The Tool‑Temp MATIC Water 160 24 B is a high‑performance pressurised water temperature control unit designed for industrial processes requiring precise thermal management up to 160 °C. With 24 kW of heating power and up to 85 kW of cooling capacity, it is engineered for demanding applications in plastics processing, die casting, laminating, and printing industries where water must operate above its atmospheric boiling point under controlled pressurised conditions. The unit is built around Tool‑Temp's IRIS control system—a next‑generation intelligent controller that combines touchscreen operation, continuous process monitoring, and predictive control algorithms to deliver consistent temperature regulation and energy efficiency.

IRIS Intelligent Control System

• Touchscreen Interface & Remote Operation: The IRIS controller features a full‑colour touchscreen for intuitive on‑site operation. An integrated web server enables full remote control and monitoring via LAN or WLAN from any device—smartphone, tablet, or PC—through a standard web browser, with user experience identical to in‑person operation.
• Predictive & Adaptive Control: Model‑based algorithms continuously capture all available process data—temperatures, pressures, flow rates, operating states, and data trends—and compare them against expected behavior. This continuous adaptation enables optimal, uninterrupted regulation of temperature and flow, as well as reliable process monitoring with proactive fault detection and troubleshooting guidance.
• Industrial Communication: Beyond the standard web server, the IRIS system supports traditional digital and analog interfaces as well as modern industrial network protocols including Profinet and EtherNet/IP, making it suitable for integration into Industry 4.0 automated production environments.

High‑Performance Heating & Cooling

• 24 kW SSR‑Controlled Heating: Fully immersed heating elements made of corrosion‑free high‑temperature nickel alloy (Incoloy 800) are driven by solid‑state relays (SSRs) for precise, fast‑responding temperature control without the wear and maintenance of mechanical contactors. The 24 kW rating ensures fast heat‑up times and stable operation under heavy thermal load.
• Dual Cooling Systems: The unit offers both direct cooling (60 kW) and indirect cooling via a tubular heat exchanger (85 kW). The limescale‑free heat exchanger design prevents mineral deposit buildup, maintaining cooling efficiency over the life of the unit without chemical descaling. Fixed stainless steel pipework further reduces corrosion and maintenance.
• Variable‑Speed Pump with ECO Mode: The pump speed is automatically adjusted to match the actual process demand, with an ECO mode that significantly reduces energy consumption during low‑load periods. The pump is available with either a mechanical seal or a magnetic coupling, providing a maintenance‑optimised solution for long‑term operation. The pump motor is monitored by the variable‑frequency drive for overload and fault protection.
• Maintenance‑Free Flow Meter: A contact‑less, maintenance‑free flow meter provides real‑time flow rate data to the IRIS system, enabling precise flow‑dependent control and early detection of flow restrictions or blockages.

Safety Systems & Operational Features

• Redundant Mechanical Temperature Limiter: A multi‑redundant mechanical temperature limiter provides an independent safety layer that operates entirely independently of the electronic IRIS controller. Temperature‑related safety does not rely solely on software or electronic sensors, ensuring failsafe overtemperature protection.
• Leakstopper — Pressure & Vacuum Mode: The Leakstopper device enables operation in both pressure and vacuum modes. In vacuum mode, coolant drawn from tooling is pulled into the tank rather than leaking onto the shop floor, providing built‑in leak management that protects the mould and factory floor without external vacuum pumps.
• Automatic Water Filling & Air Venting: Automatic water filling from the mains supply eliminates manual filling procedures. Automatic air venting removes entrapped air from the system on startup, ensuring consistent pump performance and heat transfer. Mould drainage with compressed air enables rapid and complete coolant removal during tool changes.
• Configurable Safety Limits & Audible Alarm: In addition to the mechanical temperature limiter, the IRIS controller allows configuration of safeguard limits with corresponding actions. The configurable audible alarm provides immediate notification of process deviations, allowing operators to intervene without continuously monitoring the display. The system also continuously monitors the pump motor via the variable‑frequency drive, providing overload and fault protection.

Applications

• Injection and blow moulding machine mould temperature control requiring pressurised water above 100 °C
• Die casting and metal processing where mould temperature must be precisely maintained during the casting cycle
• Calender roller temperature control in laminating, textile, and paper industries
• Printing industry roller temperature control for consistent ink transfer and drying
• Chemical and pharmaceutical reactor heating and cooling
• Any industrial process requiring pressurised water temperature control between 80 °C and 160 °C