USERGUIDE UGH014/0100 Thermolator TW Series€¦ · Step-by-step adherence to instructions outlined...

Thermolator® TW SeriesWater Temperature Control Unit

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U S E R G U I D E

U G H 0 1 4 / 0 1 0 0

www.conairgroup.com

It’s a good idea to record the model and serial number(s) ofyour equipment and the date you received it in the UserGuide. Our service department uses this information, alongwith the manual number, to provide help for the specificequipment you installed.

Please keep this User Guide and all manuals, engineeringprints and parts lists together for documentation of yourequipment.

Date:

Manual Number: UGH014/0100

Serial number(s):

Model number(s):

DISCLAIMER: The Conair Group, Inc., shall not be liable for errorscontained in this User Guide or for incidental, consequential dam-ages in connection with the furnishing, performance or use of thisinformation. Conair makes no warranty of any kind with regard tothis information, including, but not limited to the implied warrantiesof merchantability and fitness for a particular purpose.

Please record yourequipment’s model and

serial number(s) andthe date you received itin the spaces provided.

Copyright 2000 All rights reservedTHE CONAIR GROUP, INC.

UGH014/0100 Thermolator TW Model

TABLE OFCONTENTS

i

INTRODUCTION . . . . . . . . . . . . . . . . . . .1-1Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . .1-2How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . .1-2Your responsibility as a user . . . . . . . . . . . . . . . . . . . . . . .1-2ATTENTION: Read this so no one gets hurt . . . . . . . . . . .1-3

DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1What is the Thermolator TW? . . . . . . . . . . . . . . . . . . . . . .2-2Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2How it works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4Features and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

INSTALLATION . . . . . . . . . . . . . . . . . . . .3-1Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-3Connecting the water supply . . . . . . . . . . . . . . . . . . . . . . .3-4Optional purge valve hookups . . . . . . . . . . . . . . . . . . . . . .3-5Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . .3-6Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7Initial setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8Changing temperature units . . . . . . . . . . . . . . . . . . . . . . . .3-9Setting SPI communication . . . . . . . . . . . . . . . . . . . . . . .3-10Setting the security level . . . . . . . . . . . . . . . . . . . . . . . . .3-12

OPERATION . . . . . . . . . . . . . . . . . . . . . .4-1TW control features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2The menu system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3Starting the Thermolator . . . . . . . . . . . . . . . . . . . . . . . . . .4-4Stopping the Thermolator . . . . . . . . . . . . . . . . . . . . . . . . .4-5Using the manual purge option . . . . . . . . . . . . . . . . . . . . .4-8

MAINTENANCE . . . . . . . . . . . . . . . . . . . .5-1Preventative maintenance schedule . . . . . . . . . . . . . . . . . . .5-2Accessing the Thermolator enclosure . . . . . . . . . . . . . . . .5-3Performing an Autotune . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

TROUBLESHOOTING . . . . . . . . . . . . . . . .6-1Before beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2How to identify the cause of a problem . . . . . . . . . . . . . . .6-3

DiagnosticsController alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4Mechanical/electrical problems . . . . . . . . . . . . . . . . . . . .6-10Unit will not power up . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

Thermolator TW Model UGH014/0100

TABLE OFCONTENTS

TROUBLESHOOTING (CONTINUED) . . . . . . . . . .6-1RepairResetting overloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13Replacing the pump overload . . . . . . . . . . . . . . . . . . . . . .6-13Replacing the temperature controller . . . . . . . . . . . . . . . .6-14Replacing the heater contactor . . . . . . . . . . . . . . . . . . . . .6-15Checking the thermocouple . . . . . . . . . . . . . . . . . . . . . . .6-16Replacing the thermocouple . . . . . . . . . . . . . . . . . . . . . . .6-17Repairing solenoid valves . . . . . . . . . . . . . . . . . . . . . . . .6-18Replacing heater elements . . . . . . . . . . . . . . . . . . . . . . . .6-20Removing the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22Disassembling and assembling 3/4 to 2 Hp pumps . . . . . .6-23Dissassembling and assembling 3 to 7.5 Hp pumps . . . . .6-24

APPENDIXCustomer Service Information . . . . . . . . . . . . . . . . . . . . . .A-1Warranty Guarantee Information . . . . . . . . . . . . . . . . . . . .A-2Default Paramaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1Technical Information: Plumbing diagram . . . . . . . . . . . . .C-1Technical Information: Pump Curves . . . . . . . . . . . . . . . . .C-2Material Safety Data Sheets . . . . . . . . . . . . . . . . . . . . . . .D-1Series 16 Temperature Controller Instruction Manual

(included in binder pocket or instruction packet)

Additional manuals or information may be included in theappendix or instruction packet depending on the optionsinstalled on the unit.

PARTS/DIAGRAMSParts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PD-1TW wiring schematic . . . . . . . . . . . . . . . . . . . . . . . . . . .PD-5

ii

1-1UGH014/0100 Thermolator TW Model

● Purpose of the User Guide . . . .1-2● How the guide is organized . . . .1-2● Your responsibilities as a user .1-2● ATTENTION: Read this so

no one gets hurt . . . . . . . . . . .1-3

INTRODUCTION

Thermolator TW Model UGH014/01001-2 INTRODUCTION

This User Guide describes the Conair Thermolator® TW watertemperature control units and explains step-by-step how toinstall, operate, maintain and repair this equipment.

Before installing this product, please take a few moments toread the User Guide and review the diagrams and safety infor-mation in the instruction packet. You also should review man-uals covering associated equipment in your system. Thisreview won’t take long, and it could save you valuable instal-lation and operating time later.

Symbols have been used to help organize the User Guide andcall your attention to important information regarding safeinstallation and operation.

Symbols within triangles warn of conditions that couldbe hazardous to users or could damage equipment.Read and take precautions before proceeding.

Numbers within shaded squares indicate tasks or stepsto be performed by the user.

A diamond indicates the equipment’s response to anaction performed by the user.

An open box marks items in a checklist.

A shaded circle marks items in a list.

You must be familiar with all safety procedures concerninginstallation, operation and maintenance of this equipment.Responsible safety procedures include:

● Thorough review of this User Guide, paying particularattention to hazard warnings, appendices and related dia-grams.

● Thorough review of the equipment itself, with carefulattention to voltage requirements, intended uses andwarning labels.

● Thorough review of instruction manuals for associatedequipment.

● Step-by-step adherence to instructions outlined in thisUser Guide.

PURPOSE OFTHE USERGUIDE

HOW THEGUIDE ISORGANIZED

1◆

❒

●

YOURRESPONSIBILITYAS A USER

UGH014/0100 Thermolator TW Model INTRODUCTION 1-3

We design equipment with the user’s safety in mind. You canavoid the potential hazards identified on this machine byfollowing the procedures outlined below and elsewhere in theUser Guide.

ATTENTION:READ THIS SO NOONE GETS HURT

CAUTION: Hot surfaces

Surface temperatures inside the Thermolatorcan exceed 250° F (121° C). Always allow theunit to cool to below 100° F (38° C) beforeopening, servicing or disassembling the unit.

WARNING: Electrical shock hazard

This equipment is powered by three-phasemain voltage, as specified on the machine seri-al tag and data plate.

Always disconnect and lock out the incomingmain power source before opening the electri-cal enclosure or performing non-standard oper-ating procedures, such as troubleshooting ormaintenance. Only qualified personnel shouldperform procedures that require access to theelectrical enclosure while power is on.

WARNING: Improper installation,operation or servicing may result inequipment damage or personal injury.

This equipment should be installed, adjusted,and serviced by qualified technical personnelwho are familiar with the construction, opera-tion and potential hazards of this type of equip-ment.

All wiring, disconnects and fuses should beinstalled by qualified electrical technicians inaccordance with electrical codes in your region.

Always maintain a safe ground. A properlysized conductive ground wire from the incomingpower supply must be connected to the chassisground terminal inside the electrical enclosure.Improper grounding can result in personalinjury and erratic machine operation.

Do not operate the equipment at power levelsother than what is specified on the the equip-ment serial tag and data plate.

Thermolator TW Model UGH014/01001-4 INTRODUCTION

WARNING: Hazardous substanceThe electrical contactors in theThermolator have mercury contactors.Mercury is considered a hazardous sub-stance and must be dealt with accord-ingly. Material Safety Data Sheet (#7439-97) has been included in the instructionpacket. This sheet explains the potentialhazards, how to avoid them and how toclean up and dispose of the mercury if itspills.

ATTENTION:READ THIS SO NOONE GETS HURT


● What is the Thermolator TW? . .2-2● Typical applications . . . . . . . . . .2-2● How it works: . . . . . . . . . . . . . . .2-3● Specifications . . . . . . . . . . . . . .2-4● Features and options . . . . . . . . .2-5

DESCRIPTION

Thermolator TW Model UGH014/01002-2 DESCRIPTION

The Thermolator TW models circulate water at a temperaturehigher than the available water supply, to add or remove heatas needed to maintain a uniform temperature setpoint in theprocess.

The TW is available in single or multiple-zone configurations,using direct injection process heating and cooling. Multiple-zone models can control up to three temperatures at differentlocations in the process. Two- and three-zone models havecommon cooling water manifolds and electrical connections.

The best model for your application depends on the processtemperature you need to maintain and the quality of the cool-ing water supply.

TW direct injection (DI) models control the temperature bydischarging heated process water and adding cooling waterdirectly from the water supply. DI models are designed for:● Process temperatures up to 250°F (121°C).● Use with chiller water or properly treated and filtered tower

or city water.

Direct injection models may be used with glycol/waterprocess loop mixtures, as long as the glycol does not exceed25% of the mixture. If your application requires a higher per-centage of glycol, or you have a contaminated cooling watersupply, ask your Conair representative about our closed-circuitor isolated circuit Thermolator TW-1 and TW-2 models.

WHAT IS THETHERMOLATORTW?

TYPICALAPPLICATIONS

IMPORTANT: Do not use deionized water or glycolmixtures containing additives in a Thermolator.Softened water or glycol mixtures with additives, suchas automotive fluids, can damage the Thermolator.Glycol/water process loop mixtures should use onlyindustrial-grade ethylene glycol.

UGH014/0100 Thermolator TW Model DESCRIPTION 2-3

Direct injection models maintain the process temperatureby electrically heating and injecting cool water supplied tothe Thermolator by a chiller, tower or other water source.

HOW IT WORKS:DIRECT INJECTION

HeaterThermocouple

Purge Valve(optional)

To Process

From Process

Cooling Water In

Cooling Water Out

CoolingValve

ReliefValve

MixingTank

Pump

TW Direct InjectionCheck valves included only with

optional mold purge.

CheckValve

CheckValve

ReturnPressureGauge(optional)Supply

PressureGauge(optional)

A

B

The temperature of the process fluid is measuredas it leaves the unit’s heater tank. The fluid thenflows through the “To Process” line to the moldor process. The fluid returns to the unit through the“From Process” line for reheating or cooling.

1A

B

C

D

If the processtemperature isbelow the set-point, the heaterelements insidethe heater tankare energized.

EF

4 The pump moves water from the mixingtank to the heater tank. Pressure is measured before and after the pump withoptional pressure gauges .

NOTE: Some higher kW models have anadditional heater in the mixing tank

E F

The temperature of the processfluid is measured as it flows intothe mixing tank through the“From Process” line .

2

B

If the supply temperature is abovethe setpoint value, the coolingvalve opens. Cool water enters thebottom of the mixing tank via the“Cooling In” line . Warm waterflows out of the top of the tank viathe “Cooling Out” line .

C

D

3b3a

Thermolator TW Model UGH014/01002-4 DESCRIPTION

SPECIFICATIONS

CABINET STYLE REFERENCEHeater Voltage Selection Single Zone 2 Zone 3 ZoneDirect Injection (DI)9, 12, 18 or 24 kW 208, 230, 460, 575 A B C36 kW 460 or 575 A B C

Dimensions and performance characteristics vary according tothe model, voltage and components selected. See the cabinetstyle reference chart to determine dimensional information foryour specific model. Additional technical information can befound in the Appendix of this User Guide.

PERFORMANCE CHARACTERISTICSModels TW-DI

Minimum Setpoint Temperature °F {°C} 35 {1.7}Maximum Setpoint Temperature °F {°C} 250 {121}Minimum Operating Temperature °F {°C} About 20° {11°} above the

cooling water inlet temperature*Standard Cooling Valve Size inches {mm} 1/4 {6.35}Available pump sizes 0.75, 1, 2, 3, 5 or 7.5 Hp

{0.56, 0.75, 1.49, 2.24, 3.73 or 5.59 kW}Available heater sizes 9, 12, 18, 24, 36 kW

PUMP PERFORMANCE - Consult your Conair representative for pump performance characteristics at other operating points.Pump 3/4 HP {0.56 kW} 1 HP {0.75 kW} 2 HP {1.49 kW} 3 HP {2.24 kW} 5 HP {3.73 kW} 7.5 HP {5.59 kW}

Nominal Flow gpm {lpm} 40 {151} 45 {170} 55 {208} 80 {303} 100 {379} 115 {435}Pressure@ Nominal Flow psi {kg/cm2} 17 {1.2} 18 {1.3} 31 {2.2} 35 {2.5} 43 {3} 51 {3.6}

TOTAL FULL LOAD AMPS PER ZONE All voltages are 3 phase, 60 Hz.Heater 9 kW 12 kW 18 kW 24 kW 36 kW 0 heaters

Voltage 208V 230V 460V 575V 208V 230V 460V 575V 208V 230V 460V 575V 208V 230V 460V 575VPump

0.75 HP {0.56 kW} 28.9 26.2 13.1 10.5 37.3 33.8 16.9 13.5 54.0 48.8 24.4 19.5 70.7 64.0 32 25.61 HP {0.75 kW} 29.4 26.6 13.3 10.6 37.8 34.2 17.1 13.7 54.4 49.2 24.6 19.7 71.2 64.4 32.2 25.82 HP {1.49 kW} 31.8 28.8 14.4 11.5 40.2 36.4 18.2 14.6 56.8 51.4 25.7 20.6 73.6 66.6 33.3 26.63 HP {2.24 kW} 34.7 31.4 15.7 12.6 43.1 39.0 19.5 15.6 59.7 54.0 27.0 21.6 76.5 69.2 34.6 27.75 HP {3.73 kW} 38.5 34.8 17.4 13.9 46.9 42.4 21.2 17.0 63.4 57.4 28.7 23 80.2 72.6 36.3 29.07.5 HP {5.59 kW} 45.7 41.4 20.7 16.6 54.1 49.0 24.5 19.6 70.7 64.0 32.0 25.6 87.5 79.2 39.6 31.7

SHIPPING WEIGHT RANGES lbs {kg} Weights vary depending on cabinet size.Single Zone 2 Zone 3 Zone

Pump Min Max Min Max Min Max0.75 HP {0.56 kW} 240 {109} 300 {136} 480 {218} 600 {272} 720 {327} 840 {381}1 HP {0.75 kW} 240 {109} 300 {136} 480 {218} 600 {272} 720 {327} 840 {381}2 HP {1.49 kW} 250 {113} 310 {141} 500 {226} 620 {282} 750 {336} 870 {396}3 HP {2.24 kW} 260 {118} 320 {145} 520 {236} 640 {290} 780 {354} 900 {408}5 HP {3.73 kW} 270 {122} 330 {150} 540 {244} 660 {300} 810 {366} 930 {423}7.5 HP {5.59 kW} 280 {127} 340 {154} 560 {254} 680 {308} 840 {381} 960 {435}

DIMENSIONS in. {mm}Cabinet Style A B C

Height 28.0 {710} 28.0 {710} 28.0 {710}Depth 22.5 {570} 22.5 {570} 22.5 {570}Width 13.75 {350} 27.5 {700} 41.25 {1050}

A B C

208V 230V 460V 575V 208V 230V 460V 575V

— — 47.0 37.6 3.9 3.6 2.3 1.5— — 47.2 37.8 4.4 4.0 2.5 1.6— — 48.3 38.6 6.8 6.2 3.6 2.5— — 49.6 39.7 9.7 8.8 4.9 3.6— — 51.3 41.0 13.5 12.2 6.6 4.9— — 54.6 43.7 20.7 18.8 9.9 7.6

WATER CONNECTIONSAll modelsNPT inches (female)

From process 1.25Cooling water in/out 0.75

SPECIFICATION NOTES

Two-zone and three-zone models have common wiringand plumbing. Thermolators also can be ordered with-out heaters for certain applications.

* Lower operating temperatures can be obtained with larger cooling valves. Consult your Conair representative.

Specifications can change without notice. Consult Conairfor the most current information.

UGH014/0100 Thermolator TW Model DESCRIPTION 2-5

High efficiency pumpsfrom 3/4 to 7.5 Hp. Siliconcarbide seals are standard.

Pump seal flush linecontinuously cleans thepump seal for extended life.

Incoloy heatersminimize chemical andhigh temperature damage

Built-in sediment trapsettles contaminants awayfrom the pump seals.

Motor drip coverprotects motor windingsfrom moisture damage.

Two-piece cast construction

Alarm packages The Thermolator control includes an outputrelay that can be connected to an optionalexternal alarm package to call attention toalarm conditions.

Motorized Cooling Valve Eliminates thermal shock from your processcircuit by modulating the cooling water.

Compressed Air Mold PurgeQuickly evacuates fluid from the processcircuit, allowing for faster, cleaner discon-nection of the temperature controller frommolds and hoses.

Stacking RackSave floor space by stacking Thermolatorstwo-high. The stacking rack can be usedonly with single-zone models in 28-inchhigh cabinets.

OPTIONS

FEATURES ANDOPTIONS


● Unpacking the boxes . . . . . . . . .3-2● Preparing for installation . . . . . .3-3● Connecting the water supply . .3-4● Optional purge valve hookups .3-5● Connecting the main power . . .3-6● Testing the installation . . . . . . . .3-7● Initial setup . . . . . . . . . . . . . . . .3-8● Changing temperature units . . .3-9● Setting SPI communication . . .3-10● Setting the security level . . . . .3-12

INSTALLATION

Thermolator TW Model UGH014/01003-2 INSTALLATION

UNPACKING THEBOXES

Carefully remove the Thermolator and compo-nents from their shipping containers, and set upright.

Remove all packing material, protective paper,tape, and plastic. Check inside the electrical enclosureand behind the side panels for accessories or hardwarethat may have been placed there for shipping.

Carefully inspect all components to make sure nodamage occurred during shipping, and that you have allthe necessary hardware. If damage is found, notify thefreight company immediately.

Take a moment to record serial numbers andspecifications in the blanks provided on the back of theUser Guide’s title page. The information will be helpful ifyou ever need service or parts.

You are now ready to begin installation.Complete the preparation steps on the next page.

TW Microprocessor Control

Heat OnCool OnHigh Temp AlarmSetpoint Deviation AlarmCommunications Active

ProcessValue

SetValue

Err.H = Open ThermocoupleErr.L = Reversed Thermocouple

ParameterAccessIncrease

Decrease

Mode

Stop Pump

StartDepress until vent cycleends and pump starts

Alarm

PurgePush On/ Off

Control PowerPush On/ Off

FaultPush To Silence

Thermolator

1

2

3

4

5

Thermolator TW models come fully assembled. If they werespecified at the time of the order, the optional purge valve ormotorized cooling valve is factory-installed.

Motorized cooling valve(optional)

Compressed air mold purge(optional)

UGH014/0100 Thermolator TW Model INSTALLATION 3-3

The Thermolator is easy to install, if you plan the location andprepare the area properly.

Position the Thermolator as close to the processmachine as possible.

Make sure the installation area provides:❒ A three-phase power source supplying the correctcurrent for your Thermolator model. Check the serial tagon the side of the electrical enclosure for the required volt-age, phase, frequency, full load amps, disconnect fuse sizeand minimum wire connection size. Field wiring should becompleted by qualified personnel to the planned locationfor the Thermolator. All electrical wiring should complywith your region’s electrical codes.

❒ A clean, well-ventilated environment. The room temperature should not exceed 120° F (48° C)with 95% non-condensing humidity and should not fallbelow 32° F (0° C).

❒ Minimum clearance for safe operation andmaintenance. The diagram at right showsminimum clearance for operation. You alsoneed enough clearance in the rear forwater hookups. For maintenance, youshould move the Thermolator toprovide at least 36 inches on any sideof the Thermolator.

❒ A source of water for cooling.City, tower or chiller water may be used, as long as thesupply pressure is at least 25 psi and not more than 85 psi.

Install plumbing for process and cooling lines.You will need two 11/4-inch NPT male fittings for theprocess inlet and outlet and two 3/4-inch NPT male fit-tings for the cooling inlet and outlet. Larger line sizes areacceptable as long as they are reduced at the Thermolatorconnections. Smaller line sizes are not recommended.

PREPARING FORINSTALLATION1



ProcessValue

SetValue



Decrease

Mode

Stop Pump


Alarm

PurgePush On/ Off



2

Process machine

Thermolator

Alternatelocations

3

12 inches

(305 mm)

12 inches

(305 mm)20 inches(508 mm)


Motorized Cooling ValveIf you have the optional motorizedcooling valve, connect the coolingwater supply to the female 3/4 inchNPT fitting on the valve. except asnoted, all other connections shouldbe made as described above.

The Thermolator process inlets and outlets must be connectedto the plumbing that will circulate the temperature-controlledwater or fluid through the process. Cooling water inlets andoutlets are connected to the cooling water supply.

Remove the shipping pipe plug from the femaleconnections on the back of the Thermolator.

Install pipe to the rear of the Thermolator.Use male 11/4-inch NPT piping for process connectionsand male 3/4 inch NPT piping for water connections. Pipeand pipe threads must be clean and new. Clean threadswith solvent, removing all oil, grease and dirt. Allow thethreads to dry before proceeding.

Coat the pipe threads with thread sealant.Follow the sealant manufacturer’s directions.

Connect the male pipe to the appropriatefemale connection on the back of the unit. Startby hand until the threads engage, then use a pipe wrenchto tighten the connection only enough to prevent leaks.Do not over-tighten!

CONNECTINGPROCESS ANDWATER SUPPLYLINES

1

2

3

4

Tools for installation:❒ Pipe wrench large enough

for a 2-inch pipe❒ Premium quality Teflon

thread sealant

NOTE: We recommendthat you install anexternal ball valve onthe cooling water inletof the Thermolator. Thisvalve is required whenthe purge valve optionis installed.

From process

Toprocess

Cooling water out

Cooling water out

Cooling water in

DIRECT INJECTION

From process

Toprocess


A purge valve is available as an option. This valve quicklyevacuates fluid from the process circuit, allowing faster dis-connection of the temperature controller from molds andhoses. An optional manual purge button controls this valve.

If this option is ordered with the Thermolator, purge controlwiring and installation of the valve on the process line outletof the unit is completed at the factory. You still must connectprocess and cooling water inlets and outlets, as well as a sup-ply of non-lubricated compressed air.

Remove the shipping pipe plug from the femaleconnections on the back of the Thermolator.

Install an external ball valve on the coolingwater inlet of the Thermolator. This valve isrequired when a purge valve is used.

Install pipe to the rear of the Thermolator.Use male 11/4-inch NPT piping for process connectionsand male 3/4 inch NPT piping for water connections. Pipeand pipe threads must be clean and new. Clean threadswith solvent, removing all oil, grease and dirt. Allow thethreads to dry before proceeding.

Coat the pipe threads with thread sealant.Follow the sealant manufacturer’s directions.

Connect the male pipe to the appropriatefemale connection on the back of the unit.Connect cooling water lines as indicated on the previouspage. Connect process lines as indicated below. Start byhand until the threads engage, then use a pipe wrench totighten the connection only enough to prevent leaks. Donot over-tighten!

Connect the purgevalve to the compressedair supply. The air pressureshould not exceed 100 psi.

OPTIONALPURGE VALVEHOOKUPS

From process

Toprocess

Compressed airfitting

1

2

3

4

5

6


Before beginning, note the electrical specifications on thenameplate mounted to the side of the unit. The electricalhookup must match these specifications with +/- 10% maxi-mum voltage variance. An improper power supply coulddamage the unit as well as seriously injure an operator.

The electrical hookup also should run through a fused dis-connect sized for the nameplate amperage and conforming toArticle 250 of the National Electrical Code.

Open the unit’s electrical enclosure.

Insert the main power wire through the knockouthole in the right side of the enclosure.

Secure the power wire with a rubber compres-sion fitting or strain relief.

Connect the power wires to the terminals. Connect the three hotwires to L1, L2, and L3on the terminal block.

Connect the groundwire to the coppergrounding mount.If you have installed adisconnect device, followthe manufacturer’s wiringinstructions.

1

2

3

4

5

CONNECTINGTHE MAINPOWER SUPPLY

WARNING: Electrical shock hazardThis equipment is powered by three-phase mainvoltage. Always disconnect and lock out the mainpower source before performing any workinvolving electrical connections. All wiring,disconnects and fusing should conform to yourregion’s electrical codes and should be installedonly by qualified personnel.

IMPORTANT: Always referto the wiring diagrams thatcame with your temperaturecontrol unit before makingelectrical connections. Thediagrams show the mostaccurate electrical compo-nent information.

IMPORTANT! Before initiatingpower to the unit:❒ Check the system for leaks.❒ Verify that the voltage, phase,

frequency, amperage, disconnect fuseand minimum wire size meet thespecifications stated on the name-plate mounted on the side of the unit.

❒ Verify that resistance to ground oneach phase is at least 1 meg ohm.


Turn on the cooling water supply and check forleaks. If any leaks appear, stop the test and fix the prob-lem before continuing. The cooling water must be at least25 PSI or the unit will not function. The optional FAULTlight will turn on when power is applied. The light goesoff when the pressure is correct.

Apply power to the unit, then press .◆ The power button lights up to indicate the

control has power.◆ All LED segments on the display

will light for a few seconds whilethe control performs a selftest. Thecontrol then displays the softwareversion, followed by a configurationcode (upper display) and com-muncations protocol (lower display)if the SPI option is installed.

Check the rotation of the pump. Remove the topaccess panel and the pump motor drip cover. Press andhold the START button until the pump starts. Quicklypress Pump STOP button and look at the pump. Verify thatthe pump rotation matches the direction indicated on therotation sticker on top of the pump motor.

Replace the drip cover and top access panel.

Press and hold the START buttonuntil the vent cycle begins. If everything is working correctly:◆ The START button lights.◆ The unit initiates a 10-second venting sequence. The

pump starts when the venting sequence is over. ◆ Normal operation begins. The heater turns on if the

actual temperature is below setpoint. The cooling valveis active if the actual temperature is above setpoint.

The test is over. Proceed to initial setup if the unit operatednormally; refer to the TROUBLESHOOTING section if it did not.

TESTING THEINSTALLATION

1

2

3

45

WARNING: Only qualified personnelshould perform this procedure.Parts of this test require opening the unit while it isenergized. Only qualified personnel who have beentrained in the use of electrical testing devices andin avoiding the safety hazards involved in safelytroubleshooting this type of equipment should per-form this test procedure.

Control Power

Start

NOTE: If the rotation isincorrect, stop the test anddisconnect power to theunit. Open the electricalenclosure and switch anytwo of the three powersource wires on the termi-nal block. Return to Step 2and check rotation again.

NOTE: If the vent cycledoes not begin and thepump does not start, verifythat the cooling water sup-ply is connected properlyand that the water pressureis at least 25 psi.


INITIAL SETUP The temperature controller has been configured at the factoryto satisfy most applications. But you can change some settingsas needed, including:❒ The temperature units.❒ The security level allowing operator access to settings and

parameters.❒ The unit identification number (node address) and baud rate

for the SPI communications option.

CAUTION: The Thermolator will not operate correctlyif certain factory-set parameters are changed.Parameters should be changed only by qualified technical personnel who are familiar with the operation of this type of equipment. If the Thermolatordoes not appear to be working correctly, verify theparameters against the list of factory settings.

For a complete list of the factory-set parameters See DEFAULTPARAMETERS in the Appendix. For more detailed informationabout these parameters and instructions on returning the para-meters to the initial factory setup, See the SERIES 16CINSTRUCTION MANUAL included with the instruction packet.

All parameters can be changedusing the keypad and the menusystem within the temperaturecontroller.

Mode/Enter KeyUsed to access operating modes,index through menu items andenter parameter settings.

Lower KeyUsed to decrease values or togglebetween setting choices.(Hold for fast-step progression)

Raise KeyUsed to increase values or togglebetween setting choices.(Hold for fast-step progression)

Menu Access KeyUsed to enter or exit the menu system, index to the next menuand enter the Security Level menu.


CHANGINGTEMPERATUREUNITS

The temperature units are factory-set as degrees Celsius,Kelvin or Fahrenheit, as specified when the unit was ordered.

To change this setting:

Place the controller in Standby mode.a. Press and hold for

three seconds until theoperating mode appears inthe lower display.

b. Press or until the Standby mode appearsin the lower display.

c. Press again. The upper display will alternate between Standbyand the process value. You are now in Standby mode.

Press and hold for three seconds to accessthe menu system.

Press until the dSPL (Display) menu appears.

Press until Unit appearsin the lower display.

Press or to select thetemperature unit.F = FahrenheitC = CelsiusCAY = Kelvin

Press to index to the next menu withparameter settings you want to change.

If you do not want to change other parametersettings, press and hold for three secondsto return to the normal operating mode.

1

2

3

4

a

b c

5

6

SETTING SPICOMMUNICATION(OPTIONAL)


SPI compatible communication support is available as anoption on TW Thermolators. The option includes a serial communications card and a serial port installed in theThermolator.

You can use SPI communication to change or monitor the:

● Process temperature setpoint● Process status (run and alarm conditions)● Machine status● Actual temperature to process

To use the SPI communication option, you must connect theThermolator to the host machine and set the communicationbaud rate and node address using the setpoint select andadjustment buttons on the control panel.

Connect the host machine to the Thermolator.Plug the male DB9 connector into the optional serialcommunications port on the Thermolator.

Apply power to the Thermolator.

Change the Security Level, if necessary.The Security Level should be set to the Configuration(CnFg) level. See SETTING THE SECURITY LEVEL.

Press and hold for three seconds to accessthe menu system.

Press again until the SErL (Serial) menuappears in the upper display.

Press to select theID number display.The lower display will flashbetween Id.no and a numeric value.

Press the or key to set the unit address.The address may be any numberfrom 32 to 254, as long as the number has not been assigned toanother machine connected to thesame network.

1

23

4

5

6

7


SETTING SPICOMMUNICATION(OPTIONAL)

NOTE: For additional SPI programming information, see theSeries 16C Standard Options and Digital CommunicationsUser’s Guide. This supplement is included with this instruc-tion package if the SPI option is installed.

Press to select the Baud display.The lower display will flash betweenbAUd and the numeric value of thebaud rate.

Press the or key to set the baud rate.Baud rate may be set to 1200, 2400,4800 or 9600 bps.The Thermolator must be set to sendand receive data at the same baud rateas the host machine.

Press and hold for three seconds to returnto the normal operating display.

The red communication status lights (F1 and F2) onthe temperature controller should flash when the unit is communicating with the host machine.

8

9

10

Heat OnCool On

High Temp AlarmSetpoint Deviation AlarmCommunications Active


The TW Thermolators provide the ability to protect systemparameters from accidental or unauthorized changes. Six security levels are available, allowing various degrees ofaccess to the menus, setpoint and operating mode selections.

We recommend selecting the most restrictive security levelthat suits your application. The security levels are:

Key Lockout. Highest security level. No access to anycontroller functions.

Setpoint. Allows setpoint value or output percentage(manual mode) to be changed. No access to menus.

Setpoint Plus Mode. Allows changes to setpoint value,output percentage (manual mode) or the operatingmode. No access to menus.

User. Allows access to all Setpoint Level privelges, aswell as access to Operating Mode, Autotune andControl menus.

Configuration. Allows access and changes to all para-meters and menus except the Calibration menu. Accessrecommended only for trained service personnel.

Factory. Lowest security level. Allows access to allparameters, menus and calibration settings. Access rec-ommended only for factory personnel.

To change or view a Security Level:

Press and hold for about 10 seconds.The controller will display AcLv inthe upper display and the access levelcode in the lower display. (Ignore themenu label that appears in the upperdisplay after three seconds.)

Press or to indexthrough the security levels,stopping on the level that you want.

Press once to select the level and exit to the process value display.

SETTING THESECURITYLEVEL

Loc.O

SP

SP.PL

FACt

USEr

CnFg

1

2

3


● The TW control . . . . . . . . . . . . . .4-2● The TW menu system . . . . . . . . .4-3● Starting the Thermolator . . . . . .4-4● Stopping the Thermolator . . . . .4-5● Using the manual purge

option . . . . . . . . . . . . . . . . . . .4-6

OPERATION

THE TW CONTROL

Thermolator TW Model UGH014/01004-2 OPERATION

Setpoint Value DisplayThe window displays the fluidtemperature setpoint duringnormal operation. The windowalso displays operating modesand parameter selectionswhen or is pressed.


Heat OnCool On


ProcessValue

SetValue


ParameterAccess

Increase Decrease

Mode

Stop PumpStartDepress until vent cycleends and pump starts

Alarm

PurgePush On/ Off



Purge Button (Optional)

The purge uses compressed airto clear fluid from the mold andlines before a mold change.Press once to turn Purge on.Press again to turn it off.

WARNING: Shut off the supplyto cooling water inlet beforepurging.

Audible Alarm and Fault Light (Optional)

Press the red FAULT button toacknowledge the alarm lightand silence the optional audiblealarm. The optional alarm lightremains on until the cause ofthe alarm condition is fixed.

The red alarm light flashes to indicate high/low deviation, lowwater pressure, pump overloador high temperature safety.

Control Power ButtonPress to turn power to the control on oroff. The button lights when power is on.

Start ButtonPress and hold to begin normal operation. The buttonlights when the unit is running.

Stop ButtonPress to stop theThermolator.

Process Value DisplayThe window displays the actualtemperature of fluid enteringthe “To Process” line. The win-dow also displays menu levelsand error codes related to thetemperature controller.

Menu Access KeyPress and hold for three seconds to enter or exitthe menu system. Press to index to the nextmenu. This key also is used to enter the SecurityLevel menu.

CAUTION: Changing menus and parametersincorrectly can result in improper operation of theThermolator. Accessing menus and changingparameters is not necessary during normal operation.

Status lightsThe lights indicatethe operating status of the listedcomponents.

= Off or inactive= On or active

(01): Heat cycle on or off

(02): Cooling cycleon or off

(A1): High tempera-ture alarm

(A2): Setpointdeviation alarm

(F1)(F2)

: SPI Commun-ication status

Raise and Lower KeysUsed to enter the setpoint temperature, index through theoperating modes or change other parameter values. Press

to increase a value. Press to decrease a value.

TIP: Press and hold the key for faster scrolling speed.

Mode / Enter KeyPress and hold for three seconds to access Normal, Standby,Manual or Autotune operating modes.

Press to index through parameters within each menu level orreturn to the normal operating display.

THE TW MENUSYSTEM

UGH014/0100 Thermolator TW Model OPERATION 4-3

The TW temperature controller uses a menu system to accessdifferent operating modes or change system parameters.Please SEE THE APPENDIX for default parameter settings anddetailed information on each of these modes and parameters

Operating Modes

Normal. The unit operates with normal automatic control based on the parameters entered during initialsetup. The setpoint temperature can be changed in thismode as long as the Security Level allows changes.

Standby. Use to disable control outputs. You must firstbe in Standby mode to initiate an Autotune. Standbymode also is recommended when you initially configurethe controller.

Autotune. Use to ensure that the control continues toobtain good approximations of the PID constants usedto compensate for the thermal lag of the system. AnAutotune should be performed after the first two hoursof operation and whenever process variables change.See PERFORMING AN AUTOTUNE.

Manual. This mode is used for testing only. Manualmode overrides automatic control, allowing you to con-trol heat and cooling outputs by a fixed percentage ofoutput power regardless of the temperature setpoint.

Parameter Menus

Input. Use to select sensor-related parameters, such asinput type.

Display. Use to set or change display units or decimalposition.

Output. Use to specify output usage, control methodsand alarms.

Control. Use to select parameters associated with con-trol methods.

Alarm. Use to select alarm parameters.

Tune. Use to set autotune damping parameter.

Recipe. Use to set ramp and soak parameters.

Supervisor. Use to set fail-safe and supervisory parameters.

Calibration. Use to recalibrate input.

Option. Use to select an installed option, such as aserial communications card.

Serial Communications. This menu will appear only ifthe optional serial communications card is installed. Useto set node address and baud for SPI communication.

FOP

StbY

nor

dSPL

Atun

InP

CtrL

OutP

tunE

ALr

SUPr

r-S

CAL

SErL

OPtn

Press and hold forthree seconds toaccess the menus

Press to indexthrough the menus.

Press to indexthrough parametersunder each menu item.

Press and hold forthree seconds toaccess operatingmodes.

NOTE: You must be inStandby mode toaccess Autotune.


Before starting the Thermolator, verify that the system hasbeen installed correctly for your application. See theINSTALLATION section.

If the Security Level has been set to Lock Out you will not beable to change the setpoint temperature value. You may needto change the Security Level to modify any of the operatingparameters, including the temperature setpoint.

Turn on the water supply to the Thermolator.The supply pressure must be at least 25 psi. Check forleaks in the cooling water and process fluid lines beforecontinuing.

Turn on main power to the Thermolator.

Press CONTROL POWER .◆ The power button lights to indicate the control has

power.◆ All LED segments on the display

will light for a few seconds whilethe control performs a selftest. Thecontrol then displays the softwareversion, followed by a configura-tion code (upper display) and com-muncations protocol (lower dis-play) if the SPI option is installed.

Set the temperature setpoint to 35° F. Press to increase or to decrease the temperaturesetting.

Press and hold START until the vent cyclebegins. If everything is working correctly:◆ The START button lights.◆ The unit initiates a 10-second venting sequence. The

pump starts after the venting cycle is over. ◆ Normal operation begins. The heater turns on if the

actual temperature is below setpoint. The cooling valveis active if the actual temperature is above setpoint.

Set the setpoint to the desired temperature.Press to increase or to decrease the temperaturesetting.

If the optional Fault light/ alarm turns on, press FAULTto silence the optional audible alarm. Then see the TROUBLESHOOTING section.

STARTING THETHERMOLATOR

1

2

3

IMPORTANT: If you areoperating the Thermolatorfor the first time sinceinstallation, you should perform an Autotune aftertwo hours of normal opera-tion. You should perform theAuto Tune periodically toensure that the control correctly calculates howmuch heat and coolingshould be applied to main-tain the process setpoint.See PERFORMING ANAUTOTUNE.

5

4

Control Power

Start

Fault

6


STOPPING THETHERMOLATOR

You must shut down the Thermolator whenever you:● Change the water hookups.● Shut down the process machine.● Purge the process circuit of the water or fluid.● Run the unit’s diagnostic tests.● Perform routine or preventative maintenance.● See an alarm condition that requires troubleshooting.● Relocate, ship or store the unit.

To shut down the unit for purging the process lines, diagnos-tic testing, routine maintenance or troubleshooting, press theStop button. Then refer to the appropriate topic or section inthis User Guide for additional instructions.

To shut down the unit to change water hookups:

Press STOP and CONTROL POWER . .

Shut off the cooling water supply, and drain the unit ofall fluid. Use the two drain plugs onthe back of the unit.

Once the unit is cool, removethe water hookups.

To shut down the unit for relocation or storage:

Press STOP and CONTROL POWER .

Drain the unit of all fluid.Drain the unit using the two drain plugs.

Disconnect the power supply and all water feeds.

In shipment or storage, the Thermolator can withstand anenvironment between -40° F (-40° C) and 150° F (65° C)with 95% relative humidity non-condensing.

WARNING: Electrical shock and hot surface hazardsBefore attempting maintenance of any kind on the Thermolator, you must stop the unit;disconnect and lockout the main power supply; and allow the unit to cool to less than100° F (38° C).

1

2

Drain plug

1

2

Control Power

Stop Pump

3

Control PowerStop Pump

3


The TW Thermolator can be ordered with an optional purgevalve, which clears the process lines of fluid using com-pressed air. The valve is operated by an optional manual purgebutton on the control panel

IMPORTANT: Before purging the process lines, be surethat the cooling water source feed is closed. If the feed isopen and the air line has a higher pressure than the coolingwater, air may be injected into the cooling water system. Ifthe cooling water pressure is higher than the air line, coolingwater may be injected into the air line.

Press STOP PUMP to stop the Thermolator.

Shut off the cooling water supply valve.

Press PURGE to start purging.

◆ The Purge button lights.◆ The Vent and Cool outputs are activated.◆ The STOP and RUN buttons are deactivated during the

purge or when the cool delay off timer is active.

The time required to clear the process lines of fluid willvary according to the length of the process piping and thesize of the tooling.

Press PURGE again to stop purging.

USING THEMANUAL PURGEOPTION

123

4


Heat OnCool On


ProcessValue

SetValue


ParameterAccess

Increase Decrease

Mode


Alarm

PurgePush On/ Off



Purge

Stop Pump

Purge


● Maintenance schedule . . . . . . . .5-2● Accessing the Thermolator

enclosure . . . . . . . . . . . . . . . . .5-3● Performing an Autotune . . . . . .5-4

MAINTENANCE

Thermolator TW Model UGH014/01005-2 MAINTENANCE

PREVENTATIVEMAINTENANCESCHEDULE

Thermolator TW water temperature controllers are essentiallymaintenance-free. However, to maintain the best performance,we recommend the following maintenance schedule.

● Whenever process variables change❒ Perform an Autotune.

The Autotune ensures that the control continues toobtain good approximations of the PID constants usedto compensate for the thermal lag of the system.. Youshould perform an Auto Tune after the first two hours ofoperation and whenever the process changes, such asafter a mold change; installation of different pipe sizes;or change in process setpoint. See PERFORMING ANAUTOTUNE.

● Daily❒ Check for leaks in cooling and process lines.

Before and during operation, you should inspect theunit and all plumbing lines for leaks. If a leak develops,stop the Thermolator and repair it.

❒ Keep the unit and the area around it clean.Check for and remove lint, dust or other obstructions onthe unit, especially around air intake areas. Keep thefloor around the unit dry.

● Quarterly (every 3 months)❒ Inspect power cords, wires and electrical

connections. Check for loose or frayed wires, burned contacts, andsigns of overheated wires. Check exterior power cordsto the main power source and from the electrical box tothe pump and heating elements. Check the ground wireand thermocouple connections. Replace any wire thatappears damaged or has worn or cracked insulation.

UGH014/0100 Thermolator TW Model MAINTENANCE 5-3



ProcessValue

SetValue



Decrease

Mode

Stop Pump


Alarm

PurgePush On/ Off



WARNING: Electrical shock and hot surface hazardsBefore attempting maintenance of any kind on the Thermolator, you must stop the unit;disconnect and lockout the main power supply; and allow the unit to cool to less than100° F (38° C)

To access the Thermolator enclosure:

Remove the top access panel by lifting straight up. Remove the side panels by lifting straight up.

ACCESSING THETHERMOLATORENCLOSURE


You should perform an Autotune after the first two hours ofoperation and whenever process variables change (changes incooling water pressure, piping or molds; large ambientswings; new setpoint temperature) to ensure that the controlcontinues to obtain good approximations of the PID constantsused to compensate for the thermal lag of the system.

To ensure a successful Autotune, verify that:

❒ The Thermolator has been stopped and the processvalue is stable. A fluctuating process value will fool thesoftware into making inaccurate tuning decisions. If theprocess value is not stable, the Autotune terminates and thecontrol displays an error.

❒ The setpoint/process deviation is at least 25° F. Tuningaccuracy increases as the spread between the process andsetpoint values increases. If the absolute value of setpointminus the process temperature is not at least 25° F, theAutotune terminates and the control displays an error.

To perform an Autotune:

Press STOP to stop the Thermolator.

Place the controller in Standby mode.a. Press and hold for

three seconds until theoperating mode appears inthe lower display.

b. Press or until the Standby mode appearsin the lower display.

c. Press again. The upper display will alternate between Standbyand the process value. You are now in Standby mode.

Enter a setpoint value, if one has not been set.Press or until increase or decrease the setpoint.

Press and hold START until the pumpstarts.

continued on next page

PERFORMING ANAUTOTUNE

1

2

3

a

b c

Stop Pump

4Start


Initiate the Autotune.a. Press and hold again

for three seconds until CtrLand the operating mode aredisplayed.

b. Press or until the Autotune mode appearsin the lower display.

c. Press again. The upper display will alternate between “tunE”and the process value whilethe Autotune is underway.

If Autotune is successful, the controller automaticallystarts controlling using the new PID parameters.

If a fault occurs during the Autotune, the control entersStandby mode and displays the appropriate error message.

PERFORMING ANAUTO TUNE

ERROR CODE ERROR DESCRIPTION

No PID device configured.Verify that Output 1 Type and Output 2 Type are configured as PID outputs.

Incorrect output action.Verify that the outputs are set up and wired correctly.Output 1 should be reverse acting for heating. Output2 should be direct acting for cooling.

Insufficient setpoint/process deviation.If the absolute value of setpoint minus process valueis less than 25° F. The Autotune cannot be starteduntil the temperature difference is at least 25° F.

Tune timed out. Autotune will time out if a stableprocess value cannot be obtained. If this erroroccurs, verify that you followed every requirementunder “To ensure a successful Auto Tune” and perform a second tune.

Invalid tune results.The most likely causes of this error is a tune startedinappropriately or an external element (i.e., loosethermocouple) that upset the process while tuningwas in progress. Verify that you followed everyrequirement under “To ensure a successful AutoTune” and perform a second tune.

5

a

c

02

05

03

09

08


● Before beginning . . . . . . . . . . . .6-2● A few words of caution . . . . . . .6-2● How to identify the cause

of a problem . . . . . . . . . . . . . . .6-3DIAGNOSTICS● Controller alarms . . . . . . . . . . . .6-4● Mechanical/electrical

problems . . . . . . . . . . . . . . . .6-10● Unit will not power up . . . . . . .6-12REPAIR● Resetting overloads . . . . . . . . .6-13● Replacing the pump overload .6-13● Replacing the temperature

controller . . . . . . . . . . . . . . . .6-14● Replacing the heater

contactor . . . . . . . . . . . . . . . .6-15● Checking and replacing

thermocouples . . . . . . . . . . .6-16● Repairing solenoid valves . . . .6-18● Replacing heater elements . . .6-20● Removing the pump . . . . . . . . .6-22● Disassembling and assembling

3/4 - 2 HP pumps . . . . . . . . . .6-23● Disassembling and assembling

3 - 7.5 HP pumps . . . . . . . . . .6-24

TROUBLESHOOTING

Thermolator TW Model UGH014/01006-2 TROUBLESHOOTING

You can avoid most problems by following the recommendedinstallation, operation and maintenance procedures outlined inthis User Guide. If you do have a problem, this section willhelp you determine what caused it and tell you how to fix it.

Before you begin troubleshooting:

❏ Find the wiring, plumbing and other diagramsthat were shipped with your equipment. Thesediagrams are the best reference for correcting a problem.The diagrams also will note any custom features, such asspecial wiring, control or plumbing options, not covered inthis User Guide.

❏ Verify that you have manuals for other equip-ment in the process line. Solving problems mayrequire troubleshooting malfunctions or incorrect operatingprocedures on other pieces of equipment.

❏ If an alarm is present, note any indicator lightsand messages shown on the control panel. Theseindicators will help you discover the cause of the problemmore quickly.

The Thermolator is equipped with many safety devices. Donot remove or defeat them. Improper corrective action canlead to hazardous conditions, and should never be attemptedto sustain production.

BEFOREBEGINNING

A FEW WORDSOF CAUTION

WARNING: Hot surfaces and liquidsAllow the Thermolator to cool to below 100° F (38° C) before servicing the unit.

WARNING: This machine should be adjust-ed and serviced only by qualified technical per-sonnel who are familiar with construction andoperation of this type of equipment.

DANGER: Voltage hazard.Troubleshooting the electrical system of thisequipment requires use of precision electronicmeasuring equipment, and may require accessto the electrical enclosure while power is on.Exposure to potentially fatal voltage levels maybe unavoidable. These troubleshooting proce-dures should be performed only by qualifiedelectrical technicians who know how to usethis precision electronic equipment and whounderstand the hazards involved.

UGH014/0100 Thermolator TW Model TROUBLESHOOTING 6-3

Illuminated alarm lights and error codes on the temperaturecontroller will alert you to many malfunctions. If the optionalalarm package is installed, an audible alarm also will activate.

When an Alarm condition occurs:

Press to silence optional audible alarm.

Note any indicator lights or error messages tohelp determine the cause of the problem.

Find the alarm or error code in the diagnosticstables in this section of the User Guide. Causes are listedin the order of most likely to least likely problem.

Determine and fix the cause of the alarm.

HOW TO IDENTIFYTHE CAUSE OF APROBLEMTW Microprocessor Control

Heat OnCool On


ProcessValue

SetValue


ParameterAccess

Increase Decrease

Mode


Alarm

PurgePush On/ Off



1

2

3

WARNING: Always disconnect and lockout the main power source before open-ing the Thermolator or its electricalenclosure.

Disconnect air and water supply lines as needed.

4

Optional audible alarm andilluminated fault button.

See Mechanical/ElectricalProblems

Standard indicator lightsand alarm codes.

See Controller Alarms

Fault

CONTROLLERALARMS


Alarm

The actual tempera-ture of water suppliedto the processexceeds the 260° Fsafety limit that isprogrammed in thecontroller

WARNING:Only qualified electri-cal service personnelshould examine andcorrect problems thatrequire opening theunit's electricalenclosure or checkingelectrical current todiagnose the cause ofa problem.

The Thermolator willnot maintain the setpoint temperature,or takes too long toreach the setpointtemperature range.The actual tempera-ture of water suppliedto the process is outside the setpointdeviation alarm band.

Possible causeHas water stopped flow-ing through the unit orbetween the supply outletand return inlet?

Has the heater contactorfailed?

Has the optional electro-mechanical high tempera-ture safety switch beeninstalled on this unit?

Is the actual temperatureof the process fluid morethan 10° F higher thanthe setpoint temperature?

Is the actual temperatureof the process fluid morethan 10° F lower than thesetpoint temperature?

Solution

❒ Verify that the unit is run-ning and that the pump isworking.

❒ Check for closed or defec-tive cooling or vent valvesand plugged lines. SeeRepairing Solenoid Valves.

Replace the contactor if defective. See Replacing the Heater Contactor.

If yes, verify the switch set-ting. A too-low setting willcause nuisance trips. Check theswitch and replace if defective.See Checking and ReplacingSwitches.

Follow the troubleshootingprocedures in the table for aHigh Setpoint Deviation onpage 6-5.

Follow the troubleshootingprocedures in the table for aLow Setpoint Deviation onpage 6-6.

High Temp. Alarm

The Thermolator has detected a problem that could lead to equip-ment damage or personal injury if it is not corrected.

◆ The controller displays a red alarm LED or an error code indi-cating the cause of the problem.

◆ If the optional alarm package is installed, the Fault button willilluminate and the audible alarm will activate.

Setpoint Deviation





CONTROLLERALARMS

Alarm

The Thermolatorwill not cool down,or takes too long tocool down. The actu-al temperature offluid supplied to theprocess is higherthan the setpointdeviation allows.

WARNING:The Thermolator shouldbe tested and repairedonly by qualified techni-cians equipped with thecorrect tools and trainedin the maintenance andrepair of electrical sys-tems and industrialappliances.

Possible causeHas water stopped flow-ing between supply outletand return inlet?

Did the cooling valve failclosed?

Is the temperature differ-ence between the coolingwater supply and the set-point too small?

Did a heater contactorfail closed?

Is the cooling valveunder-sized for the application?

Is the deviation tempera-ture band too narrow?

SolutionCheck for a plugged pipe orclosed valve.

Check the cooling valve. SeeRepairing Solenoid Valves or theMotorized Cooling Valveinstructions.

The temperature differenceshould be at least 25° F toachieve proper cooling. Increasethe process setpoint, decreasethe cooling water supply tem-perature or increase the coolingwater supply pressure.

With power on and the HeaterLED lit: Check the amp drawon each of the three phase legsto the heater. All should matchthe FLA listed for the heater onthe unit nameplate. Replace theheater contactor if there is avoltage imbalance greater than10%. See Replacing the HeaterContactor.

Check the cooling load (Btu/hr)for which the valve was speci-fied.

Increase the deviation band. Therecommended setting is the set-point plus/minus 2° F to 10° F .

High Setpoint Deviation





CONTROLLERALARMS

Alarm

The Thermolatorwill not heat to thesetpoint temperature,or takes too long toreach the setpointtemperature. Theactual temperature offluid supplied to theprocess is lower thanthe setpoint devia-tion band allows.


Possible causeIs the cooling valve stuckopen or leaking water?

Did a heater element fail?

Did a heater contactorfail open?

Is the deviation tempera-ture band too narrow?

Is the Thermolatorunder-sized for theapplication?

SolutionDisassemble the cooling valveand check for particles block-ing the valve seat. Check thevalve seat for excessive wear.Replace as required using avalve repair kit. See RepairingSolenoid Valves.

With the unit powered down:Check for loose connections.Check resistance between thephase legs on the output sideof the heater contactor.Readings should be within0.25 ohms of each other.Replace the heater, if neces-sary. See Replacing HeaterElements.

With power on and theHeater LED lit: Check theamp draw on each of the threephase legs to the heater. Allshould match the FLA listedfor the heater on the unitnameplate. Replace the heatercontactor if there is a voltageimbalance greater than 10%.See Replacing the HeaterContactor.

Increase the deviation bandsetting. The recommended set-ting is the setpoint plus/minus2° F to 10° F.

Review specifications andselection guidelines that applyto heater and pump sizes intemperature control units.

Low Setpoint Deviation

CONTROLLERALARMS



◆ The controller displays a red alarm LED and/or an error codeindicating the cause of the problem.

Alarm

OpenSensor

The thermocouple inthe process supplyline is not workingcorrectly.

ReversedSensor

The thermocouple inthe process supplyline has failed.


CauseIs the thermocouple wiredcorrectly, or is the wireloose?

Is the input parameter inthe controller set correctly?

Has the thermocouplefailed?

Is the thermocouple wiredcorrectly, or is the wireloose?



Solution

Check the wiring and wiringconnections between the ther-mocouple and controller. Referto the wiring diagrams thatcame with your unit.

Verify that the Input SensorType in the controller’s Inputmenu is set to Ca for a Type KThermocouple. Verify otherinput settings against theDEFAULT PARAMETERS table in theAppendix.

Check thethermocouple andreplace if necessary. SeeChecking and ReplacingThermocouple.




Err.H

Err.L

CONTROLLERALARMS


Alarm

LoopBreak

The input is notchanging or respond-ing properly to theoutput action. Thiscan be caused by athermocouple, input,heater or load fail-ure.


Possible causeIs the thermocouple wiredcorrectly, or is the wireloose?



Did a heater element fail?

Did a heater contactorfail?

Solution




With the unit powered down:Check for loose connections.Check resistance between thephase legs on the output sideof the heater contactor.Readings should be within0.25 ohms of each other.Replace the heater, if neces-sary. See Replacing HeaterElements.

With power on and theHeater LED lit: Check theamp draw on each of the threephase legs to the heater. Allshould match the FLA listedfor the heater on the unitnameplate. Replace the heatercontactor if there is a voltageimbalance greater than 10%.See Replacing the HeaterContactor.

LPbr


◆ The controller displays a red alarm LED and/or an error codeindicating the cause of the problem.

CONTROLLERALARMS


Alarm

ChecksumError

RAMError

DefaultsLoaded

EEPROMWriteFailure

InvalidInterrupt

“36” will be followedby a 2-digit code.

Possible causeElectrical noise or amicroprocessor problemcaused a failure duringpower up or operation.

Electrical noise or amicroprocessor problemcaused a failure duringpower up or operation.



Power fail resume featuredisabled.

Electrical noise, CPU fail-ure or software bug causedan internal software error.

Solution

Press any key to perform a softreset and reinitialize the con-troller. If the error persists,contact Conair service.




No further resume actionsavailable.


0100

The Thermolator has detected a non-recoverable error involvingthe microprocessor control.

◆ The controller displays an error code indicating the cause of theproblem.

0101

0202

0303

38CS

36_ _

MECHANICAL /ELECTRICALPROBLEMS


Alarm

Low WaterPressure

The cooling waterpressure is less than25 psi.

PumpOverload

The pump motoroverload has tripped.The contact is open.

Possible causeIs the water supply pressure at least 25 psi?

Did the pressure switchfail?

Did the cooling valve fail?

Is the correct voltagesupplied to the pumpmotor?

Is the required water flowgreater than the pump’scapacity?

Is the motor overloadfaulty or set incorrectly?

Is the pump workingproperly?

Solution

Verify that the water supply ison and delivering water at apressure of at least 25 psi.Check for closed valve or faultypump in the supply circuit.

Watch optional gauges whileturning cooling water on andoff. If pressure vents automati-cally, check the cooling valve.

Check the cooling valve. SeeRepairing Solenoid Valves orthe Motorized Cooling Valveinstructions.

Supply voltage should matchthe rating on the pump nameplate. If voltage is correct,check wiring connections.

❒ Review pump sizing for the application.

❒ Decrease the water flow tothe process.

Disconnect the power and openthe electrical enclosure. Verifythat the overload is set to trip atthe proper amperage, whichshould not exceed the FLA.Manually trip and reset theoverload. If the problem contin-ues, replace the overload. SeeResetting and ReplacingOverloads.

Replace the pump if supplyvoltage, wiring and overloadsettings are correct, but thepump continues to draw exces-sive current.


◆ The Fault button illuminates and the audible alarm activates.

NOTE: These alarm indicators are present only if the optionalalarm package is installed.

Fault

Fault


Alarm

HighTemperatureSafety

The actual tempera-ture of water supplied to theprocess exceeds the260° F limit of theoptional electro-mechanical safetyswitch.

WARNING:Only qualified electri-cal service personnelshould examine andcorrect problems thatrequire opening theunit's electricalenclosure or checkingelectrical current todiagnose the cause ofa problem.

If the SPI option isinstalled, failure willbe indicated only bya lack of activity inthe F1 and F2 LEDlights on the tempera-ture controller whenthe unit should becommunicating withthe host machine.

Possible causeHas water stopped flow-ing through the unit orbetween the supply outletand return inlet?

Is the optional electro-mechanical safety switchimproperly set or defective?

Has the heater contactorfailed?

Is the unit connected tothe host machine?

Are the network addressand baud rate correct?

Is something wrong withthe communicationscable?

Solution

❒ Verify that the unit is run-ning and that the pump isworking properly. Check forcorrect pump rotation.

❒ Check for closed or defec-tive cooling or vent valvesand plugged lines. SeeRepairing Solenoid Valves.

Check the switch setting. Themaximum setpoint should be260° F. A setting that is toolow will cause nuisance trips.Check the switch and replaceif defective.

Replace the contactor if defective. See Replacing the Heater Contactor.

Verify that the Thermolator isconnected properly to the hostmachine.

Verify the address and baudrate. The address assigned tothe unit must not be used byany other machine on the net-work. The baud rate mustmatch the host machine. SeeSetting SPI Communication.

Check the communicationcable condition. The cablemust conform to SPI stan-dards. Check for loose cableconnections.

Fault


◆ The Fault button illuminates and the audible alarm activates.

NOTE: These alarm indicators are present only if the optionalalarm package or optional devices are installed.

MECHANICAL /ELECTRICALPROBLEMS

SPI CommunicationFailure


UNIT WILL NOTPOWER UP

If you press the CONTROL POWER button and the control paneldoes not light, you have a problem with the main power circuit orthe unit’s temperature controller.

WARNING: Electrical Shock HazardDisconnect and lockout the main power supplybefore proceeding.

Symptom

Applying powerand pressing thePower button onthe control paneldoes not turn onthe Thermolator orlight the controlpanel.

The Power buttonon the control panelis illuminated, butthe temperaturecontroller does notoperate.

Possible causeIs power reaching theThermolator?

Is the correct voltagereaching theThermolator?

Is power reaching thetemperature controller?

The temperature con-troller has failed.

Solution

❒ Verify that the main powersupply and any customer-installed electrical discon-nect or emergency stopdevices are in the ON posi-tion.

❒ Verify correct electrical con-nections between the unitand the control, andbetween the unit and thepower supply. Replace anydamaged wires or cables.

Check the electrical require-ments on the unit nameplate.Verify correct main supplyvoltage to the unit and the sec-ondary voltage supply from thetransformer to unit compo-nents. Replace the transformer,if necessary.

❒ Verify that the 16C con-troller chassis is seatedsecurely in its case housing.See Replacing theTemperature Controller.

❒ Verify correct electrical con-nections between the tem-perature controller and con-trol panel power supply.Refer to the wiring dia-grams that came with yourunit.

See Replacing the TemperatureController.


Disconnect and lockout the main power.

Open the electrical enclosure door. Turn the screwon the front panel counterclockwise to open.

Locate the pump overload module attached to the pump motor starter.

Disconnect the three power leads from the over-load module to the pump motor. Note the placement ofeach lead and label as needed.

Disconnect auxiliary wiring onthe overload module.

Remove the overload module.Loosen the three screws that connectthe overload module to the motor contactor. Pull the overload moduledown to release it from the starter.

Reverse these steps to installthe new overload module.

Set the module reset mode to M for manual.

Set the proper FLA trip point. Donot exceed the FLA for the pump motor.

RESETTINGOVERLOADS

8

9

The pump motor overload is located inside the unit’s electri-cal enclosure.


Open the electrical enclosure door. Turn thescrew on the front panel counterclockwise to open.

Check the overload.If the yellow button is out, theoverload has tripped. Press theblue button to reset the overload.Verify that the overload trip pointdoes not exceed the FLA for thepump.

1

2

3

Motor contactor

Motor overload

REPLACING THEPUMP OVERLOAD

1

2

3

4

5

6

7

REPLACING THETEMPERATURECONTROLLER


The temperature controller used in the Thermolator TW slidesin and out of its casing for easy replacement.

Disconnect and lockout the main power supply.

Press the grips on each side of the front panelbezel until the tabs release.

Pull the controller chassis out of its casing.

To reinstall or replace the controller:

Press the grips on each side of the bezel.

Carefully push the controller back into the casinguntil the tabs snap into place.

Program the new controller.Use the DEFAULT PARAMETER settings found in the Appendix.For additional information on all the parameters, see theSERIES 16C INSTRUCTION MANUAL in the Appendix.

IMPORTANT: Alwaysrefer to the wiring dia-grams that came withyour Thermolator to locatespecific electrical compo-nents. Illustrations in theUser Guide are intendedto be representative only.

1

2

3

4

5

6

Bezel Case Clip

Control PanelGasket

Grips

Controllerchassis


Thermolators use mercury displacement heater contactors.The heater contactors should be replaced if:● You have checked the amp draw on each of the three-phase

legs and discovered a voltage imbalance greater than 10%.● You have checked the continuity and found that resistance

at the coil equals zero ohms.

To replace the heater contactor:


Open the electrical enclosure door. Turn thescrew on the front panel counterclockwise to open.

Disconnect wires from the heater contactor.Make sure you label the wires to ensure you can connectthem correctly to the new contactor.

Remove the contactorby removing the screws thathold it in place.

Discard the old contac-tor using the properdisposal procedure. SeeMaterial Safety Data Sheet#7439-97 in the APPENDIX.

Reverse this procedureto install the new con-tactor. Make sure the wiresare connected correctly.

1

2

3

4

5

WARNING: Hazardous SubstanceThermolators use mercury displacement contac-tors. Mercury is considered a hazardous substanceand must be dealt with accordingly. See MaterialSafety Data Sheet #7439-97-6 for information onthe how to avoid the potential hazards and how toclean up and dispose of mercury if it spills.

IMPORTANT: Alwaysrefer to the wiring dia-grams that came withyour Thermolator tolocate specific electricalcomponents. Illustrationsin the User Guide areintended to be represen-tative only.

WARNING: Electrical Shock HazardOnly qualified service personnel who have been

trained on electrical testing and the procedures foravoiding the hazards should diagnose or correct prob-lems that require opening the unit with power on.

6

REPLACING THEHEATERCONTACTOR

Heater contactor

The Thermolator uses a type ‘K’ thermocouple to monitor thesupply process temperature. The thermocouple is installed inthe wall of the heater tank at the “to process” outlet.

Sensor error codes (Err.H, Err.L or LPbr) displayed by thetemperature controller may indicate thermocouple failure.

To check a thermocouple after a sensor error:


Open the electrical enclosure door. Turn the screwon the front panel counterclockwise to open.

Remove thermocouple wiring from thecontroller and install a jumper on the leads.Refer to the wiring diagrams that came with your unit.Perform a continuity test on the thermocouple. If youdetect an open circuit, replace the thermocouple.

Close the electrical enclosure and restorepower to the unit.

Restart the Thermolator.◆ If error message disappears, replace the thermocouple.◆ If error message does not disappear, the controller may

need to be replaced. Verify the input parameters in thecontroller, and verify the thermocouple wiring. If wiringand parameters are correct, replace the controller.

CHECKING THETHERMOCOUPLE


1

2

3

4

WARNING: Electrical Shock HazardOnly qualified service personnel who have been

trained on electrical testing and the procedures foravoiding the hazards should diagnose or correct prob-lems that require opening the unit with power on.

Temperature (˚F)0 1000 2000 3000 4000 6000

80

70

60

50

40

30

20

10

ANSI SymbolB*C**EJKR*S*T

Mill

ivo

lts

E

J

T

KN

C**

R*S*

B*

Thermocouple Millivolts*/ Temperature Curves

5

To replace a thermocouple:


Shut off the cooling water infeed and drain theunit. Drain all water using the drain plugs located thebottom of the unit.

Remove the unit’s top paneland open the electrical enclo-sure.

Remove the thermocouple.Loosen the compression nut to slidethe thermocouple out of the casing.Disconnect the thermocouple wires atthe controller.

Install the new thermocouple.Insert the tip of the new thermocoupleat least 1 inch into the tank. tightenthe compression nut. Thread the leadsthrough the raceway leading to theelectrical enclosure. Attach the ther-mocouple leads to the controller.

REPLACING THETHERMOCOUPLE


1

2

3

4

5 Thermocouple

Nut

WARNING: Hot surfacesAllow the Thermolator to cool to below 100° F (38° C) before servicing the unit.

IMPORTANT: Always refer to the wiring diagramsthat came with your Thermolator to locate specificelectrical components. Illustrations in the UserGuide are intended to be representative only.


Every Thermolator has a solenoid valve assembly that controlsthe cooling water out flow. Solenoid valves also are found onthe optional purge valve.

Shut off the cooling water infeed.

Drain the unit of all waterthrough the drain plug in the rearof the unit.

Remove the cooling waterout feed.

Disconnect and lockout main power.

Remove the solenoid valvefrom the cooling water outline.

Disassemble the solenoid valve.(See exploded views on next page.)

Inspect and clean or repair the valve bodyassembly. Remove foreign particles and replace dam-aged parts as necessary.

Reassemble the valve and other components.Reassemble in reverse order. Seal all pipe fittingswith pipe sealant. Check that all flows are in the correctdirection. Check for leaks before resuming operation.

REPAIRINGSOLENOIDVALVES

Drain plug

Cooling water in

1

2

3

4

5

WARNING: Electrical shock and hot surface hazardsBefore attempting maintenance of any kind on the Thermolator, you must stop the unit;disconnect and lockout the main power supply;and allow the unit to cool to 100° F (38° C)

Cooling water out

6

7

8


REPAIRINGSOLENOIDVALVESNameplate

Cover*

Yoke*

Housing*7/8" Dia. Hole

for 1/2" Conduit

Solenoid Base Sub-Assembly

0.9375-26 UNS-2A Thread

Core (AC) Tapped Hole in Core 0.250-28 UNF-2B

0.38 Minimum Full Thread

orRetaining Clip*

Retaining Cap*

Sleeve*Grounding Wire (Not present on all constructions)

Insulating Washer

Sleeve*

SpringWasher*

Housing*with Nameplate*

*Indicates Parts Supplied in Solenoid Enclosure Kit

Alternate Construction withNameplate on Housing

Coil

Insulating Washer

*Indicates Parts Supplied in Solenoid Enclosure Kit Cover*

Yoke*

7/8" Dia. Hole for 1/2" Conduit

Solenoid Base Sub-Assembly

0.9375-26 UNS-2A Thread

Core (AC) Tapped Hole in Core 0.250-28 UNF-2B

0.38 Minimum Full Thread

or Retaining Clip*

Sleeve*

Grounding Wire (Not present on all constructions)

Sleeve*Coil



Remove the top panel of the Thermolator.

Remove the heater cap.Use a 1/4-inch open-endwrench to remove the threebolts that hold the cap to theheater tank.

Remove the heaterwiring harness. Label the wiring layout of theheater terminals; wires arelabeled 2T1, 2T2, 2T3 andGND.

The wiring layout usulaly will be one of the following:

Then unscrew the locking screws on the wiring harnessand remove the wires.

Shut off the cooling water infeed.

Drain the Thermolator using the drain plugslocated at the rear of the unit.

Remove the four bolts that hold the heater ele-ment in place. Use a 15/16-inch socket with 1/2-inchdrive.

1

23

4

5

6


REPLACINGHEATERELEMENTS

IMPORTANT: Alwaysrefer to the wiring dia-grams that came withyour Thermolator tolocate specific electricalcomponents. Illustrationsin the User Guide areintended to be represen-tative only.

Heatercap

7


Lift the heating element out of the heater tube.Lift the element straight up.

Clean the heater casting.Remove any rust or solids that may have built up beforeinserting the heater elements.

Replace the heater gasket if it is worn or cracked.Use a high temperature Teflon paste to ensure a good seal.

Reverse these steps to install the new heaterelement and reassemble the unit.

REPLACINGHEATERELEMENTS

Heater cap

Heater element

Heater gasket

8

9

10

11



Shut off the cooling waterin feed.

Drain the unit of all fluid.Remove the drain plug at the rearof the unit.

Remove the top and sidepanels of the Thermolator.

Remove the seal flush line.Use a 1/2-inch open-end wrench to remove the vent line fromthe connection on the pumpadapter.

Remove the pumpassembly bolts. Use a9/16-inch open-end boxwrench to remove the boltsholding the pump to thevolute case. The bolt in therear will require a 9/16-inchcrows foot wrench.

Lift the pump assemblystraight up to remove.The pump can now be replacedor disassembled for repair.

Reverse the steps toreassemble the unit.

NOTE: Before restarting, close all drain openings usingsealant on the threads and reprime the pump. Do not startuntil the pump is completely filled with water.

REMOVINGTHE PUMP

1

2

3

4

5

6

7

8

Drain plug

Cooling water in


Pump seal flush line

Pumpassembly

bolts


To replace a failed seal, you must disassemble the pump.

Remove the impeller nut. Insert a screwdriver in oneof the impeller waterway passages and back off theimpeller nut.

Remove the impeller. Insert a screwdriver in the slotof the motor shaft. Unscrew the impeller while holding theshaft against the rotation.

Remove the seal, gasket case, adapter andflinger. See the exploded view for detail.

Clean the gasket and flange faces, seal seat cav-ity and shaft. The shaft shoulder that fits against theimpeller must be clean.

Replace the flinger. Lubricate the seal seat cavity ofthe adapter and the flinger with soapy water solutionbefore pressing the flinger squarely into the cavity. Do notchip or scratch the lapped seat face.

Remount the adapter to the motor. Make sure themotor shaft does not dislocate or chip the seat of the seal.

Replace the remaining seal components. Apply asoapy water solution to the motor shaft and the rubber bel-lows of the rotating seal. Be sure the rotating seal facestays in the holding collar during installation. Do not chipor scratch the lapped seat faces.

Reassemble the remaining components, holdingthe shaft against rotation as previously described. Removeany burrs caused by the screwdriver on the impeller.

Reattach the pump to the volute case. Make sureyou replace any damaged gasket or O-ring between thepump assembly and volute case. Check for free rotationafter assembly is completed.

DISASSEMBLINGAND ASSEMBLING3/4 - 2 HP PUMPS

Pump motor

Flinger*Pump adapter

Gasket, case*

Seal*

Impeller

D washer*

Impeller nut*

*Indicates Parts Supplied in the Seal Repair Kit

1

2

3

4

NOTE: Before restarting,close all drain openings usingsealant on the threads andrefill the unit with fluid. Do notstart the the pump when theunit is dry.

5

6

7

8

9


To replace a failed seal, you must disassemble the pump.

Remove the impeller retaining assembly. Insert ascrewdriver in one of the impeller waterway passages tohold the impeller steady while removing the retainer.

Remove the impeller. Be careful not to lose the key,spring and seal retainer. If the impeller is difficult toremove, you may need to use a bearing puller.

Remove the seal, adapter, shaft sleeve andflinger. See the exploded view for detail.

Clean the gasket and flange faces, seal seat cav-ity, shaft sleeve and motor shaft. Replace the shaftsleeve if it is damaged or worn.

Replace the flinger. Lubricate the seal seat cavity ofthe adapter and the flinger with soapy water solutionbefore pressing the flinger squarely into the cavity. Do notchip or scratch the lapped seat face.

Remount the adapter to the motor. Make sure themotor shaft does not dislocate or chip the seat of the seal.

Replace the remaining seal components. Apply asoapy water solution to the motor shaft and the rubber bel-lows of the rotating seal. Slide the rotating member of theseal over the shaft sleeve. Replace the seal spring and sealretainer, making sure the rotating seal face stays in theholding collar during installation. Do not chip or scratchthe lapped seat faces.

Place the key in the key seat and slide theimpeller on the shaft. Replace the impeller retainingnut. Remove any burrs caused by the screwdriver on theimpeller.

1

2

3

Pump motor

Flinger*

Pump adapter

Gasket, case*

Seal*

Impeller

O-ring, shaft*

Impellerretainer*

*Indicates Parts Supplied in Repair Kit

Shaft* sleeve

Sealretainer*

Key*

Wear ring

DISASSEMBLINGAND ASSEMBLING3 - 7.5 HP PUMPS

4

5

6

7

8


Reattach the pump tothe volute case. Makesure you replace any dam-aged gasket or O-ringbetween the pump assemblyand volute case. Check forfree rotation after assembly iscompleted.

NOTE: Before restarting, close all drain openings usingsealant on the threads and and refill the unit with fluid.Do not start the the pump when the unit is dry.

DISASSEMBLINGAND ASSEMBLING3 - 7.5 HP PUMPS

9

IMS0002/0296 SERVICE INFORMATION APPENDIX A-1

Conair has made the largest investment in customer support inthe plastics industry. Our service experts are available to helpwith any problem you might have installing and operatingyour equipment. Your Conair sales representative also can helpanalyze the nature of your problem, assuring that it did notresult from misapplication or improper use.

To contact Customer Service personnel, call:

From outside the United States, call: 814-437-6861

You can commission Conair service personnel to provide on-site service by contacting the Customer Service Department.Standard rates include an on-site hourly rate, with a one-dayminimum plus expenses.

If you do have a problem, please complete thefollowing checklist before calling Conair:

❒ Make sure you have all model, serial and parts listnumbers for your particular equipment. Servicepersonnel will need this information to assist you.

❒ Make sure power is supplied to the equipment.

❒ Make sure that all connectors and wires withinand between control systems and related components have been installed correctly.

❒ Check the troubleshooting guide of this manualfor a solution.

❒ Thoroughly examine the instruction manual(s)for associated equipment, especially controls.Each manual may have its own troubleshootingguide to help you.

❒ Check that the equipment has been operated asdescribed in this manual.

❒ Check accompanying schematic drawings for information on special considerations.

BEFORE YOU

CALL ...

HOW TO CONTACT

CUSTOMER

SERVICE

Additional manuals andprints for your Conairequipment may beordered through theCustomer Service orParts Departments for anominal fee.

WE’RE HERETO HELP

APPENDIX A-2 WARRANTY INFORMATION IMS0003/0796

EQUIPMENTGUARANTEE

PERFORMANCEWARRANTY

WARRANTYLIMITATIONS

Conair guarantees the machinery and equipment on this order,for a period as defined in the quotation from date of shipment,against defects in material and workmanship under the normaluse and service for which it was recommended (except forparts that are typically replaced after normal usage, such asfilters, liner plates, etc.). Conair’s guarantee is limited toreplacing, at our option, the part or parts determined by us tobe defective after examination. The customer assumes the costof transportation of the part or parts to and from the factory.

Conair warrants that this equipment will perform at or abovethe ratings stated in specific quotations covering the equip-ment or as detailed in engineering specifications, provided theequipment is applied, installed, operated and maintained in therecommended manner as outlined in our quotation or specifi-cations.

Should performance not meet warranted levels, Conair at itsdiscretion will exercise one of the following options:

● Inspect the equipment and perform alterations or adjust-ments to satisfy performance claims. (Charges for suchinspections and corrections will be waived unless failureto meet warranty is due to misapplication, improperinstallation, poor maintenance practices or improper oper-ation.)

● Replace the original equipment with other Conair equip-ment that will meet original performance claims at noextra cost to the customer.

● Refund the invoiced cost to the customer. Credit is sub-ject to prior notice by the customer at which time aReturn Goods Authorization Number (RGA) will beissued by Conair’s Service Department. Returned equip-ment must be well crated and in proper operating condi-tion, including all parts. Returns must be prepaid.

Purchaser must notify Conair in writing of any claim and pro-vide a customer receipt and other evidence that a claim isbeing made.

Except for the Equipment Guarantee and PerformanceWarranty stated above, Conair disclaims all other warrantieswith respect to the equipment, express or implied, arisingby operation of law, course of dealing, usage of trade or oth-erwise, including but not limited to the implied warranties ofmerchantability and fitness for a particular purpose.

UGH014/0100 DEFAULT PARAMATERS APPENDIX B-1

DEFAULTPARAMETERS

Menu Parameter Description Setting UnitsInP TyPE Input sensor type Ca (type K)

Bias Bias 0SP.LL Lower setpoint limit 35 °FSP.HL Upper setpoint limit 250 °FI.FIL Filtering 1.0 Seconds

DSPL Dec.p Decimal position 0d.FIL Display filter 0.1 SecondsUnit Temperature units F FahrenheitBLAn Blanking OFF

OutP O1.tY Output 1 type PIdO1.Ac Output 1 action rE Reverse actingO1.cY Output 1 cycle type 5O1.LL Output 1 low power limit 0%O1.HL Output 1 high power limit 100%O2.tY Output 2 type PIdO2.Ac Output 2 action Dir Direct actingO2.cY Output 2 cycle type 10 SecondsO2.LL Output 2 low power limit 0%O2.HL Output 2 high power limit 100%

CnrL Pb1 Proportional band 1 5Pb2 Proportional band 2 5DEr Derivative action - rate 4OFFS Manual reset OFFInt Integral action 21

aLr a1.aa Alarm 1 alarm action nor Normala1.ao Alarm 1 alarm operation Pro.H Process high tempa1.dL Alarm 1 delay 0 Secondsa1.IH Alarm 1 inhibit 15 Secondsa1.SP Alarm 1 setpoint 260 °Fa2.aa Alarm 2 alarm action nor Normala2.ao Alarm 2 alarm operation nor.b High/low deviationa2.dL Alarm 2 delay 0 Secondsa2.IH Alarm 2 inhibit 15 Secondsa2.SP Alarm 2 setpoint 10 °F

TunE dPnG Damping for autotuning nL Normalr-s r.Pot Ramp to setpoint menu dIS Disabled

The Thermolator will not operate correctly if certain factory-setparameters are changed. Parameters should be changed only byqualified technical personnel who are familiar with the operation ofthis type of equipment.

If the Thermolator does not appear to be working correctly, verifythe parameters against the list of factory settings.

For more detailed information about these parameters and return-ing parameters to the initial factory setup, See the SERIES 16CINSTRUCTION MANUAL included with this instruction package.

UGH014/0100 TECHNICAL INFORMATION APPENDIX C-1

HeaterThermocouple

Purge Valve(optional)

To Process

From Process

Cooling Water In

Cooling Water Out

CoolingValve

ReliefValve

MixingTank

Pump

TW Direct InjectionCheck valves included only with

optional mold purge.

CheckValve

CheckValve

ReturnPressureGauge(optional)Supply

PressureGauge(optional)

PLUMBINGDIAGRAM

PUMPCURVES

TECHNICAL INFORMATION UGH014/0100APPENDIX C-2

MTR

SP

SI

FEE

T

Gallo

ns/M

inu

te

Liters/M

inu

te

5578

180

4969

160

4361

140

3752

120

3043

100

2435

80

1826

40

1217

30

69

20

001038

207630114

40152

50190

60228

70266

80304

90342

100380

110418

120456

5 HP

2 HP

3/4 HP

1 HP

3 HP

7.5 HP

60 Hz

Material Safety Data SheetAn explanation of the terms used in this document may be found in OSHA 29 CFR 1910.1200,which is available from OSHA regional or area offices.

1. Chemical IdentificationSubstance: Mercury CAS-Number: 7439-97-6Chemical name: Mercury Synonyms: Quicksilver; Liquid silverFormula: HG Molecular weight: 200.59Trade name: Not applicable Chemical family: MetalSupplier of MSDS information:The Conair Group Inc.One Conair DrivePittsburgh, PA 15202412-312-6000

Emergency contact:For CHEMTREC assistance call800-424-9300 (in the U.S.)703-527-3887 (international)

2. Composition and Exposure LimitsMaterial Weight (%) Exposure LimitsMercury 100 0.05 mg/m3 Threshold Limit Value(skin)/TWA

0.1 mg/m3 Permissible Exposure Limit (PEL)3. Hazards IdentificationHazard Ratings (0 = no hazard; 4 = extreme hazard):Health - 4 Extreme (Poison) Carcinogenic: NTP – NoFlammability - 0 None IARC – NoReactivity - 1 Slight Z List – NoContact - 3 Severe (Life) OSHA Reg – NoPersonal Health Effects:

WARNING Mercury is a dangerous poison and an extreme contacthazard. Mercury may be absorbed by the skin or throughthe eyes. It may be fatal if swallowed or inhaled. It emitstoxic vapors, especially when heated. Do not get mercuryin your eyes, on your skin or on your clothing. Do notbreathe mercury dust. Keep mercury in a tightly closedcontainer. Use with adequate ventilation. Washthoroughly after handling.

Effects of overexposure Mercury causes skin, digestive tract and severerespiratory tract irritation. It may affect the centralnervous system and cause severe eye irritation.Inhalation of vapors may cause coughing, chest pains,nausea and vomiting.Chronic effects of overexposure may include kidneyand/or liver damage, and central nervous systemdepression. Chronic effects of mercury poisoning includea buildup of the metal in the brain, liver and kidneys.Symptoms include headache, tremors, loose teeth, lossof appetite, blisters on the skin and impaired memory.This substance has caused adverse reproductive andfetal effects in animals.

Target organs Eyes, skin, respiratory system, central nervous system,kidneys and liver.

Routes of entry Inhalation, absorption, eye contact, skin contact.4. Emergency and First Aid MeasuresCall a physician immediately.

If swallowed: Immediately induce vomiting, if person is conscious.If inhaled: Immediately remove exposed person to fresh air. If the person

is not breathing, give artificial respiration. If breathing isdifficult, give oxygen.

In case of contact: Immediately flush eyes or skin with plenty of water for at least15 minutes, while removing contaminated clothing and shoes.Wash clothing before using again.

MSDS:7439-97-6MERCURY

Appendix D-1

5. Fire and Explosion DataFire and explosion

hazards:Mercury presents a slight fire and explosion hazard whenexposed to heat or flame. Mercury vapors are heavierthan air and may travel a considerable distance to asource of ignition and flash back.

Firefighting media: Dry chemical, carbon dioxide, water spray or foam.For larger fires, use water spray, fog or alcohol foam.(1984 Emergency Response Guidebook, DOT P 5800.3).

Firefightingprocedures:

Use agents suitable for type of fire. Use water in floodingamounts as a fog. Avoid breathing corrosive andpoisonous vapors. Keep upwind. Move containers fromthe fire area if possible. Cool containers exposed toflames with water from side until well after fire is out.(1984 Emergency Response Guidebook, DOT P 5800.3).

6. Spill and Disposal ProceduresEPA Hazardous Waste Number: U151 (Toxic Waste)If spilled or discharged: Wear self-contained breathing apparatus and full

protective clothing. Clean up the spill immediately.Collect and store using a suction pump with a capillarytube. Calcium polysulfide with excess sulfur should besprinkled into cracks or inaccessible sites. Keep collectedmercury in a tightly closed bottle for recovery or disposal.

Disposal procedure: Dispose in accordance with all applicable federal, state,and local environmental regulations.

7. Storage and Handling PrecautionsMercury should be stored in a secure poison area inside a tightly closed container.

8. Exposure Control and Protective EquipmentVentilation: Use general or local exhaust ventilation to meet TLV

requirements.Respiratory protection: None required where appropriate ventilation conditions

exist. If the TLV is exceeded, a self-breathing apparatusis advised.

Eye/skin protection: Safety goggles and face shield, uniform, protective suitand rubber gloves are recommended.

9. Physical and Chemical PropertiesAppearance and odor: Silver-white, heavy, mobile liquid metal; odorlessBoiling point: 675° F (357° C) Melting point: -38° F (-39° C)Specific gravity: 13.5 Vapor pressure: 0.002 mm HGVapor density: 1.01 Solubility in H20: negligible, less than 0.1%Solubility in solvents: Sulfuric acid, nitric acid, lipids10. Stability and Reactivity DataStability: Stable Hazardous polymerization: Will not occur

Conditions to avoid: HeatIncompatibles: Strong acids

IMPORTANT: Users of this equipment should study this MSDS carefully tobecome aware of and understand the hazards associated with the product. Ifnecessary or appropriate, the reader should consider consulting reference works orindividuals who are experts in ventilation, toxicology and fire prevention to use andunderstand the data in this MSDS. To promote safe handling, the reader shouldfurnish this information to anyone whom he or she knows or believes will use thisequipment.

MSDS:7439-97-6MERCURY

Appendix D-2

PD-1UGH014/0100 Thermolator TW Model

● Parts lists . . . . . . . . . . . . . . . .PD-2● Wiring diagram . . . . . . . . . . . .PD-5

PARTS & DIAGRAMS

RECOMMENDED SPARE PARTS UGH014/0100APPENDIX PD-2

MANUALSPart No. DescriptionUGH014/0100 User Guide, Thermolator TWQCH013/0200 Quick Card, Thermolator TW

TEMPERATURE CONTROLLER / OPERATOR INTERFACEPart No. Description

20975301 Controller with standard alarms20975302 Controller with SPI communication option202017045407 Switch, amber, illuminated (control power; purge option)09003372 Switch, red, non-illuminated (stop)09003371 Switch, red, illuminated (fault option)09003370 Switch, green, illuminated (start)

ELECTRICAL / ELECTROMECHANICAL COMPONENTSPart No. Description11001213 Thermolator transformer09003621 Timer09003622 Timer base09003443 Relay09003444 Relay base11000400 Thermocouple, type K, standard temp unit, 6 feet11000050 Water pressure switch09001221 Process pressure gauge09000328 Pressure relief valve, 150 PSI09002108 High temperature control, mechanical, option

HEATER CONTACTORSPart No. Description20004401 Heater contactor for 9kW 208/230/460V20004401 Heater contactor for 12kW 230/460V20004501 Heater contactor for 12kW 208V

PUMP OVERLOADSPart No. Description20003908 Pump overload for: ¾ HP 460V20003909 Pump overload for: 1 HP 460V20003910 Pump overload for: ¾ HP 230V and 2 HP 460V20003911 Pump overload for: ¾ HP 208V and 1 HP 208/230V20003912 Pump overload for: 3 HP 460V20003913 Pump overload for: 2 HP 208/230V and 5 HP 460V20003914 Pump overload for: 3 HP 208/230V and 7½ HP 460V09000346 Pump overload for: 5 HP 208/230V09000347 Pump overload for: 7½ HP 208/230V

PUMP STARTERSPart No. Description20003801 Pump starter for: ¾ HP 208/230/460V 20003801 Pump starter for: 3 HP and 5 HP 460V20003802 Pump starter for: 3 HP 208/230/460V20003802 Pump starter for: 7½ HP 460V20003803 Pump starter for: 5 HP 208/230V20003804 Pump starter for: 7½ HP 230V11002015 Pump starter for: 7½ HP 208V

RECOMMENDEDSPARE PARTS

TW Thermolators208-230/460V 9kW & 12kW units, ¾ HP through 7½ HP

UGH014/0100 RECOMMENDED SPARE PARTS APPENDIX PD-3


TW Thermolators208-230/460V, 9kW & 12kW units, ¾ HP through 7½ HP

PUMP ASSEMBLIESSilicon carbide seal, open drip proof type motorPart No. Description09000958 ¾ HP pump model 12CS (with stainless steel impeller)09000959 1 HP pump model 12CS (with stainless steel impeller)09000960 2 HP pump model 12CS (with stainless steel impeller)09000961 3 HP pump model 50CS (with cast iron impeller)09000962 5 HP pump model 50CS (with cast iron impeller)09000963 7½ HP pump model 50CS (with cast iron impeller)

PUMP SEAL OVERHAUL KITSPart No. Description09000358 ¾ HP through 2 HP silicon carbide seal - 12CS09000359 3 HP through 7½ HP silicon carbide seal - 50CS

REPLACEMENT IMPELLERSPart No. Description09001417 ¾ HP for 12CS model (stainless steel)09001418 1 HP for 12CS model (stainless steel)09001414 2 HP for 12C models (stainless steel)09003313 3 HP for 50C model (cast iron)09003314 5 HP for 50C model (cast iron)09003315 7½ HP for 50C model (cast iron)

PUMP PARTSPart No. DescriptionF92100319 motor pump adapter, ¾ HP through 2 HP09001466 volute, ¾ HP through 2 HP09003316 motor pump adapter, 3 HP through 7½ HP09003107 volute, 3 HP through 7½ HP

PUMPMOTORSPart No. Description09001403 ¾ HP 208/230/460V/3/60 ODP (Open Drip Proof)09000378 1 HP 208/230/460V/3/60 ODP (Open Drip Proof)09000381 2 HP 208/230/460V/3/60 ODP (Open Drip Proof)09000384 3 HP 208/230/460V/3/60 ODP (Open Drip Proof)09000387 5 HP 208/230/460V/3/60 ODP (Open Drip Proof)09000390 7 ½ HP 208/230/460V/3/60 ODP (Open Drip Proof)

REPLACEMENT HEATERSPart No. Description11009001 9 KW 208V/3/60 mild steel

SET AS PARALLEL DELTA11009000 9 KW 230/460V/3/60, mild steel11009002 12 KW 208V/3/60, mild steel11009001 12 KW 230/460V/3/60, mild steel09002814 Heater tube casting09009957 Heater flange gasket

MISCELLANEOUSPart No. Description09040000 Caster

RECOMMENDED SPARE PARTS UGH014/0100APPENDIX PD-4


TW Thermolators208-230/460V, 9kW & 12kW units, ¾ HP through 7½ HP

COOLING SOLENOID OVERHAUL KITSPart No. Description09004552 ¼ inch solenoid overhaul kit, 0.72 CV09000361 3/8 inch solenoid overhaul kit, 1.5 CV09004614 ½ inch solenoid overhaul kit, 4.0 CV09004554 ¾ inch solenoid overhaul kit, 5.0 CV

COOLING SOLENOID VALVESPart No. Description09001551 ¼ inch solenoid valve, 0.72 CV09000457 3/8 inch solenoid valve, 1.5 CV09002969 ½ inch solenoid valve, 4.0 CV09004510V ¾ inch solenoid valve, 5.0 CV

MODULATING VALVES OPTIONPart No. Description09002890 ½ inch modulating valve, 1.3 CV09002931 ¾ inch modulating valve, 5.0 CV09003058 1 inch modulating valve, 11.0 CV09002892 Modulating valve actuator09002891 Modulating valve linkage

MODULATING VALVE OVERHAUL KITS for #VB7223 VALVEPart No. Description09004604 ½ inch modulating valve rebuild kits, stem and packing09004605 ¾ inch modulating valve rebuild kits, stem and packing09004606 1 inch modulating valve rebuild kits, stem and packing

PURGE VALVE OPTIONPart No. Description09001551 1/4 inch solenoid valve (2 pieces)19901904 ¾ inch 125 lb. bronze check valve19901906 11/4 inch 125 lb. bronze check valve

ALARM OPTIONSPart No. Description20908903 Alarm, piezo horn09000499 Alarm, strobe light09000500 Alarm, bell, electrical and hammer assembly09000501 Alarm, bell, gong assembly

UGH014/0100 TW WIRING DIAGRAM APPENDIX PD-5

TW WIRING

USERGUIDE UGH014/0100 Thermolator TW Series€¦ · Step-by-step adherence to instructions outlined...

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