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Econo-Cool Chillers
User Manual
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AEC Econo-Cool Chillers User Manual

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Operation and Installation Manual
Economical Series
Water Temperature
Control Units
Important! Read Carefully Before Attempting to Install or Operate Equipment
Write down your unit serial number(s) ________________ ________________ here for future reference ________________ ________________ ________________ ________________ ________________ ________________
AEC is committed
to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual
are subject to change without notice.
© Copyright AEC, Inc. 2006 All rights reserved. Effective 7/27/2006 Part No. 682.91343.00 Revision NEW Bulletin No. AE1-655
Page 2 AEC Water Temperature Control Units
Please note that our address and phone information has changed. Please reference this page for updated contact information.
These manuals are obsolete and are provided only for their technical information, data and capacities. Portions of these manuals detailing procedures or precautions in the operation, inspection, maintenance and repair of the products may be inadequate, inaccurate, and/or incomplete and shouldn’t be relied upon. Please contact the ACS Group for more current information about these manuals and their warnings and precautions.
Parts and Service Department
The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone or fax order, please have the model and serial number of your unit when you contact us. A customer replacement parts list is included in this manual for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service.
For immediate assistance, please contact:
• North, Central and South America, 8am – 5pm CST +1 (800) 483-3919 for drying, conveying, heating and cooling and automation. For size reduction: +1 (800) 229-2919. North America, emergencies after 5pm CST (847) 439-5855
North America email: acsuscanadacustserv@corpemail.com
• Mexico, Central & South America Email: acslatinamericacustserv@corpemail.com
• Europe, Middle East & Africa +48 22 390 9720
Email: acseuropecustserv@corpemail.com
• India +91 21 35329112
Email: acsindiacustserv@corpemail.com
• Asia/Australia +86 512 8717 1919
Email: acsasiacustserv@corpemail.com
Sales and Contracting Department
Our products are sold by a worldwide network of independent sales representatives. Contact our Sales Department for the name of the sales representative nearest you.
Let us install your system. The Contract Department offers any or all of these services: project planning; system packages including drawings; equipment, labor, and construction materials; and union or non-union installations.
For assistance with your sales or system contracting needs please Call:
North, Central and South America +1 (262) 641-8600 or +1 (847) 273-7700 Monday–Friday, 8am–5pm CST
Europe/Middle East/Africa +48 22 390 9720 India +91 21 35329112 Asia/Australia +86 512 8717 1919
Facilities:
ACS offers facilities around the world to service you no matter where you are located. For more information, please visit us at www.acscorporate.com
United States:
ACS Schaumburg – Corporate Offices
1100 E. Woodfield Road Suite 588 Schaumburg, IL 60173 Phone: + 1 847 273 7700 Fax: + 1 847 273 7804
ACS New Berlin – Manufacturing Facility
2900 S. 160th Street New Berlin, WI 53151 Phone : +1 262 641 8600 Fax: + 1 262 641 8653
Asia/Australia:
ACS Suzhou
109 Xingpu Road SIP Suzhou, China 215126 Phone: + 86 8717 1919 Fax: +86 512 8717 1916
Europe/Middle East/Africa:
ACS Warsaw
Ul. Działkowa 115 02-234 Warszawa Phone: + 48 22 390 9720 Fax: +48 22 390 9724
India
ACS India
Gat No. 191/1, Sandbhor Complex Mhalunge, Chakan, Tal Khed, Dist. Pune 410501, India Phone: +91 21 35329112 Fax: + 91 20 40147576
Safety Considerations
Economical Series temperature control units are designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes.
To avoid possible personnel injury or equipment damage when installing, operating, or maintaining this equipment, use good judgment and follow these safe practices:
; Only PROPERLY TRAINED personnel familiar with the
information within this manual should work on this equipment.
; Follow all local SAFETY CODES. ; AEC Economical Series cabinets and piping are hot and are
a BURN HAZARD.
; Do not operate an AEC system without all outer panels
installed. Pressurized hot water leaks can cause serious injury.
; Wear SAFETY GLASSES and WORK GLOVES. ; Use care when LOADING, UNLOADING, RIGGING,
or MOVING this equipment.
; Operate this equipment within design specifications. ; OPEN, TAG, and LOCK ALL DISCONNECTS before
working on equipment. We recommend following OSHA Lock-Out/Tag-Out Standard 29 CFR 1910.147.
; Make sure the unit is properly GROUNDED before
switching power on.
; When welding or brazing in or around this equipment, be
sure VENTILATION is ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with sheet metal. An approved FIRE EXTINGUISHER should be close at hand and ready for use if needed.
; Do not jump or bypass any electrical safety control. ; Do not restore power until all tools, test equipment, etc.
have been removed and the panels replaced.
AEC Water Temperature Control Units Page 3
Table of Contents
1-1 Introduction.....................................................................................7
1-2 Necessary Documents....................................................................8
1-3 Models Covered.............................................................................. 8
1-4 Standard Features .......................................................................... 8
1-5 Available Options............................................................................ 9
2-1 Unpacking and Inspection............................................................. 13
2-2 In the Event of Shipping Damages................................................13
2-3 If the Shipment is Not Complete....................................................14
2-4 If the Shipment is Not Correct....................................................... 14
2-5 Returns ......................................................................................... 14
2-6 Uncrating Your New Economical Series System........................... 15
3-1 Installation Location Considerations.............................................. 17
3-2 Process Approach Temperature Considerations........................... 17
3-3 External Piping Sizing Considerations .......................................... 17
3-4 Piping Considerations for Permanent Installations........................ 18
3-5 Piping Considerations for High Mobility Installations.....................19
3-6 Process Water Considerations......................................................19
3-7 Making Process Water Connections............................................. 20
3-8 Making Cooling Water Connections.............................................. 21
3-9 Making System Purge Connections.............................................. 22
3-10 Making Electrical Connections...................................................... 25
4-1 Identifying Mechanical Controls and Features .............................. 27
4-2 The Microprocessor Controller...................................................... 31
4-3 Controller Display..........................................................................31
4-4 Using Controller Keys ................................................................... 32
4-5 Using Graphic Panel Buttons........................................................ 33
4-6 Alarms........................................................................................... 34
4-7 Controller Factory Setup............................................................... 34
4-8 Controller Internal Switches.......................................................... 35
4-9 Controller Factory Setup............................................................... 35
4-10 Auto-Tuning the Controller............................................................ 35
4-11 Changing from Fahrenheit to Celsius............................................36
4-12 Operating the Unit with the Controller........................................... 36
Page 4 AEC Water Temperature Control Units
5-1 Introduction...................................................................................38
5-2 Startup Checklist........................................................................... 38
5-3 Starting the Temperature Control Unit .......................................... 39
5-4 Operating the Unit with the Controller........................................... 40
5-5 Sequence of Operation................................................................. 41
5-6 Checking Motor Rotation Direction................................................ 42
5-7 Shutting Down the Temperature Control Unit ...............................42
6-1 Preventive Maintenance................................................................ 43
6-2 Corrective Maintenance................................................................ 44
6-3 Restoring the Controller to Factory Setup.....................................46
6-4 Electrical Connections................................................................... 54
6-5 Safety Devices.............................................................................. 55
6-6 Cleaning and Storage ................................................................... 57
AEC Water Temperature Control Units Page 5
Charts and Figures
Typical Economical Series Water Temperature Control Unit
1 2 3 4 5 6 7 8
and Specifications 11
Economical Series Unit Full-Load Amps 11
Typical Piping Schematic 23
Pump Curves; 60 Hz and 50 Hz 24
Pressure Drops 24
Typical E5CK Microprocessor Controller 31
Display Readout for Mode Settings 50
Setting List for Process Temperature Controller 53
9
Pressure Switch; Side View and Top View 58
Page 6 AEC Water Temperature Control Units
1 General Information
1-1 Introduction
AEC water temperature control units are reliable, accurate, and easy-to-use process temperature control units. They are self-contained, portable, and shipped ready to use.
The Economical Series water temperature control unit is designed to circulate water through your process and to precisely, automatically, and reliably maintain it at a specified temperature. Standard unit operating range is from 0ºF (-17ºC) to 250°F (121°C), or up to 300°F (149°C) as an option. The unit is suited for use with city water, water from portable or central chillers or towers, or well water.
These units are designed for rapid recirculation of a relatively small amount of water to provide close and uniform temperature relation between To Process and From Process lines. This performance, of course, depends on the configuration of your process and any restrictions within the mold. The recirculation, combined with the large immersion heater and cooling capability, gives fast and accurate response to bring the water up to temperature or to changes in the settings when needed.
The ECU Series water temperature control unit is a self-contained system consisting of a centrifugal pump, electric immersion heater, cool/vent solenoid valve, and electrical control, including a PID microprocessor controller and thermocouple. It is designed for use in process temperature control applications using water or a water/glycol mix. Any other use or fluid is prohibited.
Some standard safety devices include a mechanical overtemperature safety thermostat, a pressure relief valve, motor overload protection, a low pressure cutout switch, branch fusing, and non-fused lockable rotary disconnect.
A properly installed, operated, and maintained AEC system provides years of reliable operation. Please read and follow the instructions in this manual to get the most satisfaction from your AEC system.
AEC Water Temperature Control Units Page 7
1-2 Necessary Documents
The following documents are necessary for the operation, installation, and maintenance of AEC water temperature control units. Additional copies are available from AEC.
Familiarize the appropriate personnel with these documents:
; This manual. ; The controller operation manual. ; The electrical schematic and connection diagram placed inside
the control enclosure.
; The operation and installation manuals for accessories and
options selected by the customer.
; The Customer Parts List included in the information packet.
1-3 Models Covered
This manual provides operation, installation, and maintenance instructions for AEC water temperature control unit.
Make sure that you know the model number, serial number, and operating voltage of your temperature control unit if you contact AEC.
1-4 Standard Features
• Compact, rugged cabinet with easy-access side panels
• Cast-and-flange design to reduce connection points
• Incoloy™ immersion heater with IEC contactors
• NEMA 1 electrical enclosure
• Off-the-shelf microprocessor controller; display includes
diagnostics features with indicator and warning status lights; CE and CUL
Page 8 AEC Water Temperature Control Units
• Independent high temperature safety thermostat
• Branch fusing
• ¼” cooling solenoid valve on all sizes
• EPDM/NI-Resist pump seal
• Adjustable low supply water pressure switch; factory-set at
16 psig (110 kPa/1.1 bars)
• 150 psig (1,034 kPa/10.3 bars) pressure relief valve
• ¾” water supply and drain connections; 1½” process
connections
• Automatic vent sequence
• 2” (76 mm) casters
• Operating range of 0ºF to 250ºF (-17ºC to 121ºC)
• One (1) -year parts and labor warranty at the factory; three
(3) -year controller warranty, and limited lifetime warranty on wetted pump components.
1-5 Available Options
Economical Series systems are available with options to tailor the unit to your requirements. Some are factory installed; some can be retro-fitted in the field. Consult your sales representative for more information. Available Economical Series options include:
• RS-232 or RS-485 communications
• Heater upgrade available to 12 kW
• Quick Cool function
• Manual bypass
• Auto system water purge (mold purge)
• Y-strainer
• Hammer arrestor (water hammer shock stop)
• Remote start/stop control
• Rubber feet; available in lieu of casters
• ½” slow-close cooling solenoid valves available on all sizes
• Two-zone stack rack with casters, common wiring and piping
available
AEC Water Temperature Control Units Page 9
• 300ºF (149ºC) operation; includes graphite-impregnated
silicon carbide seal
• Audible and visual general fault alarm
• Electrical operation available in 208, 230, 460, and 575 volts,
60 Hz; 200, 380, and 415 volts, 50 Hz
• 10 foot power cord; no plug, shipped loose
• UL/CUL-listed electrical subpanel
Page 10 AEC Water Temperature Control Units
Figure 1
Typical Economical Series Water Temperature Control Unit and Specifications
Direct Injection
Model Dimensions Shipping
number Pump H W D weight
460 / 230 hp
ECU,
9 kW heater
1 2 3 5 7½
¾
kW
0.56
0.75
1.50
2.24
3.73
5.60
gpm
30 35 50 60 75 90
lpm
113.6
132.5
189.3
227.1
283.9
454.2
psig
25 30 30 35 54 63
kPa
172.4
206.9
206.9
241.3
372.3
434.4
in.
25¾”
cm
65.4
in.
12 “
cm
30.5
in.
23”
cm
58.4
lbs.
210
240
Kg
96
109
Figure 2
Economical Series Unit Full-Load Amps
Model Full-load amps at 460 volts
hp kW 9 kW heater 12 kW heater
0.75 hp
1.00 hp
2.00 hp
3.00 hp
5.00 hp
7.50 hp
0.56 kW
0.75 kW
1.50 kW
2.24 kW
3.73 kW
5.60 kW
12.7 amps 16.5 amps
13.1 amps 16.9 amps
14.7 amps 18.5 amps
16.1 amps 19.9 amps
18.9 amps 22.7 amps
22.3 amps 26.1 amps
AEC Water Temperature Control Units Page 11
-Notes-
Page 12 AEC Water Temperature Control Units
2 Shipping Information
2-1 Unpacking and Inspection
You should inspect your Economical Series temperature control unit for possible shipping damage. If the container and packing materials are in re-usable condition, save them for reshipment if necessary.
Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In case of breakage, damage, shortage, or incorrect shipment, refer to the following sections.
2-2 In the Event of Shipping Damages
Important!
According to the contract terms and conditions of the Carrier,
the responsibility of the Shipper ends at the time and place of shipment.
; Notify the transportation company’s local agent if you discover
damage.
; Hold the damaged goods and packing material for the
examining agent’s inspection. Do not return any goods to
AEC before the transportation company inspection and authorization.
; File a claim against the transportation company. Substantiate
the claim by referring to the agent’s report. A certified copy of our invoice is available upon request. The original Bill of Lading is attached to our original invoice. If the shipment was prepaid, contact AEC at (847) 273-7700 for a receipted transportation bill.
; Advise AEC regarding your request for assistance and to
obtain an RGA (return goods authorization) number.
AEC Water Temperature Control Units Page 13
2-3 If the Shipment is Not Complete
Check the packing list. The apparent shortage may be intentional. Back-ordered items are noted on the packing list. You should have:
; AEC Economical Series water temperature control unit ; Bill of lading ; Packing list ; Operating and Installation packet ; Electrical schematic and panel layout drawings ; Component instruction manuals
Re-inspect the container and packing material to see if you missed any smaller items during unpacking. Determine that the item was not inadvertently taken from the area before you checked in the shipment. Notify AEC immediately of the shortage.
2-4 If the Shipment is Not Correct
If the shipment is not what you ordered, contact AEC immediately. Include the order number and item. Hold the items until you receive shipping instructions.
2-5 Returns
Do not return any damaged or incorrect items
until you receive shipping instructions from AEC.
Important!
Page 14 AEC Water Temperature Control Units
2-6 Uncrating Your New Economical Series System
; AEC Economical Series water temperature control units are
shipped in a cardboard box surrounded by individual foam pieces.
; Carefully open the top of the box and remove the front and
back pieces of foam.
Caution!
Be careful when cutting straps.
Straps may spring back and cause injury!
; From the top, slip two lifting straps between the bottom piece
of foam and temperature control unit. Spread the straps from the center line so it is balanced.
; Loop the straps over a fork truck fork. Lift slowly and only
high enough to clear the box..
; Carefully slide the box from beneath the unit and lower the
unit. Lower slowly. The unit should land on its casters and can be rolled into position.
; Retain the crating in case reshipment is necessary due to
hidden shipping damage.
AEC Water Temperature Control Units Page 15
- Notes -
Page 16 AEC Water Temperature Control Units
3 Installation
3-1 Installation Location Considerations
Economical Series systems are portable and can be installed almost anywhere. As with all equipment installations, follow all applicable codes and regulations.
; The recommended ambient temperature range for Economical
Series installations is from +14ºF (-10ºC) to a maximum operating ambient temperature of 131°F (55ºC). Recommended
ambient storage temperature range is from -13ºF to 149ºF (­25ºC to 65ºC). If storing the unit below freezing temperatures, make sure the unit has an antifreeze mixture circulated inside.
; Provide a minimum of twelve inches (12” or about 30 cm)
clearance on all sides of the cabinet to allow circulation of cooling air.
; Locate the unit as close to the process as is practical.
3-2 Process Approach Temperature Considerations
If the differential (U) between COOLING WATER IN and TO PROCESS temperatures is less than 10°F (7ºC), consult our Sales Department for advice on how to control low
approach applications.
3-3 External Piping Sizing Considerations
; All external hose and piping should be adequately sized to
assure minimum external pressure drop.
; Low external piping pressure drop is needed for best operation.
AEC Water Temperature Control Units Page 17
Note: Use a backup wrench to support Economical Series system piping when making process piping connections.
! CAUTION
All external valves, fittings, and hoses must be rated at a minimum of
150 psig and 250°F (1,034.25 kPa/10.34 bars and 121ºC).
The exception is when the temperature control unit
is optionally rated for 300ºF (149ºC) operation;
external valves fittings and hoses must then be rated at a minimum of
150 psig and 300ºF (1,034.25 kPa/10.34 bars and 121ºC).
3-4 Piping Considerations for Permanent
Installations
We recommend an optional (or customer-installed) strainer on the COOLING WATER
IN
inlet.
The unit must have at least 16 psig (110.32 kPa/1.1 bars) water supply pressure to prevent pump cavitation that can be caused by the water “flashing” to steam. To avoid damage to the pump or other components, make sure that maximum supply pressure does not exceed 75 psig (517.1 kPa/5.17 bars).
Keep restrictions to a minimum by using proper inlet pipe sizing. If the water supply piping is larger than ¾”, reduce the size at the unit. The table below contains the pipe sizes that are used in the unit.
Pipe sizes for ¾ hp to 7.5 hp (0.56 kW to 5.59 kW) units
Location Size in inches NPT
To Process 1½” From Process 1½” Cooling Water In ¾” Cooling Water Out
Common black pipe is recommended for permanent installations. Economical Series water circuit piping is primarily ferrous (iron) and reacts electro-chemically with non­ferrous metallic materials such as copper. Some water contains dissolved minerals that greatly accelerate the reaction between dissimilar metals. Ferrous piping is recommended to minimize galvanic action. If piping must be copper, use dielectric unions at the unit.
- depends on solenoid used -
Page 18 AEC Water Temperature Control Units
3-5 Piping Considerations for High Mobility
Installations
Mobile Economical Series systems must use high quality hose rated for at least 150 psig and 250°F (1,034.25 kPa/10.34 bars and 121ºC). Special 300°F (149ºC) high temperature Economical Series systems must use hosing rated at 150 psig and 300°F
(1,034.25 kPa/10.34 bars and 149ºC) or greater.
Quick disconnects may be used for mobility, although they cause a drop in pressure. If used, they must be sized carefully to minimize pressure drop. Don’t use quick disconnects with check valves unless absolutely necessary.
! CAUTION
Non-relieving quick connect fittings or check valves on the water supply
must have a pressure relief piped to the drain.
Failure to do so could result in a dangerous over-pressure condition!
3-6 Process Water Considerations
Raw Water
Water treatment is vital in any piping system. In some cases, raw water may be used in the system without problems; in other cases, it can result in large deposits of scale and corrosion.
We offer a complete line of water treatment equipment. Contact your sales representative for water testing and treatment options.
Distilled Water
Non-ferrous (brass, copper, or high-temperature plastic) piping is recommended for distilled water processes.
AEC Water Temperature Control Units Page 19
Deionized Water
Stainless steel (316 SS minimum) or PVC plastic components must be used with deionized water. We recommends stainless steel because of the temperature constraints with plastic.
3-7 Making Process Water Connections
Direct Injection
On the back of each unit, the connections are labeled appropriately. For Direct Injection units connect the TO PROCESS hookup to the entrance of the process and the the exit of the process. Connect the
IN
to your plant water supply. Connect the COOLING WATER OUT line to an open drain, or to the return line of your central water system.
Make sure you carefully select the connecting lines and connectors between the temperature control unit and the process to suit the needs and requirements of your application.
If your unit has a maximum operating temperature of 250ºF (121ºC), the connecting lines and connectors should have a service rating of at least 250ºF (121ºC) and 150 psig (1,034.25 kPa/10.34 bars). If it has a maximum temperature of 300ºF (149ºC), the lines and connectors should have a service rating of at least 300ºF (149ºC) and 150 psig (1,034.25 kPa/10.34 bars).
TO PROCESS — 1½” NPT
FROM PROCESS hookup to
COOLING WATER
This is the outlet for the tempered water leading to the process being controlled.
FROM PROCESS — 1½” NPT
Water from the process re-enters Economical Series system to be tempered and re­circulated back into the process.
Page 20 AEC Water Temperature Control Units
3-8 Making Cooling Water Connections
WATER IN — ¾”
The cooling water supply inlet from a cooling tower, a chiller, or a city water supply.
! CAUTION
If a non-relieving device such as a regulator, ball valve,
or check valve is installed on the WATER IN line,
you MUST install an expansion tank
of at least ½ gallon (about 2 liters) capacity.
Failure to do so can result in system overpressure from thermal expansion.
Install the tank configured as shown below:
Royal Series
unit
Expansion
tank
Non-relieving
device
Check the expansion tank frequently to make sure it is not flooded.
AEC Water Temperature Control Units Page 21
Water Out
Size Depends on Solenoid Used
The cooling water outlet leading back to the cooling tower, chiller, or drain.
Net supply pressure must be between 25 psig and 55 psig (172.38 kPa/1.72 bars and
379.2 kPa/3.79 bars). Net supply below 15 psig (103.43 kPa/1.03 bars) may allow water to flash to steam, cavitate the impeller, and damage the pump, which prevents the unit from cooling properly. Operation above 55 psig (379.2 kPa/3.79 bars) may cause premature opening of the relief valve from pump pressure and pressure surges.
PRESSURE RELIEF — ¾”
The pressure relief valve, located at the back of the unit, is pre-piped to approximately four inches (4” or 10 cm) above the floor. This piping reduces the chance of scalding nearby personnel if the relief valve should trip.
3-9 Making System Purge Connections
Economical Series systems equipped with the System Purge option have a compressed air inlet marked MOLD PURGE. Connect to a clean, dry 100 psig (689.50 kPa/6.90 bars) air line. Install your own shutoff valve to prevent process liquid from backing up into the plant air piping if the compressed air is turned off and the check valve fails.
Don’t depend on the solenoid valve to hold water pressure in the temperature control unit.
Page 22 AEC Water Temperature Control Units
Figure 3
Typical Piping Schematic
AEC Water Temperature Control Units Page 23
Figure 4
Pump Curves; 60 Hz
Pump Curves; 50 Hz
12S,
50S
12S,
50S
Figure 5
Pressure Drops
Model Pressure drop flow and loss
hp kW 9 kW htr flow gpm
0.75 hp
1.00 hp
2.00 hp
3.00 hp
5.00 hp
7.50 hp
0.56 kW
0.75 kW
1.50 kW
2.24 kW
3.73 kW
5.60 kW
12.7 amps 30.0 gpm
13.1 amps 35.0 gpm
14.7 amps 50.0 gpm
16.1 amps 60.0 gpm
18.9 amps 75.0 gpm
22.3 amps 90.0 gpm
flow lpm
113.6 lpm
132.5 lpm
189.3 lpm
227.1 lpm
283.9 lpm
340.7 lpm
Page 24 AEC Water Temperature Control Units
loss psi
0.0 psi
1.0 psi
1.5 psi
2.0 psi
2.5 psi
5.0 psi
loss kPa
0.0 kPa
6.9 kPa
10.3 kPa
13.8 kPa
17.2 kPa
34.4 kPa
3-10 Making Electrical Connections
Economical Series systems are designed for three-phase voltage operation. Refer to the unit nameplate for proper voltage and amperage requirements.
Make sure you provide a correctly sized and protected supply of electrical power to the unit.
Important!
Refer to National Electric Code (NEC) Article 430-24 through 430-26
for proper feeder conductor and supply disconnect sizing.
Maintain a safe ground and disconnect the power supply before servicing the unit. A qualified electrician should make electrical connections, and disconnect and lock out electricity using OSHA 29CFR 1910.147 standards when you need a service call.
Check serial tag voltage and amperage requirements and make sure your electrical service conforms before making any electrical connections. Total running amps for Economical Series systems are listed on the nameplate. Customer connections can be run to the supply terminals from either side of the unit. Make sure that all three phases are wired correctly. If not wired properly, the unit will run backwards. Again, check
the unit nameplate for correct voltage and amperage.
! DANGER
Improper electrical connections can damage the unit and cause serious operator injury or death!
Bring properly sized power leads and ground from a fused disconnect (installed by your electrician) to the unit. Provide external overcurrent protection to the unit, using circuit breakers or fuses. If you use fuses, make sure that they are dual-element time-delay fuses, sized according to your electrical code. Make sure that all electrical connections are tight.
AEC Water Temperature Control Units Page 25
Important!
1. Electrical connections must comply with all applicable electrical codes.
2. The temperature control unit must be grounded in accordance with NEC Article 250.
3. Voltage must be within plus or minus ten percent (±10%) of the nameplate rating.
4. Make sure your installer provides external protection.
Refer to the electrical wiring schematic
in your Customer Information packet
for additional information.
Page 26 AEC Water Temperature Control Units
4 Identifying Controls and Features
4-1 Identifying Mechanical Controls and Features
To Process Thermocouple
A type K ungrounded thermocouple with a 304SS probe is downstream from the heater to sense process temperature.
Safety Thermostat
The safety thermostat mounted on the side of the heater tank protects against thermal runaway. The thermostat guards against the unlikely event of “runaway” heating. If overheating occurs, the safety thermostat shuts down heater outputs. The unit continues to pump water through the system to prevent heater damage. We recommend that you install an audible or visual alarm to the terminals provided. Factory installed alarms are available; see the electrical schematics for more information.
Pressure Relief Valve
If the combined pressure of the cooling supply water and pump discharge exceeds 150 psig (1,034.25 kPa/10.34 bars), the pressure relief valve opens and relieves the pressure. This is a non-adjustable ASME construction valve with a stainless steel spring.
Important!
Route a pipe from the pressure relief valve
to a suitable drain to reduce potential scalding hazard.
The drain line must not have any restrictions or back pressure.
AEC Water Temperature Control Units Page 27
Low Pressure Cutout Switch
This switch, set at 16 psig with a 2 psig differential (110.3 kPa/ 1.10 bars with a 13.79 kPa/0.14 bars differential) shuts down the unit if the pressure drops below 16 psig (110.3 kPa/1.10 bars). For the 300 °F (148.9 °C) option, this switch is set at 55 psig with a 2 psig differential (379.2 kPa/ 3.79 bars).
Pumps
Pumps range in power from ¾ hp to 7.5 hp (0.56 kW to 5.59 kW) and are equipped with 3-phase ODP motors and seal flush lines as standard.
The pump is a bronze-fitted close-coupled centrifugal type. It features a split case design to facilitate replacement of the seal. It has a high output capacity with excellent discharge pressure helping it facilitate turbulence to maximize heat transfer, and is well suited for the conditions under which it was designed to operate.
Heaters
The specially designed 9 kW three-phase low watt density electrical immersion heater heats the water, and the controller regulates the temperature. The standard heater has an incolloy sheath for best heat transfer and low fouling properties.
Low watt density immersion heaters at 12 kW are available options for these models, depending upon the heating needs of the process. All models are built to provide full heat as required by the process and determined by the controller, providing more precise temperature control.
Solenoid Valves
COOLING WATER IN water
Economical Series systems use rugged, industrial design solenoids with replaceable coils and/or internal components. Depending on required cooling capacity, solenoid valves are available in sizes ranging from valves are slow-closing.
1
/4” to 3/4”; 1/2” x 9/16” and 3/4” x 3/4” solenoid
Water Hammer Arrestor (Shock Stop)
Optional
Shock waves from fast-operating solenoid valves may damage some process systems. For these applications, a welded metal bellows-type shock stop with a pre-charged and sealed nitrogen blanket can be installed in the cooling piping.
Page 28 AEC Water Temperature Control Units
Pump Starter
Economical Series high quality IEC-rated pump motor starters are industrial grade motor controls with overload protection and manual reset.
Transformer
High quality industrial design transformers are specified to suit incoming voltage on the application and provide 115 VAC control voltage. The 115 VAC circuit is protected by primary fusing and secondary grounding.
Heater Contactor
Your unit uses high-quality IEC-rated industrial-grade electromechanical contactors for heater controls.
AEC Water Temperature Control Units Page 29
Cooling
The controller automatically regulates cooling by opening and closing the solenoid valve. The unit cools by removing the required amount of warm water from the system. This process permits an equal amount of cool plant water to enter the system well ahead of the pump, allowing it to blend with the system water. The water supply temperature governs the minimum operating temperature of the unit.
Note: The plant water supply temperature governs the minimum operating temperature of the unit.
Electricals
The pump motor and the immersion heater operate on three-phase 50/60 cycle nominal voltages with the control circuit operating at 115V single phase. The control circuit voltage is provided by a single phase machine tool transformer with a grounded secondary.
The 115V control circuit and controller outputs are fuse protected. The pump motor is controlled by a full voltage magnetic non-reversing motor starter, with fused branch circuit overcurrent and thermal overload protection.
Automatic Vent
This feature automatically triggers the purging of air from the system before you start the unit. The vent actuates the solenoid valve, and forces trapped air and water out through the drain, properly filling and priming the unit prior to startup. Complete venting is necessary to prevent damage to the pump and heater.
The vent process is controlled through a timer. If you have a large process, you may need to complete the venting process by pressing the mounted switch panel.
Page 30 AEC Water Temperature Control Units
VENT button on the front-
Pressure Switch
A pressure switch built into each unit keeps the system from starting until the water supply is turned
On and subjected to the minimum water supply pressure. This feature
protects the pump seal and the heater from damage through attempted operation without water. The pressure switch is set at approximately 16 psig (110.32 kPa/1.10 bars) for 250°F (121ºC) units or 55 psig (379.23 kPa/3.79 bars) for 300°F (149ºC) units prior to leaving the factory.
4-2 The Microprocessor Controller
The controller is an easy-to-operate microprocessor-based PID control device. When the process reaches the set point, the PID control cycles the cooling valve and/or immersion heater to maintain the proper leaving water temperature.
The controller has been fully factory tested. Set the desired process temperature set point and the control does the rest.
Built-in range of operation on the controller is 0°F to 250°F (-18ºC to 121ºC).
4-3 Controller Display
Typical E5CK Microprocessor Controller
OUT1
Figure 6
PV
SV
Figure 6
PV or Process Value Numeric LED
OUT2 MANU STOP RMT AT SUB1
AT
During normal operation, the large red
PV Process
Value LED on the
OMRON
E5CK
controller displays the actual process temperature at the To Process thermocouple. It also lists parameter symbols during setup and error messages if an error occurs.
AEC Water Temperature Control Units Page 31
SV or Set Value Numeric LED
During normal operation, the green SV Set Value LED on the controller displays the process set point you want the chiller to maintain. It also displays parameter and pre-set function values during setup.
OUT1 LED
The orange OUT1 LED lights when the controller output energizes the immersion heater.
OUT2 LED
The orange OUT2 LED lights when the controller output energizes the cooling valve.
MANU LED
The orange MANU LED lights when you place the controller in Manual mode.
STOP LED
The orange STOP LED is not used.
RMT LED
The orange RMT LED is lit during remote operation.
AT LED
The orange AT LED flashes during auto-tuning.
SUB1 LED
The orange
SUB1 LED is lit during high temperature conditions.
4-4 Using Controller Keys
Figure 6
Note: Only those who are completely familiar with the unit controller should perform the operations described in Sections 4-4 through 4-14.
Page 32 AEC Water Temperature Control Units
AT
A
AT Key
Press and hold the stop the auto-tune function.
Displ ay Key
The functions of the Display key change, based on how long you press it. Press the Display key for less than one (1) second to scroll through parameters within the mode. Press the
Display key for at least one (1) second or more to display the
menu; the Display function also lets you select the mode you need to adjust.
T
AT key for two seconds to initiate or to
Important!
Do not change any of the control settings
without consulting AEC’s Service Department.
AEC warranty does not cover chiller failures
from tampering with controller settings!
Down Key
Each press of the Down Arrow key decrements or reduces the values or settings on the SV Set Value display.
Up Key
Each press of the the values or settings on the
Up Arrow key increments or advances
SV Set Value display.
4-5 Using Graphic Panel Buttons
ON/OFF Switch
Push the temperature control cycle. The switch will be illuminated whenever the unit is on.
ON/OFF rocker switch to the ON ( | )energize the unit and begin the
AEC Water Temperature Control Units Page 33
VENT Switch
Push the VENT switch for additional manual venting.
ALARM SILENCE Button
Optional
Push the ALARM SILENCE button to silence the alarm. You should investigate the alarm condition and restore the unit to normal operation before continuing with the temperature control cycle.
AIR PURGE
Optional
Press the AIR PURGE switch to initiate the purge. It is a momentary switch and must be pressed to keep the purge valve open. Releasing the switch closes the cooling/vent and compressed air solenoid valves.
QUICK COOL Button
Optional
Press the QUICK COOL button to open the cooling valve and quickly cool the process.
4-6 Alarms
Audible/Visual General Fault Alarm
Optional
The audible/visual general fault alarm sounds if any fault triggers, such as low water pressure, over-temperature, or pump overload. A signal from any of the safety devices activates a horn and flashing strobe.
Push the The optional mechanical high temperature safety alarm is interlocked with the heater.
When triggered, the heater cuts out and the pump continues to run.
ALARM SILENCE button to silence the alarm.
4-7 Controller Factory Setup
The controller is set up and tested at the factory for optimum operation, and doesn’t need to be adjusted. If the controller does not work properly, or you suspect someone has accidentally changed some settings, you can do two things. First, perform the Auto­Tune Procedure described in the following section. If that doesn’t work, restore the controller to the original factory settings as described later in this manual.
Page 34 AEC Water Temperature Control Units
4-8 Controller Internal Switches
A
The controller is set up and tested at the factory for optimum operation, and adjusting the internal switches is not necessary. If the controller does not work properly, or you suspect someone has accidentally changed some settings, there are two things to do. First, perform the Auto-Tune procedure described in Section 4-10 on Page 36. If that doesn’t work, restore the controller to the orig-inal factory settings as described in Section 6-3 on Pages 52 to 59.
4-9 Controller Factory Setup
The controller is set up and tested at the factory for optimum operation, and in most cases doesn’t need to be adjusted. If the controller does not work properly, or you suspect someone has accidentally changed some settings, you can do two things. First, perform the Auto-Tune Procedure described in the following section. If that doesn’t work, restore the control to the original factory settings as described in Section 6-3 on Pages 63.
For your protection, all menu modes and levels except 0 and 1 are locked out at the factory. Level 2 is unlocked for units with factory-installed communications options.
4-10 Auto-Tuning the Controller
The Auto-Tune function lets you fine-tune the control PID to process requirements. Activate the Auto-Tune function whenever the process under control changes. Don't be alarmed by control response. It may take the process temperature above and below the set points as many as three (3) times. It will then level off and control to the process set point. Auto-tuning can take up to 45 minutes, and is best done before any product is run.
To auto-tune the controller:
T
Press and hold down the flashes.
The
AT LED flashes to indicate that the control is tuning itself.
When the AT LED light stops flashing, the controller is tuned and ready for operation.
AT key for two (2) seconds until the AT indicator
AEC Water Temperature Control Units Page 35
4-11 Changing from Fahrenheit to Celsius
Changing the control display from ºF to ºC is done in the Setup mode, which is pre-set and locked out at the factory. Contact Customer Service if you need to change the display.
4-12 Operating the Unit with the Controller
Level 0 Mode
To change the process temperature set point:
• Press the Down Arrow key to lower the set point to the temperature you want.
• Press the Up Arrow key to raise the set point to the temperature you want.
The set point automatically updates after a two (2) -second display.
4-13 Communications
A connection port on the electrical cabinet permits easy hook-up to the host computer for RS-232C and RS-485 communications. The connection port is a direct pin-to-pin extension from the back of the controller. For pin outs, consult the Communication Manual for the Omron E5CK model controller.
Page 36 AEC Water Temperature Control Units
-Notes-
AEC Water Temperature Control Units Page 37
5 Startup and Operation
5-1 Introduction
The checklist below outlines start-up procedures for Economical Series water temperature control units. This list assumes that installation information located in this manual has been read and followed.
5-2 Startup Checklist
; Check the shipping papers against the serial tag to make sure
that system size, type, and voltage is correct for the process under control.
; Check the transformer primary voltage connections to be sure
they are configured for the electrical power you are using. The voltage at the main power connection must be within plus or minus ten percent (±10%) of the voltage listed on the serial tag. Electrical connections must conform to all applicable codes. Make sure that a qualified electrician checks all electrical connections.
; The safety thermostat is preset at the factory to 250ºF or 300ºF
(121ºC or 149ºC), depending on configuration. It trips at 265ºF or 315ºF (129ºC or 157ºC), depending on configuration.
; The relief valve should be piped to an open, unrestricted drain. ; TO PROCESS, FROM PROCESS, WATER IN, WATER OUT,
MOLD PURGE connections should be complete.
and
! CAUTION
Only use components rated at a minimum of
150 psig and 250°F (1,034.25 kPa/10.34 bars and 121ºC).
; All outer panels must be in place. ; All external process valving should be set for proper operation
of the unit.
; Cooling and/or makeup water between 16 psig and 55 psig
(110.32 kPa/1.1 bars and 379.2 kPa/3.79 bars) must be available for the unit to operate properly.
Page 38 AEC Water Temperature Control Units
; Connect the main power to the unit disconnect switch, and
press the START switch to check for proper pump rotation direction as described in Section 5-6 on Page 42. Pump rotation should be clockwise, viewed from the motor end.
; Check your work and proceed to the Startup Procedure
section on the following page.
5-3 Starting the Temperature Control Unit
; Turn on the water supply, apply main power to unit, press
ON/OFF switch to the ON position.
; The unit automatically executes a one-minute venting sequence
to expel air trapped in the process piping. We recommend a longer venting sequence on larger process systems. Press and hold the VENT button to force the cooling/vent valve open and eliminate air trapped in the process piping in larger process systems.
The controller is OFF and the Vent Cycle indicator is lighted during the vent sequence.
; Set the microprocessor controller to the process temperature
you want by pressing the Up Arrow button or the
Down Arrow button on the front of the controller.
; Allow your process to reach the set point temperature, then
auto-tune the control by pressing the AT key. See Section 4-10 on Page 36 for more information.
; Watch the drain for any bubbles or erratic flow, which
indicates if the system has been properly vented. If the stream is steady, the unit was properly vented and all air is out of the system.
; Operate the unit, checking for anything unusual that could
indicate improper operation.
Note: You can stop your temperature control unit at any time by pressing the
STOP button.
AEC Water Temperature Control Units Page 39
! CAUTION
1) Your system operates with hot water under pressure. To reduce the risk of
scalding:
• Always wear work gloves and safety glasses when operating the unit.
• Never operate the unit with panels or shields removed.
• Pipe the relief valve to an open drain.
• Never install a fitting or hose that is rated less than 150 psig and 250°F
(1,034.25 kPa/10.34 bars and 121ºC).
2) To reduce the risk of electrical shock:
• All electrical installation and repairs should be done by a qualified electrician.
• Ground the unit in accordance with electrical codes.
• Never attempt any repairs without first opening and locking out the main
disconnect.
• Never deactivate or neutralize any safety device.
5-4 Operating the Unit with the Controller
To change the process temperature set point:
• Press the Down Arrow key to lower the set point to the temperature you want.
• Press the you want.
Up Arrow key to raise the set point to the temperature
Page 40 AEC Water Temperature Control Units
5-5 Sequence of Operation
The simplicity of design and the highly engineered controller make this unit almost self-operating. The are all that is required to operate this unit.
After you complete all connections, turn the water supply ON, then turn control power
ON. The unit automatically vents for a preset time of one (1) minute. If you need
additional vent time, press the VENT button on the control panel.
As the water comes in the water supply line, the water must enter the pump, up through the tank and out through the
FROM PROCESS line, and through the solenoid line and out the drain line.
At this time, watching the drain for bubbles or erratic flow will indicate whether or not the system has been properly vented. If a steady stream flows from the drain line, it is certain that all the air is out of the system.
ON/OFF and VENT switches and the temperature controller buttons
TO PROCESS line, through the process, back through the
; TCU systems provide temperature control on processes by
directly heating the process water and injecting cooling water into the process water.
; When the unit is energized, the pump starts and a one minute
vent sequence opens the cooling/vent valve to remove any air trapped in the process piping.
; If the cooling water supply pressure is insufficient, the low
cooling water pressure cutout switch (set at 16 psig, 10 psig differential [110.32 kPa/1.10 bars, 68.95 kPa/0.69 bars differential]) opens. You need at least 16 psig (110.32 kPa/1.10 bars) for the best cooling capacity and to prevent water boiling in the process circuit at high temperatures, particularly at the pump suction.
; After venting, the microprocessor controller monitors the
PROCESS
probe, cycling open the cooling/vent valve to
TO
discharge warm water or energizing the immersion heater to maintain the process set temperature.
AEC Water Temperature Control Units Page 41
5-6 Checking Motor Rotation Direction
Check for correct pump rotation direction by looking at the end of the motor. Press the
ON/OFF switch from the OFF ( O ) position to the ON ( | ) button, and note the
direction that the motor turns. Rotation should be clockwise when viewed from the motor end.
Note: Make sure that a qualified electrician performs the following steps.
To change rotation direction:
1. Disconnect and lock out power at the fused disconnect.
2. Reverse any two incoming leads at the power terminal blocks.
3. Do not switch leads at the motor or motor starters.
5-7 Shutting Down the Temperature Control Unit
Cool the unit down by selecting a set point of zero (0). Let the unit stabilize at one temperature close to the incoming water temperature, then press the STOP button. Now press the VENT button to relieve any remaining pressure in the system.
Page 42 AEC Water Temperature Control Units
6 Unit Maintenance
! CAUTION
Never attempt to service a unit until a qualified
electrician has opened and locked out the main
The water supply should be turned off and internal pressure should be relieved before you remove panels.
All electrical connections must be done by a qualified electrician.
disconnect using OSHA 1910.147 standards.
! WARNING
Disconnect all power to the unit, let the unit cool down, and turn off the water prior to any
servicing. Failure to do so can result in SERIOUS INJURY
OR DEATH!
6-1 Preventive Maintenance
Draining
Drain the unit thoroughly if you are taking it out of service for a long period of time, or you expose it to freezing. Drain plugs are provided at the base of the heater tank and at the base of the pump.
AEC Water Temperature Control Units Page 43
Periodic Checks
Every Six Months
Inspect all electrical connections for secure attachment and for safe and secure ground connections. Inspect the power cable, especially at the entrance point to the unit. This inspection should be made by a qualified electrician. Check for leaks, especially under the pump, as it may indicate a worn pump seal.
6-2 Corrective Maintenance
Pumps and Seals
Before leaving our factory, we test each unit extensively, then we calibrate each unit. Afterwards, the unit is drained and blown out with air to remove water from piping systems. If the unit is allowed to stand idle for a long time before being installed in your factory, the housing gasket at the pump can dry out and can possibly leak when the unit is started. In most cases these gaskets will soon swell and form a tight seal. In other cases, it may be necessary for you to tighten the pump bolts to stop a leaking condition.
Pump seal surfaces can separate slightly because of rough handling or from vibration during transit. This could cause a leak at the pump seal when the pump is started, but in most cases the surfaces will mate again after the pump is allowed to run for a short period of time. If they do not reseal, you may need to open the pump and free the seal by hand. It is seldom necessary to install a replacement seal in a new unit unless the
seal has been damaged because the unit was started without water.
Our pump seals have a long period of service life. Some conditions, of course, can shorten seal life, including the presence of grit, operation of the unit without water, sustained high water temperature, or presence of certain chemicals in the water. Our pump seal assembly has been developed to resist abrasive particles that are present in many water systems. This is done by a special flushing system that uses water exiting the pump to constantly wash the seal area.
Page 44 AEC Water Temperature Control Units
It is also fitted with high temperature flexible components for maximum heat resistance. These same components remain flexible even at low temperatures. Thus, the standard seal is a fine combination of heat resistant and wear resistant components. Unfortunately, even under normal use, the seal will eventually wear and require replacement.
A small puddle underneath the unit is a sign of rotary seal wear, and if investigation confirms the pump as the source, the seal should be replaced as soon as practical. The water slinger is intended to provide temporary protection against this, but a continued and substantial leak will ruin the motor bearing and cause further damage.
After the unit has been in service for a period of years where abrasive conditions are present, you may find that the pump bracket (the top half of the pump casting), can be eroded away in the area around the seat of the rotary seal. This area should provide a straight, smooth bearing surface for the cup seal. Should your casting show signs of erosion in this area, the casting needs to be replaced. The replacement cost of the casting is very modest compared to the down time and maintenance cost for frequently replacing the seal.
Under some conditions, the pump may not start. After turning off the power supply, check the motor shaft to be certain it is free to turn. By removing the drip cover on top of the motor, you’ll have access to the end of the shaft. It has been slotted to make it easy to turn with a screwdriver. If the shaft is free to turn, next check that the motor overloads are set, check for blown fuses, and finally check the power supply on each leg to the motor. A qualified electrician should check the motor and its circuit.
Important!
If the pump motor wiring is disconnected for removal from the unit,
make sure that you check the actual rotation direction
when the motor is rewired to the unit.
A phase sensor does not always indicate proper rotation
if motor wire leads are reversed at installation.
Consult the elementary wiring diagram for more information.
AEC Water Temperature Control Units Page 45
Heaters
Heaters may need to be cleaned chemically or mechanically to remove deposits and dirt that reduce heat transfer and cause hot spots. Hot spots cause premature heater failure. Install a new gasket when reassembling. Make sure a qualified electrician disconnects and reconnects heater wires.
Solenoid Valves
; Clean annually; more often if using high mineral content water
or on high service level units.
; Sluggish operation, excessive leakage, and/or noise indicate
cleaning is necessary. Inspect the components for excessive wear while the valve is disassembled.
; Rebuild kits are available from the Parts Department.
6-3 Restoring the Controller to Factory Setup
If the preset parameters on the controller have been tampered with and it no longer properly controls temperature, you can restore the controller to factory setup parameters.
E5CK Operating Parameters
The E5CK controller has several mode selections. Within each mode are numerous parameters that can be set.
Before you can gain access to the several modes of operating parameters, you must change the security lock-out of the controller. AEC sets the security level at the factory to protect the parameters from being accidentally changed. The explanation that begins on the following page is how to change operating modes, how to change out the security level, and how to reset factory default settings.
Page 46 AEC Water Temperature Control Units
Available E5CK Modes
Menu Display
Level 0 Mode
For normal operation. Execute AT auto-tuning, change to Manual mode.
Level 1 Mode
For adjusting primary control parameters. Execute: Set alarm values; set the control period; set PID parameters.
Level 2 Mode
For adjusting secondary control parameters. Economical TCU units use E5CK default settings.
Setup Mode
For setting basic specifications. Set parameters for input type, scaling, output assignments and direct/reverse operation.
Expansion Mode
Option Mode
Calibration Mode
For setting expanded functions. Set: ST (self-tuning), SP setting limiter. Select: advance PID or ON/OFF control.
This mode is only accessible when an option board is installed.
For calibrating communication unit E53-CKF. Not used.
AEC Water Temperature Control Units Page 47
Figure 7
Display Readout for Mode Settings
PV
SV
SV
SV
SV
SV
SV
SV
Setting E5CK Security in Protect Mode
Menu display Level 0 mode
Level 1 mode
Level 2 mode
Setup mode
Expansion mode
Option mode
Calibration mode
4. To access protect mode, press and hold the
AT
AT key and
the Display key for two (2) seconds.
5. The display should read SECr for security mode. If you press
the Display key for short presses you will toggle between SECr and KEYP for AT protect.
Page 48 AEC Water Temperature Control Units
6. With the display reading SECr, set the security levels by the
arrow up and down keys. Change the security level to 1 to make changes to the operating parameters. Economical TCU units are factory set to Security Level 5.
Available Security Levels
Security level
Mode 0 1 2 3 4 5 6
Calibration X Option X X Expansion X X Setup X X Level 2 X X X Level 1 X X X X Level 0 X X X X X X
To return to the main display (run mode), press and hold the AT and Display key for 2 seconds.
Entering Operating Parameters to Select Modes
To enter the menu display:
7. Press the Display key for two seconds.
The screen displays .
8. Press the
Up Arrow key to toggle through the different
modes. The SV readout displays the mode you selected.
9. To switch parameters within a mode, press the Display
key once more for two (2) seconds. The PV readout displays the different parameters within each
mode.
AEC Water Temperature Control Units Page 49
10. Use short presses on the Display key to display each
parameter within a mode.
SV readout displays the different values for the parameter
The within a mode.
11. Press the
Down Arrow key to lower values of a
parameter; press the Up Arrow key to raise values of a parameter.
12. Press the
Display key for about two (2) seconds to
move up a level back into the different modes.
13. Press the
Down Arrow key until Level 0 displays.
14. Press the Display key for about two (2) seconds to go
to Operating mode.
E5CK Factory Setting for Process Temperature
15. Remove controller from housing and check for output board
number E53-R4R4 (Relay/Relay).
16. Make sure jumper setting for input type is set for thermocouple
TC-PT, middle jumper.
17. Return controller to housing.
18. Press the
Display key for one (1) second to enter Menu
Display.
19. Press the Up Arrow key to get to Setup mode; the
screen displays the
message.
20. To switch parameters within Setup mode, press the
Display key.
Page 50 AEC Water Temperature Control Units
Figure 8
Setting List for Process Temperature Controller
Mode Parameter Setting range Default Solenoid Valve
Protect SECr Security 0 to 6 1 5 Protect KEYP A/M Key protect ON/OFF OFF ON Level 0 PV/SV display — — — Level 0 Switch to Manual mode -5.0 to 105.0% 0.0 Default Level 0 MV monitor Cannot be set 0.0 Default Level 0 r-S Run/Stop Run/Stop Run Default
Mode Parameter Setting range Default Solenoid Valve
Level 1 At AT Execute/Cancel OFF/AT-1/AT-2 0 Default Level 1 SP-0 Set point 0
Level 1 SP-1 Set point 1 Level 1 AL-1 Alarm value 1 -1999 to 9999 EU 0 Default Level 1 AL-2 Alarm value 2 -1999 to 9999 EU 0 Level 1 AL-3 Alarm value 3 -1999 to 9999 EU 0 Default
Level 1 P Proportional band 0.1 to 999.9% FS 10.0 0.5 Level 1 I Integral time 0 to 3999 SEC 233 55 Level 1 d Derivative timer 0 to 3999 SEC 40 9 Level 1 C-SC Cooling coefficient 0.01 to 99.99 1.00 Default Level 1 C-db Dead band -19.99 to 99.99 0.00 Default Level 1 oF-r Manual reset valve 0.0 to 100.0 50.0 Default Level 1 HYS Hysteresis (heat) 0.01 to 99.99 0.10 Default Level 1 CHYS Hysteresis (cool) 0.01 to 99.99 0.10 Default Level 1 CP Control period (heat) 1 to 99 SEC 20 15 Level 1 C-CP Control period (cool) 1 to 99 SEC 20 Default
Set point lower limit to
Set point upper limit
Set point lower limit to
Set point upper limit
0 Default 0 Default
0=full heat,
+10=half heat
AEC Water Temperature Control Units Page 51
Figure 8
Setting List for Process Temperature Controller (Cont’d.)
Mode Parameter Setting range Default Solenoid Valve
Level 2 Remote/Local Level 2
Level 2 SPrt Sp Ramp Set Value 0 to 9999 EU 0 Default Level 2 Mu-5 MV at Stop -5.0 to 105.0% 0.0 Default Level 2 Mu-E MV at PV Error -5.0 to 105.0% 0.0 Default
Level 2 OL-H MV Upper Limit Level 2 OL-L MV Lower Limit Level 2
Level 2 InF Input Digital Filter 0 to 9999 SEC 0 Default Level 2 ALH2 Alarm 2 Hysteresis 0.01 to 99.99% 0.02 Default
Level 2 Level 2
SPrU Sp Ramp Time Unit
OrL MV Change Rate Limit
In5H Input Shift Upper Limit In5L Input Shift Lower Limit
Only active with comm.
board
M(Minutes)/
H(Hours)
MV Lower Limit +0.1 to
105%
-5.0 to MV Upper Limit -
0.1%
0.0 to 100.0%/SEC 0.0 Default
-199.9 to 999.9 °C
-999.9 to 999.9 °C
Local Default
M Default
105.0 Default
-5.0 Default
0.0 Default
0.0 Default
Mode Parameter Setting range Default Solenoid Valve
Setup In-t Input Type 0 to 21 2 2 Setup Setup InIt Parameter Initialize Yes/No No Default
Setup Setup Setup
Setup Alt1 Alarm 1 Type 0 to 11 2 Default Setup Setup ALt1 Alarm 2 Type 0 to 11 3 Default Setup
Setup
d-U °C/F Selection °C/F °C °F
OUt1 Control Output 1
Assignment
OUt2 Control Output 2
Assignment
Sub 1 Auxiliary Output 1
Assignment
AL1n Alarm 1 open in
alarm
AL2n Alarm 2 open in
alarm
6rEu Direct/Reverse
Operation
Heat/Cool/Alarm 1/Alarm
2/Alarm 3/ LBA
Heat/Cool/Alarm 1/Alarm
2/Alarm 3/ LBA
Alarm 1/Alm 2/Alm
3/LBA/S.ERR/E333
NO/NC NO Default
NO/NC NO Default OR-R/OR-D OR-R Default
Heat Default Cool Cool AL-1 AL-2
Page 52 AEC Water Temperature Control Units
Figure 8
Setting List for Process Temperature Controller (Cont’d.)
Mode Parameter Setting range Default Solenoid Valve
Expansion Expansion
Expansion CntL PID/ON/OFF PID/ON/OFF PID Default Expansion Expansion St Stable Range
Expansion Expansion
Expansion
Expansion Expansion AT-H AT Hysteresis 0.1 to 9.9% FS 0.2 Default
Option Eu-n Multi-SP function 0/1 0 Default Option
SL-H Set Point Upper
Limit
SL-L Set Point Lower
Limit
ST Adaptive Tuning
(Fuzzy)
ALFA α At-G AT Calculated
Gain
rESt Standby
Sequence Reset Setting Method
rEt Automatic Return
of Display Mode
Eu-1 Event input
assignment 1
SP Lower Limit +1 to
Scaling Upper Limit
Scaling Upper Limit to SP
Lower Limit
OFF/ON OFF ON
0.1 to 999.9 °C/F
0.01 to 1.00 0.65 Default
0.1 to 10.0 1.0 Default
0/1 0
0 to 99 SEC 0 Default
STOP/MAN STOP Default
1300 250ºF; 300ºC opt.
-200 0
15 Default
Default
AEC Water Temperature Control Units Page 53
Communications Option
Mode Parameter Setting range Default
Communications stop bit 1 to 2 2 2 Communications data length 7 to 8 7 7 Communications parity None, Even, Odd Even Even Communications baud rate Communications unit number 0-99 0 0
1.2, 2.4, 4.8,
9.6, 19.2 K
9.6 9.6
Transfer Output
Mode Parameter Setting range Default
Transfer output type
SP, PV,
SP RAMP, MV
PV PV
Solenoid or
Modulating
Valve
Solenoid or
Modulating
Valve
Transfer output upper limit -200 to 1300 1300 250 Transfer output lower limit -200 to 1300 -200 0
6-4 Electrical Connections
Make sure that a qualified electrician inspects all electrical components and connections every six (6) months for secure attachment and ground connections. Inspect all wiring for fraying or damage, especially power lines where they enter the unit. All wiring connections must be tight.
Page 54 AEC Water Temperature Control Units
6-5 Safety Devices
Make sure that only qualified electricians test safety devices!
Safety devices should be tested for function every six (6) months. Perform the following procedures for testing:
Motor Overload
Disconnect main power. Open the electrical enclosure and rotate the manual TEST button on the motor overload to the tripped position. Close the enclosure and reconnect main power. Push the START button. The unit should not start and the Pump
Overload
Press the RESET button. The unit is now ready for operation.
Pressure Switch
indicator should illuminate.
Caution!
With the unit running, program a set point of 30ºF (-1ºC). Allow the process temperature to drop under 100ºF (38ºC). When the process temperature reaches that point, turn off the water supply. The pump should stop and the Low Water Pressure indicator should illuminate. Turn the water supply on to reset the pressure switch.
Adjusting the Pressure Switch
The pressure switch used in your Economical Series water temperature control unit is factory set at 16 psig (110.3 kPa/1.1 bars). However, if the process does not require the unit to operate at 250ºF (121ºC), you can adjust the switch to meet your process needs.
Tools Required
• Small flat blade screwdriver
• #2 Phillips head screwdriver
AEC Water Temperature Control Units Page 55
! CAUTION
HAZARDOUS ELECTRICAL CURRENT PRESENT. Maintain a safe ground and disconnect the power
supply before servicing the unit.
Make sure a qualified electrician makes electrical
connections; disonnect/lock out electricity using OSHA
20CFR 1910.147 standards when servicing the unit.
To adjust the pressure switch:
Using a small, flat-blade screwdriver, carefully remove the plug at the top of the switch.
Figure 9
Pressure Switch
Side View and Top View
Phillips head screw
Under the plug is a Phillips-head adjusting screw:
Turn the screw counterclockwise to reduce the pressure.
- or -
Turn the screw clockwise to increase the pressure.
A quarter turn (90º rotation) approximates 15 psi (103.4 kPa/
1.0 bars).
Replace the plug on the top of the switch.
If the plug gets damaged, the switch is still sealed internally.
Page 56 AEC Water Temperature Control Units
Safety Thermostat
Disconnect main power. Open the electrical enclosure and disconnect the neutral lead on the safety thermostat from the terminal strip. Protect the stripped lead to prevent short circuits. Close the enclosure, reconnect main power, and push the START button and press ON/OFF switch to the ON position. The heater should not turn on and the
Over Temperature indicator should illuminate. Disconnect main power before
reconnecting the thermostat lead.
Make sure that the high limit on the controller is set to the values listed in the following table, based on the switch adjustment. This prevents the pump from cavitating and damaging the seal, the switch, and heater element(s).
psig kPa Max. temp. ºF Max. temp. ºC
5 psig 34.4 kPa 227ºF 108ºC 10 psig 68.9 kPa 240ºF 116ºC 15 psig 103.4 kPa 250ºF 121ºC
6-6 Cleaning and Storage
• Inspect the unit daily for leaks. Wipe down the unit
periodically to remove dirt and dust buildup, especially the motor casing.
• Drain and flush the unit every six (6) months to remove
sediment buildup.
• Completely drain the unit and carefully blow out the piping
with pressurized air before placing the unit in storage.
AEC Water Temperature Control Units Page 57
- Notes -
Page 58 AEC Water Temperature Control Units
7 Troubleshooting
Condition Possible cause Solution
Check main disconnect, fuses, wiring, and power lead to unit. Voltage must be within plus or minus 10% of nameplate rating.
Locate and repair. Repair or replace.
Check for at least 16 psig (110.32 kPa/1.1 bars) water pressure on WATER IN or CITY WATER MAKEUP.
Open water supply. Reset and test each leg for
balanced amp draws. Verify proper rotation. If not
clockwise, reverse any two incoming power leads.
As long as there is satisfactory process temperature control there is no problem.
Clean the system. Check for closed valves etc. Be
sure all lines are properly sized. As long as there is satisfactory
process temperature control there is no problem.
Check for 25 psig (172.38 kPa/1.72 bars) water pressure on WATER IN or CITY WATER MAKEUP.
Jump power across switch and see if unit starts. Replace switch if needed.
Unit does not turn on.
Unit does not run.
Low pump pressure.
High pump pressure.
Pressure switch circuit is open.
No power. Wrong voltage supplied to unit.
Defective on/off switch. Replace. Control circuit fuse blown. Replace. Defective control transformer. Check transformer. Broken or loose wire in pump motor control circuit. Pump motor contactor holding coil is open.
Low water pressure light on.
Water supply to unit is turned off.
Pump overload light on.
Pump running in reverse. Foreign matter in the system. Clean the system.
System has minimal back pressure, and is operating at the far end of the pump curve.
Foreign matter obstructing system.
Restricted water flow. System has high back pressure,
and is operating at the near end of the pump curve; a low flow condition.
Insufficient cooling or makeup water pressure.
Switch is broken.
AEC Water Temperature Control Units Page 59
Condition Possible cause Solution
Temperature fluctuations/rapid cycling from hot to cold.
Unit overheats or does not cool.
Relief valve leaks.
Unit runs continuously cooling or heating, and cannot attain set point.
Undersized connectors/water lines. Long connecting lines between unit and mold.
Serpentine flow through mold. Blocked water line in mold.
Quick disconnect fitting with check valve.
Increase size of connectors/ water lines. Move the unit closer to the mold and shorten connecting lines. Connect lines for parallel flow instead of series flow. Check mold for metal chips or lime buildup. Clean mold. Remove and replace fitting or valve.
Lime buildup in unit piping. Clean or replace.
Check unit by connecting ¾” line directly from To Process to From
Faulty TCU.
Process line. Run unit to determine if TCU controls set
point temperature. Reversed probes. Drain is plugged or excessive
back pressure is in drain line.
Switch To and From Process
probes.
Clear drain line or eliminate
back pressure condition.
Test solenoid valve by pressing Faulty solenoid valve.
VENT button and listen for valve
operation. Replace if faulty. Controller Cool output relay
open. Solenoid valve is not operating,
but
COOL LED is on.
Solenoid coil circuit is open.
Modulating valve is not operating, but OUT2 LED is on.
Insufficient pressure differential between cooling
OUT lines.
WATER IN and
Cooling valve is undersize. Foreign material under valve
seat. High system pressure.
Replace output relay.
Set process temperature to
minimum and check for mag-
netism on solenoid coil top.
Check coil resistance. If MΩ
range, replace solenoid coil.
Set process temperature to
minimum and check for
complete travel of valve.
Find a means to get less back
pressure in the
WATER OUT line.
Replace cooling valve with a
larger valve.
Manually open valve to clear
seat of material.
Reduce
WATER IN or MAKEUP
water pressure. Unit under-sized for application. Call sales representative.
Page 60 AEC Water Temperature Control Units
Condition Possible cause Solution
Unit does not heat/cannot achieve set point.
Visually inspect coil and Defective heater contactor.
contacts; repair/replace
defective contactors.
Check resistance on all three (3) Defective immersion heater.
legs of the heater with an ohm
meter. If not all equal, contact
factory for replacement heater.
Check the heater output with an
ohm meter to ground. It should Controller heat output open.
read in the mega-ohm range.
Infinite or zero readings indicate
a defective output. Heater contactor is not
energizing, but
HEAT LED is on.
Immersion heater elements dirty.
Set process temperature to
maximum and check for control
voltage at heater contactor.
Remove heater and clean
elements.
Check heater tank for
scorched/discolored paint.
Check resistance on all three (3)
legs of the heater with an ohm Immersion heater element is burned out.
meter. Replace heater as
required.
Check for balanced amp draws,
and supply voltage. If not
present replace immersion
heater.
OUT1 indicator is on, but no
voltage on heater contact.
Replace relay board on
controller. Cooling valve is leaking. Dismantle valve and clean out.
Set process temperature to Solenoid valve is not operating, but
COOL LED is on.
minimum and check for
magnetism on top of solenoid
coil. Magnetism on coil. Clean coil.
Press
Faulty/dirty solenoid valve.
VENT button several times
to flush the valve.
AEC Water Temperature Control Units Page 61
Service Notes
Page 62 AEC Water Temperature Control Units
Service Notes
AEC Water Temperature Control Units Page 63
Service Notes
Page 64 AEC Water Temperature Control Units
Service Notes
AEC Water Temperature Control Units Page 65
I Index
Air Purge switch, 34 Alarm Silence button, 34 Alarms, 34 AT key, 33 AT LED, 32 Audible/visual general fault
alarm, 34 Automatic vent, 30 Auto-tuning the controller, 36 Available options, 9–10
Checking motor rotation
direction, 42 Cleaning and storage, 57 Closed circuit/direct injection
connections, 19 Communications, 37 Communications option list, 54 Controller display, 31 Controller factory setup, 34, 35 Controller internal switches, 35 Controller operation, 36 Cooling regulation, 30 Cooling water connections, 20 Copyright information, 2 Corrective maintenance, 44–46 Cutout switch, low pressure, 28
Deionized water applications, 19 Disclaimer information, 2 Display key, 33 Display readout for mode
settings, 48 Distilled water applications, 18 Down key, 33 Draining, 43
E5CK modes, 47 E5CK operating parameters, 46 E5CK security, 48 Electrical connections, 24, 54 Electrical wiring schematics, 26 Electricals, 30 Expansion tank, 20 External piping sizing
considerations, 16 Fahrenheit to Celsius, 36 General information
Available options, 9–10
Models covered, 8
Necessary documents, 7–8
Standard features, 9 Graphic panel buttons, 33
Heater contactor, 29 Heaters, 28 High-mobility piping
considerations, 18
Identifying controls and displays
Controller internal switches,
35
Identifying controls and features,
27–37 Alarms, 34 Auto-tuning the controller, 36 Communications, 37 Controller display, 31 Controller factory setup, 34,
35 Controller operation, 36 Fahrenheit to Celsius, 36 Graphic panel buttons, 33 Identifying mechanical
controls and features, 27–
31 Microprocessor controller, 31
Identifying mechanical controls
and features, 27–31
Incomplete shipment, 13 Incorrect shipment, 13 Installation information, 16–26
Cooling water connections,
20 Electrical connections, 24 External piping sizing
considerations, 16 High-mobility piping
considerations, 18 Location considerations, 16 Permanent piping
considerations, 17 Process approach
temperature
considerations, 16 Process water connections,
19 Process water
considerations, 18 System purge connections,
21
Location considerations, 16 Low pressure cutout switch, 28
Maintenance
Cleaning and storage, 57 Corrective maintenance, 44–
46
Draining, 43 Electrical connections, 54 Heaters, 46 Motor overload, 55 Periodic checks, 44 Pressure switch, 55 Preventive maintenance, 43 Pumps and seals, 44 Restoring the controller, 46–
54 Safety devices, 55, 54–57 Safety thermostat, 57 Solenoid valves, 46
MANU LED, 32 Microprocessor controller, 31 Models covered, 8
Necessary documents, 7–8 ON/OFF switch, 33
Operation, 40 Options, 9–10 OUT1 LED, 32 OUT2 LED, 32
Periodic checks, 44 Permanent piping
considerations, 17
Pipe sizes for ¾ hp to 7½ hp
units, 17
Pressure drops, 23 Pressure relief valve, 27 Pressure switch, 31 Preventive maintenance, 43 Process approach temperature
considerations, 16
Process temperature factory
setting, 50
Process water connections, 19 Process water considerations,
18
Pump curves
50 Hz pump curves, 23 60 Hz pump curves, 23
Pump starter, 29 Pumps, 28 Pumps and seals, 44 PV LED, 31
Quick Cool button, 34 Raw water treatment, 18
Restoring the controller, 46–54 Returns, 13 RMT LED, 32
Page 66 AEC Water Temperature Control Units
Safety considerations, 3 Safety devices, 54–57 Safety thermostat, 27 Sequence of operation, 41 Setting list for process
temperature controller, 51 Shipping damages, 12 Shipping information
Incomplete shipment, 13
Incorrect shipment, 13
Returns, 13
Shipping damages, 12
Uncrating, 14
Unpacking and inspection, 12 Shock stop, 29 Shutting down the unit, 42 Solenoid valves, 28 Specifications, 11
Standard features, 8–9 Starting the unit, 39 Startup and operation
Checking motor rotation
direction, 42 Operation, 40 Sequence of operation, 41 Shutting down the unit, 42 Starting the unit, 39 Startup checklist, 38
Startup checklist, 38 STOP LED, 32 SUB1 LED, 32 SV LED, 32 System purge connections, 21
TCU drawing, 11 TCU specifications, 11
Thermocouple, 27 Thermostat, 27 To Process thermocouple, 27 Transformer, 29 Troubleshooting, 59–61 Typical piping schematic, 22
Uncrating, 14 Unit drawing, 11 Unpacking and inspection, 12 Up key, 33
Vent button, 34 Water hammer arrestor, 29
AEC Water Temperature Control Units Page 67
Technical Assistance
Parts Department
Call toll-free 7am–5pm CST [800] 423-3183 or call [847] 273-7700, Fax [847] 273-7804 AEC Customer Service Group will provide your company with genui ne OEM quality parts manufactur ed to engineering design specifications, which will maxim ize your equipment’s performance and efficiency. To assist in expediting your phone or fax order, please have the mode l and serial number of your unit when you contact us. A customer replacement parts list is included in this manual for your convenience. AEC welcomes inquiries on all your p arts needs and is dedicated to providing excellent customer service.
Service Department
Call toll-free 8am–5pm CST [800] 233-4819 or call [847] 273-7700 Emergencies after 5pm CST, call [847] 273-7700 We have a qualified service department ready to help. Service contracts are available for most products.
Sales Department
Call [847] 273-7700 Monday–Friday, 8am–5pm CST Our products are sold by a worldwide network of independent sales representatives. Contact our Sales Department for the name of the sales representative nearest you.
Contract Department
Call [847] 273-7700 Monday–Friday, 8am–5pm CST Let us install your system. The Contract Department offers any or all of these services: project planning; system packages including drawings; equipment, labor, and construction materials; and union or non­union installations.
Page 68 AEC Water Temperature Control Units
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