
SP process
pump
A 11 13 15 18 25 27 29 32 37 51 60 69 117 135
Total max. electrical
load and FLA
kW - 9 9 9 16 16 17 21 24 34 37 42 80 91
HP process
pump
A - 15 15 18 26 28 31 37 42 55 64 73 136 154
Compressed air
(min. 4 - max 7.5 bar) - Si

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

Compressed Air
Connections
mm - 6

(*) Cooling capacities are based on supply to process/condenser inlet water Available supply voltage: 400V±10%/3/50Hz; 460V±10%/3/60Hz; 380V±10%/3/60Hz
temperatures and process water delta T = 2°C On request: UL electrical panel for 60 Hz versions
(**) See pump performance curves on page 8.

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

Summit TPC: Vanguard Tame Park, Tamworth, Staffordshire B77 5DY

T: +44(0)1827 213401 | www.totalprocesscooling.co.uk
sales@summit-tpc.co.uk
Microgel - RCD/RCM
Process pumps curves 50Hz
RCM 18 Process pumps
RCM single zone
HP - HIGH PRESS
single pump
SP - STD PRESS
RCD dual zone
two pumps

RC_40 RC_60-80

RC_100-130-170L RC_170-210

RC_300-350-450 RC_700-900

Summit TPC: Vanguard Tame Park, Tamworth, Staffordshire B77 5DY

T: +44(0)1827 213401 | www.totalprocesscooling.co.uk
sales@summit-tpc.co.uk
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

HP 3 4 6 7,5 10 13,5 13,5 15 20 25 30
Compressor
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 2,20 3,00 5,50 7,50

kW 16 16 18 30 31 34 36 40 63 70 77
SP process
pump
A 380V 25 27 28 48 52 57 62 68 105 106 116

Total max. electrical

A 460V 21 25 27 42 46 49 53 58 94 103 113
load and FLA
kW 16 17 19 32 33 37 41 45 67 74 81
HP pro-
cess pump
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
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 Con-
nections
mm - 6

(*) Cooling capacities are based on supply to process/condenser inlet water Available supply voltage: 400V±10%/3/50Hz; 460V±10%/3/60Hz; 380V±10%/3/60Hz
temperatures and process water delta T = 2°C On request: UL electrical panel for 60 Hz versions
(**) See pump performance curves on page 8.

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

Summit TPC: Vanguard Tame Park, Tamworth, Staffordshire B77 5DY

T: +44(0)1827 213401 | www.totalprocesscooling.co.uk
sales@summit-tpc.co.uk
Microgel - RCD/RCM
Technical and dimensional data RCM - 60Hz
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 --

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

Compressor
Re-
Type Scroll Multiscroll
cipr.
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 2,20 3,00 5,50 7,50 22,00
(**)
kW 7 8 9 10 16 16 20 21 25 34 41 47 81 94
SP process
pump A 380V 11 14 15 15 26 30 34 38 44 60 62 72 121 141

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

load and FLA
kW - 9 10 11 17 17 21 24 27 36 43 49 92 105
HP process
pump 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
Compressed air
- Yes
(min. 4 - max 7.5 bar)
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

Compressed Air
mm - 6
Connections

(*) Cooling capacities are based on supply to process/condenser inlet water Available supply voltage: 400V±10%/3/50Hz; 460V±10%/3/60Hz; 380V±10%/3/60Hz
temperatures and process water delta T = 2°C On request: UL electrical panel for 60 Hz versions
(**) See pump performance curves on page 8.

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

Summit TPC: Vanguard Tame Park, Tamworth, Staffordshire B77 5DY

T: +44(0)1827 213401 | www.totalprocesscooling.co.uk
sales@summit-tpc.co.uk
Microgel - RCD/RCM
Process pumps curves 60Hz
RCM 18 Process pumps
RCM single zone
HP - HIGH PRESS
single pump
SP - STD PRESS
RCD dual zone
two pumps

RC_40 RC_60-80

RC_100-130-170L RC_170-210

RC_300-350-450 RCM 700-900

Summit TPC: Vanguard Tame Park, Tamworth, Staffordshire B77 5DY

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Microgel - RCD/RCM
Connection example

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

Order code

Summit TPC: Vanguard Tame Park, Tamworth, Staffordshire B77 5DY

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