Conair Thermolator TW-1, Thermolator TW-2, Thermolator TW User Manual

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Page 1

Thermolator

TW Series

Water Temperature Control Units

TW, TW-1 and TW-2

Corporate Office: 724.584.5500 | Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861

USER GUIDE UGH025-0504

www.conairgroup.com

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Please record your equipment’s model and serial number(s) and the date you received it in the spaces provided.

It’s a good idea to record the model and serial number(s) of your equipment and the date you received it in the User Guide. Our service department uses this information, along with the manual number, to provide help for the specific equipment you installed.

Please keep this User Guide and all manuals, engineering prints and parts lists together for documentation of your equipment.

Date:

Manual Number: UGH025-0504

Serial Number(s):

Model Number(s):

DISCLAIMER: Conair shall not be liable for errors contained in this User Guide or for incidental, consequential damages in connection with the furnishing, performance or use of this information. Conair makes no warranty of any kind with regard to this information, including, but not limited to the implied warranties of merchantability and fitness for a particular purpose.

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UGH025-0504 Thermolator TW Series

TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . .1-1

Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

How the Guide is Organized . . . . . . . . . . . . . . . . . . . . . . . .1-2

Your Responsibility as a User . . . . . . . . . . . . . . . . . . . . . . . .1-2

ATTENTION: Read this so no one gets hurt . . . . . . . . . . . .1-3

DESCRIPTION . . . . . . . . . . . . . . . . . . . . .2-1

What is the Thermolator? . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

How it Works: Direct Injection . . . . . . . . . . . . . . . . . . . . . . .2-3

How it Works: Closed Circuit . . . . . . . . . . . . . . . . . . . . . . .2-4

How it Works: Isolated Circuit . . . . . . . . . . . . . . . . . . . . . . .2-5

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Features and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

INSTALLATION . . . . . . . . . . . . . . . . . . . . .3-1

Unpacking the Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Connecting Process and Water Supply Lines . . . . . . . . . . . .3-4

Purge Valve Hookups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Connecting the Main Power Supply . . . . . . . . . . . . . . . . . . .3-6

Testing the Installation TW Control . . . . . . . . . . . . . . . . . . .3-7

Testing the Installation TW-1, TW-2 Control . . . . . . . . . . . .3-8

TW Control Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

TW Control Changing Temperature Units . . . . . . . . . . . . .3-10

TW-1, TW-2 Control Initial Setup . . . . . . . . . . . . . . . . . . .3-11

TW-1, TW-2 Control Changing Temperature Units . . . . . .3-12

TW-1, TW-2 Control Passcode Protection . . . . . . . . . . . . .3-13

TW-2 Control Selecting the Temperature Control Point . .3-15 TW-1, TW-2 Control Entering Temperature

Deviation Alarm Parameters . . . . . . . . . . . . . . . . . . . . . .3-17

TW-2 Control Installing the Auto Start Feature . . . . . . . . .3-18

Positioning the TW-2 Control Panel . . . . . . . . . . . . . . . . . .3-20

OPERATION . . . . . . . . . . . . . . . . . . . . . . .4-1

TW Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

TW Control Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

TW-1 Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

TW-2 Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Starting the TW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Stopping the TW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Starting the TW-1, TW-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Stopping the TW-2, TW-2 . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Using the TW Purge Option . . . . . . . . . . . . . . . . . . . . . . . .4-10

Using the TW-1 Purge Option . . . . . . . . . . . . . . . . . . . . . .4-11

Using the TW-2 Purge Option . . . . . . . . . . . . . . . . . . . . . .4-12

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Thermolator TW Series UGH025-0504

TABLE OF CONTENTS

OPERATION . . . . . . . . . . . . . . . . . . . . . .CONT’D

TW Control Performing an Auto Tune . . . . . . . . . . . . . . . .4-13

TW-1, TW-2 Control Performing an Auto Tune . . . . . . . .4-14

TW-1, TW-2 Control Entering Passcodes . . . . . . . . . . . . .4-16

MAINTENANCE . . . . . . . . . . . . . . . . . . . . .5-1

Preventative Maintenance Schedule . . . . . . . . . . . . . . . . . . .5-2

Accessing the Thermolator Enclosure . . . . . . . . . . . . . . . . .5-3

Checking Reservoir Fluid Levels (IC) . . . . . . . . . . . . . . . . .5-4

TW-1, TW-2 Control Performing System Tests . . . . . . . . . .5-5

TW-1, TW-2 Control Key/Display Test . . . . . . . . . . . . . . . .5-6

TW-1, TW-2 Control Input Test . . . . . . . . . . . . . . . . . . . . . .5-7

TW-1, TW-2 Control Output Test . . . . . . . . . . . . . . . . . . . . .5-8

TW-1, TW-2 Control Output Monitors . . . . . . . . . . . . . . . . .5-9

TW-1, TW-2 Control Calibrating Temperature Sensors . . .5-10

TW-1, TW-2 Control Logging Operating Hours . . . . . . . .5-12

TW-1, TW-2 Control Pulse Mode Description . . . . . . . . . .5-13

TW-1, TW-2 Control Pulse Mode Setup . . . . . . . . . . . . . .5-13

TW-1, TW-2 Control Pulse Mode Limits & Defaults . . . .5-14

TW Control Deviation Alarm/Band and Delay . . . . . . . . .5-14

TW-1, TW-2 Control Vent Timer Adjustment . . . . . . . . . .5-15

TROUBLESHOOTING . . . . . . . . . . . . . . . . .6-1

Before Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

A Few Words of Caution . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

Identifying the Cause of a Problem . . . . . . . . . . . . . . . . . . .6-3

TW Control Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

TW Control Mechanical/Electrical Alarms . . . . . . . . . . . .6-11

TW-1, TW-2 Control Shut Down Alarms . . . . . . . . . . . . . .6-12

TW-1, TW-2 Control Warning Alarms . . . . . . . . . . . . . . . .6-13

TW-1, TW-2 Control Other Warnings . . . . . . . . . . . . . . . .6-15

TW-1, TW-2 Control System Alarms . . . . . . . . . . . . . . . . .6-16

Thermolator Will Not Power Up . . . . . . . . . . . . . . . . . . . .6-17

Replacing the TW Control . . . . . . . . . . . . . . . . . . . . . . . . .6-18

Checking and Replacing Fuses . . . . . . . . . . . . . . . . . . . . . .6-19

Resetting Overloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

Replacing Pump Overload . . . . . . . . . . . . . . . . . . . . . . . . .6-20

Replacing the Motherboard TW-1, TW-2 . . . . . . . . . . . . . .6-21

Replacing the Heater Contactor . . . . . . . . . . . . . . . . . . . . .6-22

Checking Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . .6-23

Replacing Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . .6-23

PT1000 Sensor Test Readings TW . . . . . . . . . . . . . . . . . . .6-24

Repairing Cooling Valves . . . . . . . . . . . . . . . . . . . . . . . . . .6-25

Repairing Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . .6-26

Repairing Motorized Valves . . . . . . . . . . . . . . . . . . . . . . . .6-27

Replacing Heater Elements . . . . . . . . . . . . . . . . . . . . . . . . .6-28

Removing the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30

Disassembling and Assembling 3/4 to 2 HP Pumps . . . . .6-31

Disassembling and Assembling 3 to 7.5 HP Pumps . . . . . .6-32

APPENDIX

Customer Service Information . . . . . . . . . . . . . . . . . . . . . . .A-1

Warranty/Guarantee Information . . . . . . . . . . . . . . . . . . . . .A-2

Pump Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

TW Control Default Parameters . . . . . . . . . . . . . . . . . . . . .C-1

TW-1, TW-2 SPI Commands and Status Words . . . . . . . . .D-1

PARTS/DIAGRAMS

TW-1 Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PD-3

TW-2 Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PD-4

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1-1

UGH025-0504 Thermolator TW Series

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

Page 6

Thermolator TW Series UGH025-0504

1-2 INTRODUCTION

This User Guide describes the Conair Thermolator®TW Series water temperature controllers and explains step-by-step how to install, operate, maintain and repair this equipment.

Before installing this product, please take a few moments to read the User Guide and review the diagrams and safety information in the instruction packet. You also should review manuals covering associated equipment in your system. This review won’t take long, and it could save you valuable installation and operating time later.

Symbols have been used to help organize the User Guide and call your attention to important information regarding safe installation and operation.

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

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

A diamond indicates the equipment’s response to an action 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 concerning installation, operation and maintenance of this equipment. Responsible safety procedures include:

l Thorough review of this User Guide, paying particular

attention to hazard warnings, appendices and related diagrams.

l Thorough review of the equipment itself, with careful

attention to voltage requirements, intended uses and warning labels.

l Thorough review of instruction manuals for associated

equipment.

l Step-by-step adherence to instructions outlined in this

User Guide.

PURPOSE OF THE USER GUIDE

HOW THE GUIDE IS ORGANIZED

YOUR RESPONSIBILITY ASAUSER

Page 7

UGH025-0504 Thermolator TW Series

INTRODUCTION 1-3

We design equipment with the user’s safety in mind. You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide.

ATTENTION:

READ THIS SO NO

ONE GETS HURT

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

This equipment should be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation and potential hazards of this type of equipment.

All wiring, disconnects and fuses should be installed by qualified electrical technicians in accordance with electrical codes in your region.

Always maintain a safe ground. A properly sized conductive ground wire from the incoming power supply must be connected to the chassis ground terminal inside the electrical enclosure. Improper grounding can result in personal injury and erratic machine operation.

Do not operate the equipment at power levels other than what is specified on the the equipment serial tag and data plate.

WARNING: Electrical shock hazard

This equipment is powered by three-phase main voltage, as specified on the machine serial tag and data plate.

Always disconnect and lock out the incoming main power source before opening the electrical enclosure or performing non-standard operating procedures, such as troubleshooting or maintenance. Only qualified personnel should perform procedures that require access to the electrical enclosure while power is on.

CAUTION: Hot surfaces

Surface temperatures inside the Thermolator can exceed 250°F (121°C). Always allow the unit to cool to below 100°F (38°C) before opening, servicing or disassembling the unit.

Page 8

WARNING: Hazardous substance

The contactors used in the Thermolator are mercury displacement relays. Mercury is considered a hazardous substance and must be dealt with accordingly. See the Material Safety Data Sheet which explains the potential hazards, how to avoid them and how to clean up and dispose of the mercury if it spills.

ATTENTION:

READ THIS SO NO

ONE GETS HURT

Thermolator TW Series UGH025-0504

1-4 INTRODUCTION

Page 9

2-1

UGH025-0504 Thermolator TW Series

What is the Thermolator

TW Series? . . . . . . . . . . . . . . . .2-2

Typical Applications . . . . . . . . . .2-2

How it Works:

Direct Injection (DI) Models . . .2-3

How it Works:

Closed Circuit (CC) Models . . . .2-4

How it Works:

Isolated Circuit (IC) Models . . . .2-5

Specifications . . . . . . . . . . . . . . .2-6

Features and Options . . . . . . . . .2-8

DESCRIPTION

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The Thermolator TW models circulate water at a temperature higher than the available water supply, to add or remove heat as needed to maintain a uniform temperature setpoint in the process. Conair TW Thermolators are available in single or dual-zone configurations, using resistance heating and direct injection or closed circuit cooling. Dual-zone models can control at two different temperatures at different locations in the process. Two-zone models have common cooling water manifolds and electrical connections.

WHAT IS THE THERMOLATOR?

Thermolator TW Series UGH025-0504

2-2 DESCRIPTION

TYPICAL APPLICATIONS

IMPORTANT: Do not use

deionized water or glycol mixtures containing additives in a Thermolator. Softened water or glycol mixtures with additives, such as automotive fluids, can damage the Thermolator. Glycol/water process loop mixtures should use industrial-grade ethylene glycol only.

The best model for your application depends on the process temperature you need to maintain and the quality of the cooling water supply.

Direct injection (DI) models control the temperature by discharging heated process water and adding cooling water directly from the water supply. DI models are designed for:

l Process temperatures up to 250°F (121°C). l Use with chiller water or properly treated and filtered

tower or city water.

Closed circuit (CC) models add cooling water to the process loop only during the initial filling or when make-up water is needed. CC models are recommended for:

l Process temperatures up to 250°F (121°C). l Use with contaminated cooling water.

Isolated circuit (IC) models separate the cooling water from the process fluid, which is held in a reservoir. IC models are recommended for:

l Process temperatures up to 180°F (82°C). l Use with contaminated cooling water. l When process and cooling fluids are different.

Page 11

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

HOW IT WORKS: D

IRECT INJECTION

UGH025-0504 Thermolator TW Series

DESCRIPTION 2-3

The temperature of the process fluid is measured as it leaves the unit’s heater tank. The fluid then flows through the “To Process” line to the mold or process. The fluid returns to the unit through the “From Process” line for reheating or cooling.

If the process temperature is below the setpoint, the heater elements inside the heater tank are energized.

The pump moves water from the mixing tank to the heater tank. Pressure is measured before and after the pump .

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

The temperature of the process fluid is measured as it flows into the mixing tank through the “From Process” line .

If the average temperature is above the setpoint value, the cooling valve opens. Cool water enters the bottom of the mixing tank via the “Cooling In” line . Warm water flows out through the “Cooling Out” line .

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HOW IT WORKS: C

LOSED CIRCUIT

Thermolator TW Series UGH025-0504

2-4 DESCRIPTION

If the process temperature is below the setpoint, the heater elements inside the heater tank are energized.

The pump moves water from the mixing tank to the heater tank. Pressure is measured before and after the pump .

The temperature of the process fluid is measured as it flows into the cooling tank through the “From Process” line .

If the temperature is above the setpoint value, the cooling valve opens. Cool water enters the cooling piping and circulates through a tube heat exchanger to cool the process fluid. The cooling valve allows warm fluid to escape through the “Cooling Out” line .

Closed Circuit models maintain the process temperature by electrically heating and indirectly cooling fluid in the process circuit. Cooling water supplied by a chiller, tower or other water source, is mixed with the process fluid only during the initial filling or when water is needed to make up process fluid loss.

Page 13

HOW IT WORKS: I

SOLATED CIRCUIT

UGH025-0504 Thermolator TW Series

DESCRIPTION 2-5

Isolated Circuit models maintain the process temperature by electrically heating and indirectly cooling fluid in the process circuit. The process fluid, which is stored in a reservoir, is isolated from cooling water supplied by a chiller, tower or other source.

If the process temperature is below the setpoint, the heater elements inside the heater tank are energized.

The pump moves water from the mixing tank to the heater tank. Pressure is measured after the pump .

The temperature of the process fluid is measured as it flows into the cooling tank through the “From Process” line .

If the temperature is above the setpoint value, the cooling valve opens. Cool water enters the cooling piping and circulates through a tube heat exchanger to cool the process fluid.

The vent line allows warm process fluid to expand to the reservoir . The reservoir supplies process fluid through a make-up line as needed.

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SPECIFICATIONS

Thermolator TW Series UGH025-0504

2-6 DESCRIPTION

CABINET STYLE REFERENCE

Heater Voltage Selection Single Zone Dual Zone

Direct Injection (DI)

9, 12, 18 or 24 kW 208, 230, 460, 575 A B 36 kW 230 C D 36 kW 460 or 575 A B 48 kW 230, 460, 575 C D Closed Circuit (CC) 9 or 12 kW 208, 230, 460, 575 A B 18 or 24 kW 208, 230, 460, 575 C D Isolated Circuit (IC) 9, 12, 18 or 24 kW 208, 230, 460, 575 C D

Dimensions and performance characteristics vary according to the model, voltage and components selected. See the cabinet style reference chart to determine dimensional information for your specific model. Additional technical information can be found in the Appendix of this User Guide.

Height

Width

Single Zone

Width

2- Zone

Depth

Width

Single Zone

Width

2- Zone

Height

Depth

NOTE: Dual zone models have common wiring and cooling water plumbing.

WATER CONNECTIONS

All models NPT inches (female)

To/From process 1.25 Cooling water in/out 0.75

Page 15

SPECIFICATIONS

UGH025-0504 Thermolator TW Series

DESCRIPTION 2-7

Direct Injection (DI) Closed Circuit (CC) Isolated Circuit (IC)

PERFORMANCE CHARACTERISTICS -

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

Models TW-DI TW-CC TW-IC

Minimum Setpoint Temperature °F {°C} 32 {0} 32 {0} 32 {0}

Maximum Setpoint Temperature °F {°C} 250 {121} 250 {121} 180 {82} Minimum Operating Temperature °F {°C} Approximately 20° {11°} above the cooling water inlet temperature* Standard Cooling Valve Size inches {mm} 1/4 {6.35} 3/4 {19.05} 3/4 {19.05} 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 or 48 kW 9, 12, 18 or 24 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/cm

} 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 48 kW

Voltage

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

Pump

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 25.6 1 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 25.8 2 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 26.6 3 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 27.7 5 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 29.0

7.5 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 and cooling type (DI, CC or IC).

Single Zone Dual Zone

Pump Min Max Min Max

0.75 HP {0.56 kW} 240 {109} 300 {136} 480 {218} 600 {272} 1 HP {0.75 kW} 240 {109} 300 {136} 480 {218} 600 {272} 2 HP {1.49 kW} 250 {113} 310 {141} 500 {226} 620 {282} 3 HP {2.24 kW} 260 {118} 320 {145} 520 {236} 640 {290} 5 HP {3.73 kW} 270 {122} 330 {150} 540 {244} 660 {300}

7.5 HP {5.59 kW} 280 {127} 340 {154} 560 {254} 680 {308}

DIMENSIONS in. {mm} Cabinet Style A B C D

Height 28.0 {710} 28.0 {710} 43.0 {1090} 43.0 {1090} Depth 22.5 {570} 22.5 {570} 31.5 {800} 31.5 {800} Width 13.75 {350} 27.5 {700} 14.0 {355} 28.0 {710}

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

104.0 94.0 47.0 37.6 137.0 124.0 62.1 49.7

104.3 94.4 47.2 37.8 137.7 124.6 62.3 49.6

106.7 96.6 48.3 38.6 140 126.8 63.4 50.7

109.6 99.2 49.6 39.7 143 129.4 64.7 51.8

113.4 102.6 51.3 41.0 146.7 132.8 66.4 53.1

120.7 109.2 54.6 43.7 154 139.4 69.7 55.8

MODEL DESIGNATIONS

TOTAL FULL LOAD AMPS PER ZONE All voltages are 3 phase, 60 Hz. Heater 0 heaters Voltage 208V 230V 460V 575V Pump

0.75 HP {0.56 kW} 3.9 3.6 2.3 1.5 1 HP {0.75 kW} 4.4 4.0 2.5 1.6 2 HP {1.49 kW} 6.8 6.2 3.6 2.5 3 HP {2.24 kW} 9.7 8.8 4.9 3.6 5 HP {3.73 kW} 13.5 12.2 6.6 4.9

7.5 HP {5.59 kW} 20.7 18.8 9.9 7.6

NOTE: Thermolators can be ordered without heaters for certain applications.

Page 16

High efficiency pumps

from 3/4 to 7.5 Hp. Silicon carbide seals are standard.

Pump seal flush line

continuously cleans the pump seal for extended life.

Incoloy heaters

minimize chemical and high temperature damage

Built-in sediment trap

settles contaminants away from the pump seals.

Motor drip cover

protects motor windings from moisture damage.

Two-piece cast construction

Alarm packages

Add an audible or visual alarm to call attention to alarm conditions.

Motorized Cooling Valve

Slow open/close cycle time eliminates thermal shock and water hammer from your process circuit.

Compressed Air Mold Purge

Quickly evacuates fluid from the process circuit, allowing for faster, cleaner disconnection of the temperature controller from molds and hoses.

Stacking Rack

Save floor space by stacking Thermolators two-high. The stacking rack can be used only with single-zone models in 28-inch high cabinets.

OPTIONS

Thermolator TW Series UGH025-0504

2-8 DESCRIPTION

FEATURES AND OPTIONS

Page 17

3-1

UGH025-0504 Thermolator TW Series

Unpacking the Boxes . . . . . . . . . . . . .3-2

Preparing for Installation . . . . . . . . . .3-3

Connecting Process and

Water Supply Lines . . . . . . . . . . . . .3-4

purge Valve Hookups . . . . . . . . . . . . .3-5

Connecting the Main Power . . . . . . . .3-6

Testing the Installation TW Control .3-7

Testing the Installation

TW-1, TW-2 Controls . . . . . . . . . . . .3-8

TW Control Initial Setup . . . . . . . . . . .3-9

TW Control Changing

Temperature Units . . . . . . . . . . . . .3-10

TW-1, TW-2 Control Initial Setup . . .3-11

TW-1, TW-2 Control Changing

Temperature Units . . . . . . . . . . . . .3-12

TW-1, TW-2 Control Enabling and

Disabling Passcode Protection . . . .3-13

TW-2 Selecting the Temperature

Control Point . . . . . . . . . . . . . . . . .3-15

TW-1, TW-2 Control Entering

Temperature Deviation Alarm

Parameters . . . . . . . . . . . . . . . . . . . . .3-17

TW-2 Control Installing the

Auto Start Feature . . . . . . . . . . . . .3-18

Positioning the TW-2

Control Panel . . . . . . . . . . . . . . . . .3-20

INSTALLATION

Page 18

UNPACKING THE BOXES

Thermolator TW Series UGH025-0504

3-2 INSTALLATION

Carefully remove the Thermolator and

components from their shipping containers.

Remove all packing material, protective

paper, tape and plastic. Check inside the electrical enclosure and behind the side panels for accessories or hardware that may have been placed there for shipping.

Carefully inspect all components to make sure

no damage occurred during shipping, and that you have all the necessary hardware. If damage is found, notify the freight company immediately.

Take a moment to record serial numbers and

specifications in the blanks provided on the back of the User Guide’s title page. The information will be helpful if you ever need service or parts.

You are now ready to begin installation.

Complete the preparation steps on the next page.

Thermolator

Thermolator TW models come fully assembled. If they were specified at the time of the order, the purge valve or motorized cooling valve is factory-installed.

Page 19

UGH025-0504 Thermolator TW Series

INSTALLATION 3-3

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

Position the Thermolator as close to the

process machine as possible.

Make sure the installation area provides:

r A three-phase power source supplying the correct

current for your Thermolator model. Check the serial tag on the side of the electrical enclosure for the required voltage, phase, frequency, full load amps, disconnect fuse size and minimum wire connection size. Field wiring should be completed by qualified personnel to the planned location for the Thermolator. All electrical wiring should comply with your region’s electrical codes.

r A clean, well-ventilated environment.

The room temperature should not exceed 120°F (48°C) with 95% non-condensing humidity and should not fall below 32°F (0°C).

r Minimum clearance for safe operation and main- tenance. The diagram at right shows minimum clearance for operation. You also need enough clearance in the rear for water hookups. For maintenance, you should move the Thermolator to provide at least 36 inches on any side of the Thermolator.

r A source of water for cooling.

City, tower or chiller water may be used. The minimum supply pressure is 25 psi and the maximum pressure is shown in the following chart.

Install plumbing for process and cooling lines.

You will need two 1

-inch NPT male fittings for the process inlet and outlet and two 3/4-inch NPT male fittings for the cooling inlet and outlet. Larger line sizes are acceptable as long as they are reduced at the Thermolator connections. Smaller line sizes are not recommended.

PREPARING FOR INSTALLATION

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Thermolator

Alternate locations

12 inches

(305 mm)

12 inches

(305 mm)

20 inches (508 mm)

Pump HP Max Cooling

3/4 HP 95 PSI 1 85 2 70 3 70 5 60

Page 20

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

Remove the shipping pipe plug from the

female connections on the back of the Thermolator.

Install pipe to the rear of the Thermolator.

Use male 1

-inch NPT piping for process connections

and male

inch NPT piping for water connections. Pipe and pipe threads must be clean and new. Clean threads with solvent, removing all oil, grease and dirt. Allow the threads to dry before proceeding.

Coat the pipe threads with thread sealant.

Follow the sealant manufacturer’s directions.

Connect the male pipe to the appropriate

female connection on the back of the unit. Start by hand until the threads engage, then use a pipe wrench to tighten the connection only enough to prevent leaks. Do not overtighten!

CONNECTING PROCESS AND WATER SUPPLY LINES

Thermolator TW Series UGH025-0504

3-4 INSTALLATION

Tools for installation:

r Pipe wrench large enough

for a 2-inch pipe

r Premium quality Teflon

thread sealant

NOTE: We recommend that you install an external ball valve on the cooling water inlet of the Thermolator. This valve is required when the purge valve option is installed.

From

process

From

process

Cooling water out

Cooling water in

DIRECT INJECTION

CLOSED CIRCUIT

ISOLATED CIRCUIT

(BUT IN TALL CABINET)

Cooling water out

Page 21

A purge valve is available as an option on Direct Injection and Closed Circuit units only. This valve quickly evacuates fluid from the process circuit, allowing faster disconnection of the temperature controller from molds and hoses. An optional manual purge button controls this valve on models with TW or TW-1 controls. There is a built-in purge button on the TW2 control panel.

If this option is ordered with the Thermolator, purge control wiring and installation of the valve on the process line outlet of the unit is completed at the factory. You still must connect process and cooling water inlets and outlets, as well as a supply of non-lubricated compressed air.

Remove the shipping pipe plug from the

female connections on the back of the Thermolator.

Install an external ball valve on the cooling

water inlet of the Thermolator. This valve is required when a purge valve is used.

Install pipe to the rear of the Thermolator.

Use male 1

-inch NPT piping for process connections

and male

inch NPT piping for water connections. Pipe and pipe threads must be clean and new. Clean threads with solvent, removing all oil, grease and dirt. Allow the threads to dry before proceeding.

Coat the pipe threads with thread sealant.

Follow the sealant manufacturer’s directions.

Connect the male pipe to the appropriate

female connection on the back of the unit. Connect cooling water lines as indicated on the previous page. Connect process lines as indicated below. Start by hand until the threads engage, then use a pipe wrench to tighten the connection only enough to prevent leaks. Do not over-tighten!

Connect the purge

valve to the compressed air supply. The air pressure should not exceed 100 psi.

UGH025-0504 Thermolator TW Series

PURGE VALVE HOOKUPS

INSTALLATION 3-5

From

process

Compressed air

fitting

Page 22

Thermolator TW Series UGH025-0504

Before beginning, note the electrical specifications on the nameplate mounted to the side of the unit. The electrical

hookup must match these specifications with +/- 10% maximum voltage variance. An improper power supply could damage the unit as well as seriously injure an operator.

The electrical hookup also should run through a fused disconnect sized for the nameplate amperage and conforming to Article 250 of the National Electrical Code.

Open the unit’s electrical enclosure.

Insert the main power wire through the

knockout hole in the right side of the enclosure.

Secure the power wire with a rubber

compression fitting or strain relief.

Connect the power wires to the terminals.

Connect the three hot wires to L1, L2, and L3 on the terminal block.

Connect the ground

wire to the copper grounding mount. If you have installed a disconnect device, follow the manufacturer’s wiring instructions.

CONNECTING THE MAIN POWER SUPPLY

3-6 INSTALLATION

WARNING: Electrical shock hazard

This equipment is powered by three-phase main voltage. Always disconnect and lock out the main power source before performing any work involving electrical connections. All wiring, disconnects and fusing should conform to your region’s electrical codes and should be installed only by qualified personnel.

IMPORTANT: Always refer to the wiring diagrams that came with your temperature control unit before making electrical connections. The diagrams show the most accurate electrical component information.

IMPORTANT! Before initiating power to the unit:

r Check the system for leaks. r Verify that the voltage, phase,

frequency, amperage, disconnect fuse and minimum wire size meet the specifications stated on the nameplate mounted on the side of the unit.

r Verify that resistance to ground on

each phase is at least 1 meg ohm.

Page 23

UGH025-0504 Thermolator TW Series

INSTALLATION 3-7

Turn on the cooling water supply and check

for leaks. If any leaks appear, stop the test and fix the problem before continuing. The cooling water must be at least 25 PSI or the unit will not function.

Apply power to the unit.

Check the rotation of the pump.

Remove the top access panel and the pump motor drip cover. Press and hold the START button until the pump starts. Quickly press Pump STOP button; verify that the pump rotation matches the direction indicated on the rotation sticker on top of the pump.

Replace the drip cover and top access panel.

Press and hold the START button until the

vent cycle starts. If everything is working correctly:

u The START button lights. u The unit initiates a venting sequence. Cooling and

venting valves are active for the first half of the sequence. The pump is active for the final half of the sequence. Indicator lights energize when the device is active.

u Normal operation begins. The heater turns on if the

actual temperature is below setpoint. The cooling valve opens if the actual temperature is above setpoint.

The test is over. If testing proceeded normally follow the remaining Installation steps for the TW Control. Otherwise refer to the Troubleshooting section.

TESTING THE INSTALLATION TW CONTROL

4 5

WARNING: Only qualified personnel should perform this procedure.

Parts of this test requires opening the unit while it is energized. Only qualified personnel who have been trained in the use of electrical testing devices and in avoiding the safety hazards involved in safely troubleshooting this type of equipment should perform this test procedure.

NOTE: If the rotation is incorrect, stop the test and disconnect power to the unit. Open the electrical enclosure and switch any two of the three power source wires on the terminal block. Return to Step 2 and check rotation again.

Page 24

TESTING THE INSTALLATION TW-1, TW-2 C

ONTROLS

Thermolator TW Series UGH025-0504

3-8 INSTALLATION

WARNING: Only qualified personnel should perform this procedure.

Turn on the cooling water supply and check

for leaks. If any leaks appear, stop the test and fix the problem before continuing. The cooling water must be at least 25 PSI or the unit will not function. The LOW WATER PRESSURE light will come on when power is applied. The light goes off when the pressure is adequate.

Apply power to the unit.

u Indicator lights on the control panel blink green, then

red, to test operation of the LEDs.

u Setpoint and actual windows display 888 for three sec-

onds, followed by the software version. The windows then display the factory default setpoint of 100°F and the actual temperature.

Check the rotation of the pump.

Remove the top access panel and the pump motor drip cover. Press the Run button until the pump starts. Quickly press Pump Stop button; verify that the pump rotation matches the direction indicated on the rotation sticker on top of the pump.

Replace the drip cover and top access panel.

Press the Run button to start the unit.

If everything is working correctly:

u The Run/Stop light turns green. u The unit initiates a venting sequence. Cooling and

venting valves are active for the first half of the sequence. The pump is active for the final half of the sequence. Indicator lights energize when the device is active.

u Normal operation begins. The heater turns on if the

actual temperature is below setpoint. The cooling valve opens if the actual temperature is above setpoint.

The test is over. If testing proceeded normally follow the remaining Installation steps for the TW-1, TW-2 Controls. Otherwise refer to the Troubleshooting section.

4 5

NOTE: If the rotation is incor-

rect, stop the test and disconnect power to the unit. Open the electrical enclosure and switch any two of the three power source wires on the terminal block. Return to Step 2 and check rotation again.

Page 25

UGH025-0504 Thermolator TW Series

INSTALLATION 3-9

TW CONTROL INITIAL SETUP

Menus on the Controller:

The controller has information available in 5 areas. Four of them are user accessible. These are: the Main Menu, the Setpoint Menu, the Configuration menu and the Alarm Page. The service page also has additional parameters that are accessible in cases of need.

Relaying Control information via three modes:

The controller relays information via three modes.

1. The status lights indicate the state of the machine and its control components. In the thermolator these are Pump, Heater and Cooling valve.

2. The digital indication of the process in temperatures and times.

3. The alpha abbreviation of the process parameters to isolate the variables and the alarms from each other.

Main Menu

The main menu is the normal operating page. The controller always defaults to this page after a certain amount of inactivity (buttons being pushed). The first screen is the process variable. This is a user selectable parameter and could be the to process, from process or an average temperature. The rest of the variables are accessed in a circular queue using only the up and down arrow keys.

The parameters include:

Process Variable- in the units selected on the Configuration

page. This parameter has its decimal fixed to whole numbers only.

Machine State - For the thermolator this is on/off. The To Process temperature - in units selected as above. This

parameter has its decimal fixed at 0.1º The From Process temperature - in units selected above. This parameter has its decimal fixed at 0.1º

There are two additional temperature indicators available for the thermolator and must be purchased separately. If installed they will indicate only the temperature of the media to which they are exposed. These were intended to display condensing media temperature to the thermolator operator however they could display any temperature in the operating range of 0-250ºF. These temperature displays are also shown as whole numbers.

Page 26

Thermolator TW Series UGH025-0504

3-10 INSTALLATION

TW CONTROL CHANGING TEMPERATURE UNITS

Press the Enter key unit the default configuration page UN is displayed.

Press Enter again to show ºC or ºF.

Toggle between the up/down to select your desired units.

Press Enter to accept the units.

The Temperature units parameter allows selection of the displayed temperature units. The available selection is either degrees Celsius or Fahrenheit. ºC or ºF depicts this.

2 3

Page 27

UGH025-0504 Thermolator TW Series

INSTALLATION 3-11

TW-1, TW-2 C

ONTROL

INITIAL SETUP

NOTE: All dip switch illustra-

tions in this manual show switches 7 and 8 set to ON. If you have an Isolated Circuit model, these switches should be set to OFF. Do not change the factory settings of these dip switches.

The factory-set parameters and operating modes will satisfy most applications. But you can change some settings and enable or disable features as needed.

You can modify the parameters for high and low process temperature deviation warnings from the control panel. See

Setting Setpoint Deviation Parameters, Section 3.

Dip switches on the TW-1 and TW-2 motherboard inside the electrical enclosure allow you to:

r Select the units of measure for tem-

perature displays.

r Enable password protection. r Enable the Auto Tune. r Enable the Auto Start feature. r Enable the Test Mode. r Select the source point of tempera-

ture control.

To change the dip switch settings, see the appropriate topic on the following pages.

876

54321

Dipswitch Configuration

No. OFF ON

1 Display units in °F Display units °C 2 Auto Tune disabled Auto Tune enabled 3 Passcode protect Password reset/modify 4 * Auto Start disabled Auto Start enabled 5 * Control point protect Control point source select 6 Test Mode disabled Test mode enabled 7 † Controller type selection Controller type selection 8 † Controller type selection Controller type selection

* Available only on TW-2 models. † Switches 7 and 8 must be ON for Direct Injection and Closed Circuit

models. Switches 7 and 8 must be OFF for Isolated Circuit models. Do not change these settings.

WARNING: Electric shock hazard

This equipment is powered by high voltage. Always disconnect and lock out the main power source before opening the unit or the electrical enclosure to modify factory settings. Failure to disconnect and lock out the main power source can result in severe personal injury.

Page 28

Thermolator TW Series UGH025-0504

3-12 INSTALLATION

TW-1, TW-2 C

ONTROL

CHANGING TEMPERATURE UNITS

NOTE: All dip switch illustra-

tions in this manual show switches 7 and 8 set to ON. If you have an Isolated Circuit model, these switches should be set to OFF.

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

When the Thermolator is on, the indicator lights to the right of the Actual temperature display on the control panel will show which temperature unit has been set.

To change this setting, move Dip Switch 1 on the control circuit board.

Disconnect and lock out main power to the

Thermolator.

Open the electrical enclosure.

Change Dip Switch 1 to:

OFF for °F ON for °C

Close the electrical enclosure and restore

main power to begin operating.

876

54321

2 3

876

54321

WARNING: Electric shock hazard

Page 29

UGH025-0504 Thermolator TW Series

INSTALLATION 3-13

TW-1, TW-2 C

ONTROL

ENABLING AND DISABLING PASSCODE PROTECTION

NOTE: All dip switch illustra-

tions in this manual show switches 7 and 8 set to ON. If you have an Isolated Circuit model, these switches should be set to OFF.

The TW-1 and TW-2 controls provide the ability to protect system parameters from unauthorized changes during normal operating mode. When system passcode protection is enabled, the following parameters cannot be changed unless you enter the correct passcode:

l The Process Setpoint l High Deviation Alarm Setpoint l Low Deviation Alarm Setpoint l Baud Rate selection for serial communications l Address selection for serial communications

When the unit is turned on for the first time, passcode protection is disabled. To enable passcode protection:

Disconnect and lock out main power to

the unit.

Open the electrical enclosure.

Set dip switch 3 to ON

and switches 5 and 6 to OFF.

Close the electrical enclosure and restore

power to the unit.

Press any

button when the control displays “Pas rSt” (Passcode Reset). The control will display the last passcode used.

Select a new passcode using the s and t

setpoint adjustment buttons. Stop pressing the setpoint buttons when the passcode you want appears in the setpoint display window. Selecting “OFF” as the passcode will disable the passcode feature.

WARNING: Electric shock hazard

2 3

876543

Continued

Page 30

Thermolator TW Series UGH025-0504

3-14 INSTALLATION

Press the RUN button to save the passcode.

The control will display “Pr OFF” to prompt you to

remove power to the unit.

IMPORTANT: If RUN is not pressed, the new passcode will not be saved.

Turn off power to the unit. Disconnect and

lock out the main power supply.

Open the electrical

enclosure.

Set dip switch 3 to

OFF.

Close the electrical enclosure and restore

power to the unit. A passcode now is required to change system parameters.

Disabling Passcode Protection

To disable passcode protection and allow universal access to system parameters:

Follow Steps 1

through 5 in the previous section on enabling passcode protection.

Hold down the t setpoint adjustment button

to select “OFF” as the new passcode.

Follow steps 7 through 11, above.

TW-1, TW-2 C

ONTROL

ENABLING AND DISABLING PASSCODE PROTECTION

CONTINUED

876543

Page 31

UGH025-0504 Thermolator TW Series

INSTALLATION 3-15

TW-2 CONTROL SELECTING THE TEMPERATURE CONTROL POINT

NOTE: All dip switch illustra-

tions in this manual show switches 7 and 8 set to ON. If you have an Isolated Circuit model, these switches should be set to OFF.

TW-1 controls the process temperature based upon the average of the temperatures recorded at the supply (to process) and return (from process) thermocouples.

TW-2 allows you to select how the unit will measure and control the process temperature. The control point can be selected as the supply, the return or the average of the the two temperatures.

To select the control point source on TW-2 models:

Disconnect and lockout power to the unit.

Open the electrical enclosure.

Set dip switches 3 and

6 to the OFF position.

Set dip switch 5 to the

ON position.

Close the electrical enclosure and restore

power to the unit.

Press any button when the control displays

“Cnt Pt”. The controller displays “Sel CnP” and flashes the LED for the current control point.

Select a new control point using the Display

button. Stop pressing the select button until the indicator light next to the control point you want illuminates.

2 3

WARNING: Electric shock hazard

876543

Continued

Page 32

Thermolator TW Series UGH025-0504

3-16 INSTALLATION

Press the RUN button to save the control

point.

The control will display “Pr OFF” to prompt you to

remove power to the unit.

IMPORTANT: If RUN is not pressed, the new control point source will not be saved.

Turn off power to the unit.

Disconnect and lock out the main power supply.

Open the electrical

enclosure.

Set dip switch 5 to OFF.

Close the electrical enclosure and restore

power to the unit. The TW-2 will now control the process temperature based on actual temperatures recorded at the new control point source.

876

54321

TW-2 CONTROL SELECTING THE TEMPERATURE CONTROL POINT

CONTINUED

Page 33

UGH025-0504 Thermolator TW Series

INSTALLATION 3-17

TW-1, TW-2 C

ONTROL

ENTERING TEMPERATURE DEVIATION ALARM PARAMETERS

You can establish a normal operating range around the process temperature setpoint using the high and low deviation parameters. If the process temperature exceeds the high deviation limit, or falls below the low deviation limit for longer than the set delay time, the Thermolator alerts you to the unacceptable temperature variation with an alarm light, and optional audible or strobe.

These temperature deviation limits will adjust automatically relative to the process temperature setpoint.

The factory default setting for both the high and low deviation parameters is 25°F. These parameters are adjustable to establish a narrower or wider acceptable temperature band for normal operation.

To change the temperature deviation settings:

Press the Setpoint Select

button to select the deviation parameter you want to change.

Use the s and t setpoint

buttons to enter the deviation temperature. The setting is stored in memory even when the power is turned off. The recommended setting is ± 2-10°F.

NOTE: If you enabled passcode protection, you must enter

the passcode to change this parameter. To enter the passcode:

Hold down the Setpoint Select button for 5 seconds. When the control displays “ 1 PaS”, use the setpoint adjustment buttons to enter the passcode. Press the Setpoint Select button again. If the correct passcode was entered the controller will display ACC PAS for 3 seconds. If the passcode was incorrect, the controller will display rEJ PAS (rejected passcode).

Access to system parameters remain until power is cycled or the RUN or STOP button is pressed.

Page 34

Thermolator TW Series UGH025-0504

3-18 INSTALLATION

TW-2 CONTROL INSTALLING THE AUTO START FEATURE

If you have a TW-2 model, you can automatically start and stop the Thermolator from a remote switching or timing device that has power contacts rated 110VAC, such as the process machine control.

Wiring the device to the Thermolator is accomplished through a dry contact to the appropriate terminals on the motherboard. After wiring the device to the unit, Auto Start must be enabled by configuring a dip switch on the motherboard.

Disconnect and lockout power to the unit.

Open the electrical enclosure.

Punch a small hole in the left side of the

electrical enclosure. The hole must be large enough to accommodate conduit for the power contact wires from your switching or timing device.

Insert the two power leads from the device

through the conduit into the electrical enclosure.

Connect the 110VAC device contact wires to

the Auto Start terminals. Make sure terminals are screwed tight.

1 2 3

AC IN 4

AC IN + 3

AC OUT 2

AC OUT + 1

LLS/WPS

AUTOSTART

HPS/LPS

OPS

FSTAT

65432

432

WARNING: Electric shock hazard

Device contacts

IMPORTANT: Always

refer to the wiring diagrams that came with your temperature control unit before making electrical connections. The diagrams show the most accurate electrical component information.

Page 35

UGH025-0504 Thermolator TW Series

INSTALLATION 3-19

TW-2 CONTROL INSTALLING THE AUTO START FEATURE

NOTE: All dip switch illus-

trations in this manual show switches 7 and 8 set to ON. If you have an Isolated Circuit model, these switches should be set to OFF.

Set dip switch 4 to the

ON position.

Close the electrical

enclosure and restore power to the unit.

When Auto Start is enabled:

u The Auto Start indicator light flashes to indicate that the

Thermolator can start at any time. The Thermolator will start whenever the remote switching or timing device sends a signal to start processing.

u The Auto Start indicator light is on whenever the

Thermolator is under the control of the remote device.

To disable Auto Start:

Repeat steps 1, 2 and 7, setting dip switch 4 to the OFF position instead of the ON position.

876

54321

Page 36

Thermolator TW-1 and TW-2 UGH015/0100

POSITIONING

THE

TW-2

ONTROL

PANEL

The TW-2 control panel can be mounted up to 50 feet from the unit, using a remote control cable and the magnets on the back of the panel.

Do not stretch the cable. The cable is available in 30 and 50 foot lengths so that you can order the appropriate cable for your installation.

To detach the TW-2 control panel:

Grasp the black control panel handles and pull upward.

Use the magnetic back to mount the control panel in the remote location. Connect the remotemounted control to the unit with the cable provided.

CAUTION: Improper handling of the con-

trol panel can damage the unit.

DO NOT mount the detached TW-2 control panel

to a hot surface.

3-20 INSTALLATION

Page 37

4-1

UGH025-0504 Thermolator TW Series

TW Control Features . . . . . . . . . .4-2

TW Control Menu . . . . . . . . . . . .4-3

TW-1 Control Features . . . . . . . .4-4

TW-2 Control Features . . . . . . . .4-5

Starting the TW . . . . . . . . . . . . . .4-6

Stopping the TW . . . . . . . . . . . . .4-7

Starting the TW-1, TW-2 . . . . . . .4-8

Stopping the TW-1, TW-2 . . . . . .4-9

Using the TW Manual Purge

Option . . . . . . . . . . . . . . . . . . . .4-10

Using the TW-1 Manual Purge

Option . . . . . . . . . . . . . . . . . . . .4-11

Using the TW-2 Purge Feature 4-12

TW Control Performing

an Auto Tune . . . . . . . . . . . . . .4-13

TW-1, TW-2 Control Performing

an Auto Tune . . . . . . . . . . . . . .4-14

TW-1, TW-2 Control Entering

Passcodes . . . . . . . . . . . . . . . .4-16

OPERATION

Page 38

Thermolator TW Series UGH025-0504

4-2 OPERATION

TW CONTROL FEATURES

Enter

Press to enter or change setpoint, and to index to the next menu.

Raise Button

Increases values, and steps up through menus.

Lower Button

Decreases values; and steps down through menus.

Display

3-digit screen shows Process temperature, Alpha Alarms and Operation indicators. Indicator light shows hot gas unloading.

Alarm Codes

Informs user of types of alarms

3-Digit Alpha/numeric display for temperatures and alarms

On/Off Button

Powers on/off the chiller

Main Menu

Contents

Setpoint Procedure

Status Lights

For Pump, Heater and Cooling Valve

Page 39

UGH025-0504 Thermolator TW Series

OPERATION 4-3

TW CONTROL MENU

The TW temperature controller uses a menu system to access different operating modes or change system parameters. Please see the Appendix for default parameter settings and detailed information on each of these modes and parameters

Parameter Menus

Temperature Units. Allows selection of the displayed

temperature units. Process Variable. Allows the operator to select the controlled temperature from the following: To Process, From Process and Average.

Tuning the Thermolator. The controller has three preconfigured tuning parameter sets, one of which should allow optimum temperature control.

Control. Used to select parameters associated with control methods.

Alarm. Used to select alarm parameters.

Vent Time 1. Cooling Valve on.

Vent Time 2. Cooling valve with pump on.

Alarm Acknowledge timer. Sets the time that an

alarm can be acknowledged and silenced without being satisfied.

Software Version. This “read only” parameter depicts the version of software that has been downloaded into the controller.

PUS

Uni

DSP

PIT

VT1

DDT

AAT

VT2

T01

Press and hold for five seconds to access the menus

Press to index through the menus.

Press to index through parameters under each menu item.

Page 40

All normal operating functions can be controlled from the TW-1 control panel. If you have the optional manual mold purge, the control switch is located on the side of the Thermolator electrical enclosure.

TW-1 CONTROL FEATURES

Thermolator TW Series UGH025-0504

4-4 OPERATION

Setpoint adjustment buttons

Press s or t to enter the process temperature setpoint, SPI parameters and passcodes.

Press s to increase a value. Press t to decrease a value.

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

NOTE: Passcode protection prevents accidental or unauthorized changes to all operating parameters. If passcode protection has been enabled, you must enter the correct passcode to change the process temperature setpoint.

Actual values display

The green window displays the temperature at the middle of the mold. This temperature is calculated as an average of the temperatures of the supply water and return water.

The lights indicate whether the temperature is in degrees Fahrenheit or Celsius. See

Installation, section 3 for instructions on how to change the temperature units.

Setpoint display

The Setpoint display shows the setpoints entered for fluid temperature, high and low temperature deviation alarms, the SPI baud rate, and the SPI address.

Setpoint and Actual value display windows also display some alarm codes and setup instructions.

Run/Stop

Press RUN button to start normal operation. Press STOP to stop the temperature control unit.

= Running (green)

= Stopped (red)

= Alarm (red, flashing)

Status lights

The lights indicate the operating status of the listed components. Except in Test Mode, the lights indicate:

= Off or inactive = On or active (green) = Alarm condition (red)

Test Mode is used for testing displays, keys and input/output functions. When test mode is enabled, normal operation is disabled.

= Test Mode off = Test Mode on (red);

unit disabled

Alarm

Press to acknowledge the alarm light and silence the optional audible alarm. The alarm light will flash until the cause of the alarm condition is fixed. See Troubleshooting for alarm descriptions and remedies.

Setpoint Select button

Press repeatedly until the green light appears next to the parameter you want to program or view.

NOTE: Default settings for the deviation setpoints are: High = setpoint + 25°F Low = setpoint - 25°F A warning alarm occurs (indicator light red) whenever the actual temperature is outside this setpoint range for more than the set delay. Recommended setting: ± 2-10°F.

Page 41

TW-2 CONTROL FEATURES

UGH025-0504 Thermolator TW Series

OPERATION 4-5

Purge Valve

The light indicates the operating status of the purge valve. Except in Test Mode and Auto Start, the light indicates:

= Off or inactive

= On or active

Display Select button

Press repeatedly until the green light appears next to the temperature you want to view.

All normal operating functions can be controlled from the TW-2 control panel, including the optional mold purge.

Status lights

The lights indicate the operating status of the listed components. Except in Test Mode and Auto Start, the lights indicate:

= Off or inactive = On or active (green) = Alarm condition (red)

Test Mode is used for testing displays, keys and input/output functions. When test mode is enabled, normal operation is disabled.

= Test Mode off = Test Mode on (red);

unit disabled

Auto Start allows you to start and stop the unit from a remote switching or timing device, such as the processing machine control. This feature can only ben enabled by configuring a dip switch on the control motherboard.

= Disabled; Auto Start

not available

= Enabled

(flashing green);

unit can start any time

= On and under control of

the remote device

Actual values display

The green window displays the temperature at the middle of the mold. This temperature is calculated as an average of the temperatures of the supply water and return water.

The lights indicate whether the temperature is in degrees Fahrenheit or Celsius. See Installation, section 3 for instructions on how to change the temperature units.

Setpoint display

The Setpoint display shows the setpoints entered for fluid temperature, high and low temperature deviation alarms, the SPI baud rate, and the SPI address.

Setpoint and Actual value display windows also display some alarm codes and setup instructions.

Run/Stop

Press RUN button to start normal operation. Press STOP to stop the temperature control unit.

= Running (green)

= Stopped (red)

= Alarm (red, flashing)

Setpoint adjustment buttons

Press s or t to enter the process temperature setpoint, SPI parameters and passcodes.

Press s to increase a value. Press t to decrease a value.

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

Alarm

Setpoint Select button

Press repeatedly until the green light appears next to the parameter you want to program or view.

Page 42

Thermolator TW Series UGH025-0504

4-6 OPERATION

Before starting the Thermolator, verify that the system has been installed correctly for your application. See Installation,

section 3.

Turn on the water supply to the Thermolator.

The supply pressure must be at least 25 psi. Check for leaks in the cooling water and process fluid lines before continuing.

Turn on main power to the Thermolator.

Set the temperature setpoint to 100° F.

Press to increase or to decrease the tempera ture setting. Press to accept.

Press and hold START until the vent cycle begins.

If everything is working correctly:

u The Cooling indicator lights. u The unit initiates a variable venting sequence. The

pump starts after the vent time 1 is over.

u Normal operation begins. The heater turns on if the

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

Set the setpoint to the desired temperature.

Press to increase or to decrease the tempera ture setting. Press to accept.

STARTING THE TW

If, after setting the setpoint to the desired temperature, the optional Fault light/ alarm turns on, press the FAULT button to silence the alarm. Then go to the Troubleshooting section to correct problem.

Page 43

UGH025-0504 Thermolator TW Series

OPERATION 4-7

STOPPING THE TW

You must shut down the Thermolator whenever you:

l Change the water hookups. l Shut down the process machine. l Purge the process circuit of the water or fluid. l Run the unit’s diagnostic tests. l Perform routine or preventative maintenance. l See an alarm condition that requires troubleshooting. l Relocate, ship or store the unit.

To shut down the unit for purging the process lines, diagnostic testing, routine maintenance or troubleshooting, press the Stop/Start button. Then refer to the appropriate topic or section in this User Guide for additional instructions.

To shut down the unit to change water hookups:

Cool Unit to Less than 100º F

Press

Stop/Start

Shut off the cooling water

supply, and drain the unit of all fluid. Use the two drain plugs on the back of the unit.

Once the unit is cool, remove

the water hookups.

To shut down the unit for relocation or storage:

Press

Stop/Start

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 an environment between -40°F (-40°C) and 150°F (65°C) with 95% relative humidity non-condensing.

WARNING: Electrical shock and

hot surface hazards

Before 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 than 100°F (38°C).

Drain plug

1 2

Page 44

Thermolator TW Series UGH025-0504

4-8 OPERATION

Before starting the Thermolator, verify that the system has been installed correctly for your application. See Installation,

Section 3.

If Passcode Protection has been enabled, you must enter the correct passcode before you can change or enter any of the operating parameters, including the temperature setpoint.

Turn on the water supply to the Thermolator.

The supply must be at least 25 psi. Check for leaks in the cooling water and process fluid lines before continuing.

Turn on main power to the Thermolator.

The control initiates a brief self test.

u Indicator lights blink green, then red. u Setpoint and actual windows will display for

three seconds, followed by the software version. The windows then display the factory default setpoint of 100° F and the actual temperature.

Enter the passcode,

if necessary. Hold the Setpoint Select button for 5 seconds. When the control displays 1 PaS, use the setpoint adjustment buttons to enter the passcode. Press the Setpoint Select button again.

Enter the temperature

setpoint. Press the Setpoint Select button until the green light appears next to Temperature. Press s to increase or t to decrease the temperature setting.

Press to start normal operation.

u The RUN/STOP light turns green. u The unit initiates a 60-second venting sequence.

Cooling and venting valves are active for 60 seconds. The pump is active for the final 30 seconds.

u Normal operation begins. The heater turns on when the

actual temperature is below setpoint. The cooling valve turns on if the actual temperature is above the setpoint.

If the Alarm light turns on, press to silence the option- al audible alarm. See

Troubleshooting, Section 6.

STARTING THE TW-1, TW-2

Run

IMPORTANT: If you are

operating the Thermolator for the first time since installation, you should perform an Auto Tune after two hours of normal operation. You should perform the Auto Tune periodically to ensure that the control correctly calculates how much heat and cooling should be applied to maintain the process setpoint.

See Performing an Auto Tune, Section 4

Page 45

UGH025-0504 Thermolator TW Series

OPERATION 4-9

STOPPING THE TW-1, TW-2

You must shut down the Thermolator whenever you:

To shut down the unit for purging the process lines, diagnostic testing, routine maintenance or troubleshooting, press the Stop button. Then refer to the appropriate topic or section in this User Guide.

To shut down the unit to change water hookups:

Press and drain the unit

of all water or fluid. Drain the unit using the two drain plugs on the back of the unit.

Once the unit is cool, remove

the water hookups.

To shut down the unit for relocation or storage:

Press and drain the unit of all fluid.

Drain the unit using the two drain plugs.

Disconnect the power supply and all water

feeds.

Position the control panel to rest flush with the

unit.

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

WARNING: Electrical shock and

hot surface hazards

Before 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 than 100°F (38°C).

Stop

Page 46

Thermolator TW Series UGH025-0504

4-10 OPERATION

The TW Thermolator can be ordered with an optional purge valve, which clears the process lines of fluid using compressed air. The valve is operated by an optional manual purge button on the control panel

IMPORTANT:

Before purging the process lines, be sure that the cooling water source feed is closed. If the feed is open and the air line has a higher pressure than the cooling water, air may be injected into the cooling water system. If the cooling water pressure is higher than the air line, cooling water may be injected into the air line.

Press Stop/Start to stop the Thermolator.

Shut off the cooling water supply valve.

Press Both at once to toggle Mold Purge (PUr) to start purging.

u The Purge button lights. u The Vent and Cool outputs are activated. u 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 will vary according to the length of the process piping and the size of the tooling.

Press Both again to stop purging.

USING THE TW M

ANUAL PURGE

OPTION

Page 47

UGH025-0504 Thermolator TW Series

OPERATION 4-11

USING THE TW-1 M

ANUAL PURGE

OPTION

The TW-1 direct injection and closed circuit models can be ordered with optional mold purge, which clears the process lines of fluid using compressed air. The purge is operated by a manual switch on the left side of the unit.

IMPORTANT:

Press to shut down the Thermolator.

u The RUN/STOP LED turns red.

Shut off the cooling water supply to the unit.

Turn the manual purge switch to the “ON”

position to start purging.

u The Purge Valve LED lights. u The Vent and Cool outputs are activated. u 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 will vary according to the length of the process piping and the size of the tooling.

Turn the purge switch to the “OFF” position to

stop purging. u The Vent and Cool solenoids remain energized for 5

seconds after the purge is terminated.

Stop

2 3

NOTE: The purge operation will terminate immediately if the

unit detects a blown fuse in the Vent or Cool output. The unit will alarm and shut down.

See Troubleshooting, Section 6, for instructions on how to clear the alarm and fix the problem.

Page 48

Thermolator TW Series UGH025-0504

4-12 OPERATION

The TW-2 direct injection and closed circuit models can be ordered with optional mold purge, which clears the process lines of fluid using compressed air. The purge is operated by a button on the control panel.

IMPORTANT:

Press to shut down the Thermolator.

u The RUN/STOP light turns red.

Shut off the cooling water supply to the unit.

Press to open the valve and start purging.

u The Purge Valve LED lights. u The Vent and Cool outputs are activated. u 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 will vary according to the length of the process piping and the size of the tooling.

Press to close the valve and stop purging.

u The Vent and Cool solenoids remain energized for 5

seconds after the purge is terminated.

USING THE TW-2 M

ANUAL PURGE

OPTION

Stop

NOTE: The purge operation will terminate immediately if the

unit detects a blown fuse in the Vent or Cool output. The unit will alarm and shut down.

See Troubleshooting, Section 6 for instructions on how to clear the alarm and fix the problem.

Page 49

UGH025-0504 Thermolator TW Series

OPERATION 4-13

TW CONTROL PERFORMING AN AUTOTUNE

The controller has three pre-configured tuning parameter sets, one of which should allow optimum temperature control. Following is a description of each of the choices available to an operator:

Slow Responding system:

Select the slow setting “SLO” for large systems*. More than 1,700 pounds (200 gallons) of water and more than 14,000 lbs of steel might be considered a large system. This setting has the smallest proportional band (5ºF), which allows larger changes in the control output when the process temperature is far from setpoint. This should reduce cycling around the setpoint.

Normal Responding System:

Normal “nOr” is the factory default tuning setting, as it will cover the majority of applications. This setting is appropriate for systems* with 250 to 1,700 pounds (130-200 gallons) of water and 1,000 to 14,000 pounds of steel. The default value for the normal proportional band is 10ºF.

NOTE: Normal parameter is the factory default setting

Fast Responding System:

Select the fast setting “FSt” for small systems*. Less than 80 pounds of water (10 gallons) and 1,000 pounds of steel might be considered a small system. This setting has the largest proportional band (15ºF), which allows a fast response to small deviations between the process variable and setpoint. This system is typical for small thermolators with small molds or other process machinery. If improperly set up, the configuration might cause oscillation around the setpoint temperature.

Setup Menu

To access the Setup Menu,

Press and hold the “enter” key for approximately five seconds, until the service menu is active.

Toggle the Up/Down keys until “PiT” is dis- played. Press the “enter” key once to see the cur

rent tuning setting.

Toggle the Up/Down arrow keys to the desired SLO, nOr or FSt setting. Press “enter” again to

save this value. If at any time no key is pressed for 10 seconds the control will return to “Home Page”, dis- playing the process variable. If the unit is in any alarm condition, you must clear it before you can adjust the tuning selector.

Page 50

TW-1, TW-2 C

ONTROL

PERFORMING AN AUTO TUNE

Thermolator TW Series UGH025-0504

4-14 OPERATION

You should perform an Auto Tune after the first two hours of operation and whenever process variables change (changes in cooling water pressure, piping or molds; large ambient swings; new setpoint temperature) to ensure that the control continues to obtain good approximations of the PID constants used to compensate for the thermal lag of the system.

To ensure a successful Auto Tune, verify that:

r The Auto Tune feature has been enabled. Auto Tune is

enabled or disabled via dip switch 2 on the motherboard.

r The process value is stable. A fluctuating process value

will fool the software into making inaccurate tuning decisions. The software waits 5 minutes for the process value to stabilize before it starts the Auto Tune process. If the process value still fluctuates after 5 minutes, the Auto Tune terminates and the control displays the “At ti” error.

r The control is in STOP mode and the process value is in

ambient temperature. This allows the software to obtain

good approximations of process parameters, which are critical for performing an accurate tune. If this requirement is not met, then a good tune cannot be guaranteed.

r The setpoint/process deviation is at least 25° F. If the

absolute value of setpoint - process temperature is not greater than or equal to 25°F, the Auto Tune will terminate. The control will display an “At dEV” error.

Press to shut down the Thermolator.

Disconnect and lock out main power to the unit.

Enable Auto Tune.

Open the electrical enclosure. Set dip switch 2 to ON. Close the electrical enclosure and restore power to the unit.

Restore power to the unit.

876

54321

WARNING: Electric shock hazard

2 3

Stop

Page 51

UGH025-0504 Thermolator TW Series

OPERATION 4-15

TW-1, TW-2 C

ONTROL

PERFORMING AN AUTO TUNE

Set the setpoint to desired value.

Press and (the Setpoint Select button)

simultaneously to begin the Auto Tune. The pump energizes, the Actual display flashes “At” and the current process temperature to indicate that an Auto Tune is underway.

If Auto Tune is successful, the controller automatically starts controlling using the new PID parameters.

If you press the STOP button or a fault occurs during the Auto Tune, the control enters stop mode and Auto Tuning immediately terminates. The Actual display stops flashing “At.” If a fault occurred, the control displays the appropriate error message.

Run

ERROR MESSAGE ERROR DESCRIPTION

Insufficient setpoint/process deviation.

If the absolute value of (setpoint - process value) is less than 25°F. The Auto Tune cannot be started until the temperature difference is at least 25°F.

Auto Tune timed out. Auto Tune will time out if a stable process value cannot be obtained 5 minutes into the tune, or if the tuning process takes longer than 30 minutes. If this error occurs, verify that you followed every requirement under “To ensure a successful Auto Tune” and perform a second tune.

Invalid PID constants were generated.

The most likely causes of this error is a tune started inappropriately or an external element (i.e., loose thermocouple) that upset the process while tuning was in progress. Verify that you followed every requirement under “To ensure a successful Auto Tune” and perform a second tune.

dEv

bad

5 6

Page 52

Thermolator TW Series UGH025-0504

4-16 OPERATION

TW-1, TW-2 C

ONTROL

ENTERING PASSCODES

The TW-1 and TW-2 models have a security feature that prevents accidental or unauthorized changes to the setpoint temperature, high and low deviation limits, SPI address, and baud rate.

If passcode protection is enabled, you must enter the correct passcode to change these parameters. To enter the passcode:

Press and hold the Setpoint Select button

for 5 seconds. The control will display 1 PaS to indicate a passcode is needed.

Press the Select s button until the correct

passcode appears in the display.

Press again to enter the passcode.

If the passcode is correct, the control displays ACC PAS for 3 seconds. If the passcode is incorrect, the control displays rEJ PAS (rejected passcode) for 3 seconds.

Press Setpoint to select the parameter you

want to change.

You have access to the system parameters until:

l The power is cycled off and on. l The RUN or STOP button is pressed.

NOTE: Pressing the STOP or RUN key while you are entering a passcode will abort the passcode entry sequence.

Page 53

5-1

UGH025-0504 Thermolator TW Series

Maintenance Schedule . . . . . . . . . . . .5-2

Accessing the Thermolator

Enclosure . . . . . . . . . . . . . . . . . . . . .5-3

Checking Reservoir

Fluid Levels . . . . . . . . . . . . . . . . . . .5-4

TW-1, TW-2 Control Performing

System Tests . . . . . . . . . . . . . . . . . . .5-5

TW-1, TW-2 Control Key/Display Test5-6

TW-1, TW-2 Control Input Test . . . . . .5-7

TW-1, TW-2 Control Output Test . . . .5-8

TW-1, TW-2 Control Disabling or

Enabling Output Monitors . . . . . . . .5-9

TW-1, TW-2 Control Calibrating

Temperature Sensors . . . . . . . . . . . .5-10

TW-1, TW-2 Control Logging

Operating Hours . . . . . . . . . . . . . . .5-12

TW-1, TW-2 Control Pulse Mode

Description . . . . . . . . . . . . . . . . . . . .5-13

TW-1, TW-2 Control Pulse

Mode Setup . . . . . . . . . . . . . . . . . . .5-13

TW-1, TW-2 Control Pulse Mode

Limits & Defaults . . . . . . . . . . . . . .5-14

TW Control Deviation

Alarm/Band and Delay . . . . . . . . . .5-14

TW-1, TW-2 Control Vent Timer

Adjustment . . . . . . . . . . . . . . . . . . . .5-15

MAINTENANCE

Page 54

Thermolator TW Series UGH025-0504

5-2 MAINTENANCE

PREVENTATIVE MAINTENANCE SCHEDULE FOR TW-1 AND TW-2

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

l Whenever process variables change

r Perform an Auto Tune. The Auto Tune ensures that the control continues to

obtain good approximations of the PID constants used to compensate for the thermal lag of the system. You should perform an Auto Tune after the first two hours of operation and whenever the process changes, such as after a mold change; installation of different pipe sizes; or change in process setpoint. See Performing an Auto

Tune, Section 4.

l Daily

r Check for leaks in cooling and process lines. Before and during operation, you should inspect the

unit 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 on

the unit, especially around air intake areas. Keep the floor around the unit dry.

Check the process fluid level (IC models).

Isolated circuit models have an internal reservoir that contains the process fluid. Check the level indicator on the back of the unit to make sure the reservoir contains an adequate amount of process fluid. Refill as needed.

l Monthly, or as often as needed.

r Inspect the fluid reservoir (IC models only). Check the level switches in the process fluid reservoir for debris or deposits that could interfere with proper operation. Flush and clean the reservoir, if necessary.

l Quarterly (every 3 months)

r Inspect power cords, wires and electrical

connections.

Check for loose or frayed wires, burned contacts, and

signs of overheated wires. Check exterior power cords to the main power source and from the electrical box to the pump and heating elements. Check the ground wire and thermocouple connections. Replace any wire that appears damaged or has worn or cracked insulation.

NOTE: There is no Auto-tune for the JCI control.

Continued

Page 55

PREVENTATIVE MAINTENANCE SCHEDULE FOR TW-1 AND TW-2

CONTINUED

UGH025-0504 Thermolator TW Series

MAINTENANCE 5-3

l Annually (every 12 months)

r Test and calibrate the unit’s control systems. The TW-1 and TW-2 control Test Mode checks the operation of displays, control buttons, inputs and out puts. You can also calibrate the supply and return thermo couples. See Performing System Tests, Section 5.

WARNING: Electrical shock and

hot surface hazards

Before 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 than 100°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

THE

THERMOLATOR ENCLOSURE

Page 56

The isolated, or totally closed circuit models separate the cooling water from the process fluid, which is held in a reservoir inside the unit. This reservoir should be kept at about threequarters full of the process fluid.

You can check the fluid level in the reservoir using the sight glass on the back of the Thermolator.

To fill the reservoir:

Disconnect and lockout power, and remove the

top panel of the Thermolator.

Locate the reservoir near the top of the unit.

Locate the fill port at the top of the reservoir.

Refill the reservoir. Monitor the level using the

sight glass on the back of the unit. Because IC units can use pure water or glycol mixtures, make sure you are adding the correct fluid for your application.

Replace the top panel of the Thermolator.

CHECKING THE RESERVOIR FLUID LEVEL

(IC MODELS ONLY)

Thermolator TW Series UGH025-0504

5-4 MAINTENANCE

3 4

IMPORTANT: Do not use deionized water or gly-

col mixtures containing additives in a Thermolator. Softened water or glycol mixtures with additives, such as automotive fluids, can damage the Thermolator. Glycol/water process loop mixtures should use industrial-grade ethylene glycol only.

Sight glass

Page 57

Conair Thermolators with TW-1 or TW-2 controls provide a Test Mode that tests displays and keys on the control panel, as well as inputs and outputs. The Test Mode also allows calibration of the supply and return line thermocouples.

System tests and calibration should be performed annually.

To enable Test Mode:

Press to shut down the Thermolator.

Disconnect and lock out main power to the unit,

then open the electrical enclosure.

Set dip switches 3 and

5 to OFF.

Set dip switch 6 to ON.

Close the electrical enclosure and restore

power to the unit.

u The control displays “tSt.” u The Test Mode LED lights.

Press any button to display the first test menu.

Test mode provides the following menus:

l Key/Display Test l Input Test l Output Test l Calibration l Total Operating Hours l Output Monitor Enable/Disable

After performing each test, hold the Setpoint

for 3 seconds to index to the next test menu. The procedure for each test is described on the following pages.

TW-1, TW-2 C

ONTROL

PERFORMING SYSTEM TESTS

UGH025-0504 Thermolator TW Series

MAINTENANCE 5-5

Stop

876

54321

1 2

IMPORTANT: All normal

operating functions are disabled while Test Mode is enabled. To return to normal operation, you must disable Test Mode.

To disable Test Mode, repeat steps 2 through 5, setting dip switch 6 to OFF instead of ON.

Page 58

The Key/Display Test verifies the function of displays, LEDs and buttons on the control panel.

Enable Test Mode.

Press any key.

If necessary, index to the Key/Display menu.

Press and hold the Setpoint key for 3 seconds to index to each test menu until the controller displays “dSP”.

Press any key to clear all displays.

Repeatedly press any key to test displays.

With each key press, a new segment of all six 8-segment LEDs and a select group of LED indicator lights will illuminate.

Exit the test and enter the next test.

Press and hold the Setpoint key for 5 seconds to exit and index to the next test.

TW-1, TW-2 C

ONTROL

KEY/DISPLAY TEST

Thermolator TW Series UGH025-0504

5-6 MAINTENANCE

1 2

4 5

Page 59

The Input Test verifies the function of inputs available on models with TW-1 or TW-2 controls. Not all inputs are used on all models. The performance evaluation of the inputs is based on the voltage sensing device (VSD).

Connect all inputs to the system.

Press any key to display the first test menus.

Select the Input Test menu.

Press and hold the Setpoint key for 3 seconds to index to each test menu until the controller displays “InP”.

Repeatedly press and release any key to test.

With each key press and release, the left display will indicate the number of the input being tested (v1, v2, v3, etc.). The right display indicates either “1” for voltage present or “O” for an absence of voltage.

Only inputs that are actually used by the particular model will be tested.

Exit the test and enter the next test.

Press and hold the Setpoint key for 3 seconds to exit and index to the next test.

TW-1, TW-2 C

ONTROL INPUT

TEST

UGH025-0504 Thermolator TW Series

MAINTENANCE 5-7

2 3

Page 60

TW-1, TW-2 C

ONTROL

OUTPUT TEST

Thermolator TW Series UGH025-0504

5-8 MAINTENANCE

The Output Test verifies the function of outputs available on the models with TW-1 or TW-2 controls. Not all outputs are used on all models. The performance evaluation of the inputs is based on the output monitors (OM).

Connect all outputs to the system.

Enable Test Mode.

Press any key to display the first test menus.

Select the Output Test menu.

Press and hold the Setpoint key for 3 seconds to index to each test menu until the controller displays “oUt”.

Repeatedly press and release any key to test.

With each key press and release, the left display will indicate the number of the output being tested (oS1= OM1; oS2 = OM2; etc.). The right display indicates either “1” for a good output or “O” for a failed output.

Only outputs that are actually used by the particular model will be tested.

Exit the test and enter the next test.

Press and hold the Setpoint key for 3 seconds to exit and index to the next test.

IMPORTANT: Testing each output requires the firing of the associated solid state relay. Make sure an output device is connected to the controller, otherwise the test result will be erroneous.

2 3 4

Page 61

All output monitors on the Thermolator can be enabled or disabled permanently through the OM Enable/Disable Menu in Test Mode.

You need to use this feature if you have replaced the motherboard, or if dip switches 7 and 8 have been changed erroneously. This will enable any required output monitors that were disabled and give fuse failures.

Enable Test Mode.

Press any key to display the first test menus.

Select the OM Enable/Disable menu.

Press and hold the Setpoint key for 3 seconds to index to each test menu until the controller indicates “oS1” in the actual display and the status of the selected output in the Select display.

Press the Setpoint s or t key to change the status.

Each press of the key changes the output status

from ON to OFF or OFF to ON.

Press the Setpoint to select the next output.

Repeat Step 4 to change the status of the output, or press any key to continue indexing through the outputs.

Save changes and exit the output menu.

Press and hold the Select key for 3 seconds to save the changes and exit.

TW-1, TW-2 C

ONTROL

DISABLING OR ENABLING OUTPUT MONITORS

UGH025-0504 Thermolator TW Series

MAINTENANCE 5-9

1 2

OUTPUT MONITOR SELECTION GUIDE

MODEL TYPE DI CC IC

OM1 Pump ON ON ON OM2 Heat ON ON ON OM3 Cool ON ON ON OM4 Vent OFF ON OFF OM5 Purge (TW-2 option only) ON ON OFF

Page 62

Thermolators with TW-1 or TW-2 controls use type “K” thermocouples to sense the temperature in the return and supply process lines. These thermocouples should be calibrated annually, or when a new thermocouple is installed, to ensure correct operation.

The Thermolator’s Calibration Mode provides zero and span calibration of both the supply and return line thermocouples. You access the Calibration Mode while in Test Mode.

Enable Test Mode.

See Performing System Tests, Section 5.

Press any button to display the first test menu.

Select the Calibration Mode menu.

Press and hold the Setpoint key for 3 seconds to index to each test menu until the controller indicates “SC.L” in the Actual display.

Release the Setpoint key.

You are now in calibration mode. Each press and release of this key will exit the current calibration and start the next calibration. The table below lists the calibrations that will be performed.

Using the thermocouple calibrator, apply the

appropriate temperature to the control input.

TW-1, TW-2 C

ONTROL

CALIBRATING TEMPERATURE SENSORS

Thermolator TW Series UGH025-0504

5-10 MAINTENANCE

Special Tools Needed:

r type K thermocouple

calibrator

2 3

SETPOINT ACTUAL

CALIBRATION DISPLAY DISPLAY

Zero Calibrate Supply Sensor 32°F (0°C) SC.L

Zero Calibrate Return Sensor 32°F (0°C) rC.L

Span Calibrate Supply Sensor 510°F (266°C) SC.H

Span Calibrate Return Sensor 510°F (266°C) rC.H

Page 63

Press the up s key to begin calibrating.

The controller displays the name of the current calibration (examples: 32 SC.L; 32 rC.L; 510 SC.H; or 510 rC.H).

Wait until the control displays ‘don’ or ‘bad’.

A “don” message in the Setpoint display indicates the calibration was successful. A “bad” message in the Setpoint display indicates a bad calibration.

Press Select to start the next calibration.

Pressing and releasing the Select key at the end of a calibration tells the controller to perform the next calibration.

Exit Calibration Mode.

Press and hold the Select key for 3 seconds to exit the Calibration Mode.

You can now proceed to the next test in Test Mode, or disable Test Mode and resume normal operation.

TW-1, TW-2 C

ONTROL

CALIBRATING TEMPERATURE SENSORS

UGH025-0504 Thermolator TW Series

MAINTENANCE 5-11

NOTE: The original calibration value stored in

EEProm can be restored for the current calibration by pressing the STOP key at any time.

TO DISABLE TEST MODE, complete steps 2

through 5 in “Performing System Tests”, setting dip switch 6 to OFF instead of ON.

Page 64

You can see the total numbers of operation by accessing the Total Operating Hours Log in Test Mode.

Enable Test Mode.

Press any key to display the first test menus.

Index through test menus to the operating log.

Press and hold the Setpoint key for 3 seconds to index to each test menu until the Actual display indicates “Log”. The Setpoint display indicates the total number of operating hours in 100-hour units.

Exit the Operating Hours Log.

Press and hold the Select key for 3 seconds to exit and index to the next test.

You can now proceed to another menu in Test Mode, or disable Test Mode and resume normal operation.

TW-1, TW-2 C

ONTROL

LOGGING OPERATING HOURS

Thermolator TW Series UGH025-0504

5-12 MAINTENANCE

1 2

TO DISABLE TEST MODE, complete steps 2 through 5

in “Performing System Tests, Section 5” setting dip switch 6 to OFF instead of ON.

Page 65

The Thermolator Direct Injection Model has a Pulse Mode in which software pulses the cool and vent valves at a predetermined rate under normal control and autotune when all of the following conditions are met.

l The Control Point temperature is less than 245°F. l The setpoint is greater than the control point tem-

perature by more than 5°F.

Pulse Mode is used to relieve excess pressure that can build up from thermal expansion of water in the process loop. The Pulse Time and Pulse Cycle Time parameters are adjustable under Test Mode. Pulse Time is the time in which the cool and vent valves shall be activated within the pulse cycle. Pulse Cycle Time determines the cycle time for each pulse to be repeated. The cycle time can be set to ‘OFF’ to disable Pulse Mode.

TW-1, TW-2 C

ONTROL

PULSE MODE DESCRIPTION

UGH025-0504 Thermolator TW Series

MAINTENANCE 5-13

Pulse Mode Setup establishes the characteristics of the pulse in Thermolator Direct Injection Model’s Pulse Mode.

To access the Pulse Mode Setup:

Follow Steps 1 through 7 in Test mode until

“P.Cy” displays on the Actual screen. This is the Pulse Cycle Time parameter.

Release the Parameter Select button.

The left display shows the Pulse Cycle Time value.

Use the UP and DOWN Arrow buttons to set a

new Pulse Cycle Time value.

Momentarily press and release the Parameter

Select button to save the newly entered Pulse Cycle Time value into non-volatile memory. P.tI displays on the Actual display. This is the Pulse CTime parameter.

Use the UP and DOWN Arrow buttons to set

a new Pulse Time value.

Momentarily press and release the Parameter

Select button to save the newly entered Pulse Time value to non-volatile memory.

Press and hold the Parameter Select button to

exit Pulse Mode Setup and to enter the next service on the menu.

TW-1, TW-2 C

ONTROL

PULSE MODE SETUP

IMPORTANT: If the

Parameter Select button is not pressed after a new value is entered, then the newly entered value is not saved to non-volatile memory.

Page 66

Whenever the process value is within the alarm band, the alarm delay shall be canceled. The deviation alarm delay timer only starts when out of dead band.

Follow these steps to access the deviation alarm inhibition/delay parameters:

The table lists the limits and defaults for the Alarm Inhibition/Alarm Delay parameters. The values are adjustable in 0.5 minute increments.

TW D

EVIATION

ALARM/BAND

AND

DELAY

Parameter

Alarm Delay Time

Deviation Band

Low Limit

1.0 second

1ºF

High Limit

1800 seconds

45ºF

Default Value

600 seconds

20ºF

Thermolator TW Series UGH025-0504

5-14 MAINTENANCE

TW-1, TW-2 P

ULSE MODE

LIMITS AND DEFAULTS

Parameter

Pulse Cycle Time

Pulse Time

Low Limit

Off, 0.1 minute

0.5 seconds

High Limit

15.0 minutes

5 seconds

Default Value

Off

1 second

When the Pulse Cycle Time is set to Off the Pulse Mode is disabled.

The table lists the limits and defaults for the pulse mode parameters.

Page 67

UGH025-0504 Thermolator TW Series

MAINTENANCE 5-15

When the unit starts, i.e. on/off is pressed the Vent sequence is initiated.

The venting sequence is divided into two phases. In the first phase the cool output energize for the set venting sequence time, VT1. This is followed by a second phase in which the cool, and pump outputs are energized for the VT2 time.

To access the Vent Timer setups:

Press and hold the “enter” key till Uni is shown on screen.

Press the “down” key till VT1 is shown on

screen.

Press the “enter” key to display the value. (15 second default).

Press the “up/down” keys to change the value.

Press the “enter”key to accept the change in value.

Vent Bypass

If the unit remains full of fluid and it is not advantageous to vent the unit may be bypassed on start-up.

Press and hold until the vent cycle

begins immediately.

TW-1, TW-2 C

ONTROL

VENT TIMER ADJUSTMENT

Page 68

Thermolator TW Series UGH025-0504

5-16 MAINTENANCE

Page 69

6-1

UGH025-0504 Thermolator TW Series

Before Beginning . . . . . . . . . . . . . . . . . . . . . .6-2

A Few Words of Caution . . . . . . . . . . . . . . . .6-2

Identifying the Cause of a Problem

for the TW Control . . . . . . . . . . . . . . . . . . .6-3

Identifying the Cause of a Problem

for the TW-1, TW-2 Control . . . . . . . . . . . .6-4

TW Control Alarms . . . . . . . . . . . . . . . . . . . .6-5

TW Control Mechanical/Electrical Alarms .6-11

TW-1, TW-2 Control Shut Down Alarms . .6-12

TW-1, TW-2 Control Warning Alarms . . . . .6-13

TW-1, TW-2 Control Other Warnings . . . . .6-15

TW-1, TW-2 Control System Alarms . . . . .6-16

Thermolator Will Not Power Up . . . . . . . . .6-17

Replacing the TW Control . . . . . . . . . . . . .6-18

Checking and Replacing Fuses . . . . . . . . .6-19

Resetting Overloads . . . . . . . . . . . . . . . . . .6-20

Replacing Pump Overload . . . . . . . . . . . . .6-20

Replacing the Motherboard . . . . . . . . . . . .6-21

Replacing the Heater

Contactor . . . . . . . . . . . . . . . . . . . . . . . . .6-22

Checking Thermocouples . . . . . . . . . . . . . .6-23

Replacing Thermocouples . . . . . . . . . . . . .6-23

PT1000 Sensor Readings TW Control . . . .6-24

Repairing Cooling Valves . . . . . . . . . . . . . .6-25

Repairing Solenoid Valves . . . . . . . . . . . . .6-26

Repairing Motorized Valves . . . . . . . . . . . .6-27

Replacing Heater Elements . . . . . . . . . . . .6-28

Removing the Pump . . . . . . . . . . . . . . . . . .6-30

Disassembling and Assembling

3/4 - 2 HP Pumps . . . . . . . . . . . . . . . . . . .6-31

Disassembling and Assembling

3 - 7.5 HP Pumps . . . . . . . . . . . . . . . . . . .6-32

TROUBLESHOOTING

Page 70

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

Before you begin troubleshooting:

o Find the wiring, plumbing or other diagrams

that were shipped with your equipment. These diagrams are the best reference for correcting a problem. The diagrams also will note any custom features, such as special wiring, control or plumbing options, not covered in this User Guide.

o Verify that you have manuals for other equip-

ment in the process line. Solving problems may require troubleshooting malfunctions or incorrect operating procedures on other pieces of equipment.

o If an alarm is present, note any indicator lights

and messages shown on the control panel. These indicators will help you discover the cause of the problem more quickly.

The Thermolator is equipped with many safety devices. Do not remove or defeat them. Improper corrective action can lead to hazardous conditions, and should never be attempted to sustain production.

Thermolator TW Series UGH025-0504

6-2 TROUBLESHOOTING

BEFORE BEGINNING

A FEW WORDS

CAUTION

WARNING: This machines should be adjust-

ed and serviced only by qualified technical personnel who are familiar with construction and operation of this type of equipment.

WARNING: Hot surfaces and liquids

Allow the Thermolator to cool to below 100°F (38°C) before servicing the unit.

DANGER: Voltage hazard.

Troubleshooting the electrical system of this equipment requires use of precision electronic measuring equipment, and may require access to the electrical enclosure while power is on. Exposure to potentially fatal voltage levels may be unavoidable. These troubleshooting procedures should be performed only by qualified electrical technicians who know how to use this precision electronic equipment and who understand the hazards involved.

Page 71

UGH025-0504 Thermolator TW Series

TROUBLESHOOTING 6-3

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

When an Alarm condition occurs:

Press the up/down buttons to silence optional audible alarm.

Note any indicator lights or error messages to

help determine the cause of the problem.

Find the alarm or error code in the diagnostics

tables in this section of the User Guide. Causes are listed in the order of most likely to least likely problem.

Determine and fix the cause of the alarm.

IDENTIFYING THE CAUSE OF A PROBLEM FOR

THE

ONTROL

WARNING: Always disconnect and lock out the main power source before opening the Thermolator or its electrical enclosure.

Disconnect air and water supply lines as needed.

Standard indicator lights

and alarm codes.

See Controller Alarms

Page 72

Thermolator TW Series UGH025-0504

6-4 TROUBLESHOOTING

A status light that turns from green to red indicates an alarm condition.

Most Thermolator malfunctions are indicated by an illuminated alarm light and error codes displayed on the control panel.

A problem can trigger three types of alarms:

l Shut Down Alarms: The Thermolator detected a problem

that caused it to shut down automatically to prevent equipment damage or personal injury.

l Warning Alarms: The Thermolator continues to operate,

but warns of a problem that could lead to a condition that will shut down the unit.

l System Errors: The system error codes indicate a non-

recoverable problem with the microprocessor control.

When the Thermolator control detects a problem, the red Alarm light is activated and the RUN/STOP light changes from green to flashing red.

IDENTIFYING THE CAUSE OF A PROBLEM FOR

THE

TW-1, TW-

2 C

ONTROL

WARNING:

Disconnect and lockout the main power source before opening the Thermolator or its electrical enclosure for servicing. Disconnect air and water supply lines as needed.

When an Alarm condition occurs:

Press to silence any optional audible or

visual alarm. The RUN/STOP light changes from flashing red to steady red.

Note any indicator lights or error messages to

help determine the cause of the problem.

Find the alarm or error code in the diagnostics

tables in the Troubleshooting section of this manual.

If the unit is still operating, press to clear

the alarm and shut down the Thermolator to correct the problem.

Press to resume normal operation after

the problem is corrected.

Stop

Run

Page 73

UGH025-0504 Thermolator TW Series

TROUBLESHOOTING 6-5

TW CONTROL ALARMS

Alarm

The actual temperature of water supplied to the process exceeds the 260°F safety limit.

WARNING:

Only qualified

electrical service personnel should examine and correct problems that require opening the unit's electrical enclosure or checking electrical current to diagnose the cause of a problem.

The Thermolator will not maintain the setpoint temperature, or takes too long to reach the setpoint temperature range. The actual temperature of water supplied to the process is outside the setpoint deviation alarm band.

Possible cause

Water stopped flowing through the unit or between the supply outlet and return inlet.

The heater contactor failed.

The optional electromechanical high temperature safety switch been installed on this unit.

The actual temperature of the process fluid is more than 10°F higher than the setpoint temperature.

The actual temperature of the process fluid is more than 10°F lower than the setpoint temperature.

Solution

r Verify that the unit is run-

ning and that the pump is working.

r Check for closed or defec-

tive cooling or vent valves and plugged lines. See

Repairing Solenoid Valves, Section 6.

Replace the contactor if defective. See Replacing

the Heater Contactor, Section

Verify the switch setting. A too-low setting will cause nuisance trips. Check the switch and replace if defective. See

Checking and Replacing Switches, Section 6.

Follow the troubleshooting procedures in the table for a

See High Setpoint Deviation, Section 6 .

Follow the troubleshooting procedures in the table for a

See Low Setpoint Deviation, Section 6.

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

u The controller displays a red alarm LED or an error code indi-

cating the cause of the problem.

u If the optional alarm package is installed, the Fault button will

illuminate and the audible alarm will activate.

tAH

dTA

Page 74

Thermolator TW Series UGH025-0504

6-6 TROUBLESHOOTING

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

u The controller displays a red alarm LED or an error code indi-

cating the cause of the problem.

u If the optional alarm package is installed, the Fault button will

illuminate and the audible alarm will activate.

TW CONTROL ALARMS

Alarm

The Thermolator will not cool down, or takes too long to cool down. The actual temperature of fluid supplied to the process is higher than the setpoint deviation allows.

WARNING:

The Thermolator should be tested and repaired only by qualified technicians equipped with the correct tools and trained in the maintenance and repair of electrical systems and industrial appliances.

Possible cause

Water has stopped flowing between supply outlet and return inlet.

The cooling valve fail to close.

The temperature difference between the cooling water supply and the setpoint is too small.

A heater contactor failed to close.

The cooling valve undersized for the application.

The deviation temperature band is too narrow.

Solution

Check for a plugged pipe or closed valve.

Check the cooling valve. See

Repairing Solenoid Valves or Motorized Cooling Valves, Section 6.

The temperature difference should be at least 25°F to achieve proper cooling. Increase the process setpoint, decrease the cooling water supply temperature or increase the cooling water supply pressure.

With power on and the Heater LED lit: Check the amp draw

on each of the three phase legs to the heater. All should match the FLA listed for the heater on the unit nameplate. Replace the heater contactor if there is a voltage imbalance greater than 10%. See Replacing the Heater

Contactor, Section 6.

Check the cooling load (Btu/hr) for which the valve was specified.

Increase the deviation band. The recommended setting is the setpoint plus/minus 2°F to 10°F .

High Setpoint Deviation

Page 75

UGH025-0504 Thermolator TW Series

TROUBLESHOOTING 6-7

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

u The controller displays a red alarm LED or an error code indi-

cating the cause of the problem.

u If the optional alarm package is installed, the Fault button will

illuminate and the audible alarm will activate.

TW CONTROL ALARMS

Alarm

The Thermolator will not heat to the setpoint temperature, or takes too long to reach the setpoint temperature. The actual temperature of fluid supplied to the process is lower than the setpoint deviation band allows.

WARNING:

The Thermolator

should be tested and repaired only by qualified technicians equipped with the correct tools and trained in the maintenance and repair of electrical systems and industrial appliances.

Possible cause

The cooling valve is stuck open or leaking water.

A heater element failed.

A heater contactor failed to open.

The deviation temperature band is too narrow.

The Thermolator is under-sized for the application.

Solution

Disassemble the cooling valve and check for particles blocking the valve seat. Check the valve seat for excessive wear. Replace as required using a valve repair kit. See Repairing

Solenoid Valves, Section 6.

With the unit powered down:

Check for loose connections. Check resistance between the phase legs on the output side of the heater contactor. Readings should be within

0.25 ohms of each other. Replace the heater, if necessary. See Replacing Heater

Elements, Section 6.

With power on and the Heater LED lit: Check the

amp draw on each of the three phase legs to the heater. All should match the FLA listed for the heater on the unit nameplate. Replace the heater contactor if there is a voltage imbalance greater than 10%.

See Replacing the Heater Contactor, Section 6.

Increase the deviation band setting. The recommended setting is the setpoint plus/minus 2°F to 10°F.

Review specifications and selection guidelines that apply to heater and pump sizes in temperature control units.

Low Setpoint Deviation

Page 76

Thermolator TW Series UGH025-0504

6-8 TROUBLESHOOTING

TW CONTROL ALARMS

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

u The controller displays a red alarm LED and/or an error code

indicating the cause of the problem.

Alarm

Low Water Pressure

The cooling water pressure is less than 25 psi.

Note: The unit will re-start automatically after a two-second delay if the water pressure returns to at least 25 psi.

The pump motor overload has tripped. The contact is open.

WARNING:

Only qualified electrical service personnel should examine and correct problems that require opening the unit's electrical enclosure or checking electrical current to diagnose the cause of a problem.

Cause

The water supply pressure is below 25 psi.

The pressure switch failed.

The cooling valve failed.

The incorrect voltage is supplied to the pump motor.

The required water flow is greater than the pump’s capacity.

The motor overload is faulty or set incorrectly.

The pump is not working properly.

Solution

Verify that the water supply is on and delivering water at a pressure of at least 25 psi. Check for closed valve or faulty pump in the supply circuit.

Watch gauges while turning cooling water on and off. If pressure vents automatically, check vent or cooling valve.

Check the thermocouple and replace if necessary. See

Repairing Solenoid Valves or Motorized Cooling Valves, Section 6.

Supply voltage should match the rating on the pump name plate. If voltage is correct, check wiring connections.

Review pump sizing for the application.

Decrease the process water

flow. Disconnect the power and open the electrical enclosure. Verify that the overload is set to trip at the proper amperage, which should not exceed the FLA. Manually trip and reset the overload. If the problem continues, replace the overload. See

Resetting and Replacing Overloads, Section 6.

Replace the pump if supply voltage, wiring and overload settings are correct, but the pump continues to draw excessive current.

PAL

Page 77

UGH025-0504 Thermolator TW Series

TROUBLESHOOTING 6-9

Alarm

The actual temperature of water supplied to the process exceeds the 260°F safety switch limit.

WARNING:

Only qualified electrical service personnel should examine and correct problems that require opening the unit's electrical enclosure or checking electrical current to diagnose the cause of a problem.

The actual temperature of water supplied to the process exceeds the programmed 260°F safety limit.

WARNING:

Only qualified electrical service personnel should examine and correct problems that require opening the unit's electrical enclosure or checking electrical current to diagnose the cause of a problem.

Possible cause

Water stopped flowing through the unit or between the supply and return.

The optional electromechanical safety switch is improperly set or defective.

The heater contactor has failed.

Water stopped flowing through the unit or between the supply and return.

The heater contactor failed.

Solution

r Verify that the unit is running

and that the pump is working.

r Check for closed or defective

cooling or vent valves and plugged lines. See Repairing

Solenoid Valves, Section 6.

Check the switch setting. A setting that is too low will cause nuisance trips. Check the switch and replace if defective. See

Checking and Replacing Switches, Section 6.

Replace the contactor if defective. See Replacing the

Heater Contactor, Section 6.

r Verify that the unit is running

and that the pump is working.

r Check for closed or defective

cooling or vent valves and plugged lines. See Repairing

Solenoid Valves, Section 6.

Replace the contactor if defective. See Replacing

the Heater Contactor, Section 6.

High Temp. Safety

TW-1, TW-2 C

ONTROL SHUT

DOWN ALARMS

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

u The Alarm LED lights and the STOP/RUN LED flashes red. u The Thermolator automatically shuts down. u The control displays a red LED or alarm code indicating the

source of the problem.

SAF

Page 78

6-10 TROUBLESHOOTING

Thermolator TW Series UGH025-0504

Alarm

The cooling water pressure is less than 25 psi.

Note: The unit will

re-start automatically after a two-second delay if the water pressure returns to at least 25 psi.

The pump motor overload has tripped. The contact is open.

WARNING:

Only qualified electrical service personnel should examine and correct problems that require opening the unit's electrical enclosure or checking electrical current to diagnose the cause of a problem.

Possible cause

The water supply pressure is below 25 psi.

The pressure switch failed.

The cooling valve failed.

The incorrect voltage is supplied to the pump motor.

The required water flow is greater than the pump’s capacity.

The motor overload is faulty or set incorrectly.

The pump is not working properly.

Solution

Verify that the water supply is on and delivering water at a pressure of at least 25 psi. Check for closed valve or faulty pump in the supply circuit.

Watch gauges while turning cooling water on and off. If pressure vents automatically, check vent or cooling valve.

Check the cooling valve. See

Repairing Solenoid Valves or Motorized Cooling Valves, Section 6.

Supply voltage should match the rating on the pump name plate. If voltage is correct, check wiring connections.

Review pump sizing for the appli-

cation.

Decrease the process water flow.

Disconnect the power and open the electrical enclosure. Verify that the overload is set to trip at the proper amperage, which should not exceed the FLA. Manually trip and reset the overload. If the problem continues, replace the overload. See Resetting

and Replacing Overloads, Section 6.

Replace the pump if supply voltage, wiring and overload settings are correct, but the pump continues to draw excessive current.

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

u The Alarm LED lights and the STOP/RUN LED flashes red. u The Thermolator automatically shuts down. u The control displays a red LED or alarm code indicating the

source of the problem.

Low Water Pressure

Pump

TW-1, TW-2 C

ONTROL

SHUT

DOWN ALARMS

Page 79

UGH025-0504 Thermolator TW Series

TROUBLESHOOTING 6-11

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

u The Alarm LED lights and the STOP/RUN LED flashes red. u The Thermolator automatically shuts down. u The control displays a red LED or alarm code indicating the

source of the problem..

Alarm

The incoming power is out of phase. A leg may have failed or is disconnected.

NOTE: This alarm is

available only on models with TW-2 control.

Pump fuse.

Heater fuse.

Cooling valve fuse.

Vent valve fuse.

Purge valve fuse.

Possible cause

The pump is rotating in the wrong direction.

One of the main supply wire leads has disconnected.

The indicated device has blown a fuse.

The incorrect device is being used for this fuse location.

The motherboard output SSR at the designated fuse failed.

Solution

Check pump rotation against the arrow stamped on the pump. If the pump is rotating in the wrong direction, disconnect and lockout the main power source. Open the electrical enclosure, and reverse any two leads on the incoming power connection.

Disconnect power and open the electrical enclosure. Check for loose connections in main supply and on motherboard.

Disconnect and lockout the main power. Open the electrical enclosure. Check for loose wires and incorrectly installed jumpers or terminal blocks associated with the fuse error. Replace the fuse, if necessary.

See Checking and Replacing Fuses, Section 6.

Replace the fuse, then enter Test Mode. Turn off the Output Monitor associated with the fuse location and test outputs.

See Performing System Tests and Disabling or Enabling Output Monitors, Section 5.

Replace the motherboard. See Checking and Replacing the Motherboard, Section 6.

Err

PHS

002

FUS

003

FUS

004

FUS

005

FUS

006

FUS

TW-1, TW-2 C

ONTROL SHUT

DOWN ALARMS

Page 80

Thermolator TW Series UGH025-0504

6-12 TROUBLESHOOTING

Alarm

Actual temperature of water supplied to the process is below the programmed 20° F safety limit.

The thermocouple in the process return line failed.

The thermocouple in the process supply line failed.

Possible cause

The cooling valve is stuck open.

The heater failed.

The thermocouple is loose.

The thermocouple failed.

The thermocouple is loose.

The thermocouple failed.

Solution

Disassemble the cooling valve and check for particles blocking the valve seat. Check the valve seat for excessive wear. Replace parts as required using a valve repair kit. See

Repairing Solenoid Valves, Section 6.

Check for a bad heating element, or a heater contactor that failed in the open position.

See Replacing the Heater Contactor and Replacing Heater Elements, Section 6.

Check for a loose thermocouple or loose wire connections to the thermocouple.

Check the thermocouple and replace if necessary. See

Checking and Replacing Thermocouples, Section 6.

Check for a loose thermocouple or loose wire connections to the thermocouple.

Check the thermocouple and replace if necessary. See

Checking and Replacing Thermocouples, Section 6.

SAF

Err

Pbr

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

u The Alarm LED lights and the STOP/RUN LED flashes red. u The Thermolator automatically shuts down. u The control displays a red LED or alarm code indicating the

source of the problem.

Err

PbS

TW-1, TW-2 C

ONTROL

SHUT

DOWN ALARMS

Page 81

TROUBLESHOOTING 6-13

UGH025-0504 Thermolator TW Series

TW-1, TW-2 C

ONTROL

WARNING ALARMS

Alarm

The Thermolator will not cool down, or takes too long to cool down. The actual temperature of fluid supplied to the process is higher than the setpoint deviation allows.

WARNING:

The Thermolator should be tested and repaired only by qualified technicians equipped with the correct tools and trained in the maintenance and repair of electrical systems and industrial appliances.

Possible cause

Water stopped flowing between the supply and return.

The cooling valve failed.

The temperature difference between the cooling water supply and the setpoint is too small.

A heater contactor failed.

The cooling valve is the wrong size.

The high deviation temperature is set too low.

Solution

Check for a plugged pipe or closed valve.

Check the cooling valve. See

Repairing Solenoid Valves or Motorized Cooling Valves, Section 6.

The temperature difference should be at least 25°F to achieve proper cooling. Increase the process setpoint, decrease the cooling water supply temperature. or increase cooling water supply pressure.

With power on and the Heater LED lit: Check the amp draw

Contactor.

Check the cooling load (Btu/hr) for which the valve was specified.

Increase the high deviation setpoint. The recommended setting is 2°F to 10°F .

High Deviation

The Thermolator has detected a problem that could lead to a shut down condition if it is not corrected.

u The Alarm LED lights. u The Thermolator continues operating. u The control displays a red LED or alarm code indicating the

source of the problem.

Page 82

Thermolator TW Series UGH025-0504

6-14 TROUBLESHOOTING

Alarm

WARNING:

The Thermolator should be tested and repaired only by qualified technicians equipped with the correct tools and trained in the maintenance and repair of electrical systems and industrial appliances.

Possible cause

The cooling valve is stuck open or leaking water.

A heater element fail.

A heater contactor failed.

The low deviation temperature is set too low.

The Thermolator is incorrectly sized for the application.

Solution

Disassemble the cooling valve and check for particles blocking the valve seat. Check the valve seat for excessive wear. Replace as required using a valve repair kit. See Repairing

Solenoid Valves, Section 6.

With the unit powered down:

Check for loose connections. Check resistance between the phases on the output side of the heater contactor. Readings should be within 0.25 ohms of each other. Replace the heater, if necessary. See Replacing

Heater Elements, Section 6.

With power on and the Heater LED lit: Check the

amp draw on each of the three phases to the heater. All should match the FLA listed for the heater on the unit nameplate. Replace the heater contactor if there is a voltage imbalance greater than 10%. See

Replacing the Heater Contactor, Section 6.

Increase the low deviation setting. The recommended setting is 2°F to 10°F.

Review specifications and selection guidelines that apply to heater and pump sizes in temperature control units.

Low Deviation

The Thermolator has detected a problem that could lead to a shut down condition if it is not corrected.

u The Alarm LED lights. u The Thermolator continues operating. u The control displays a red LED or alarm code indicating the

source of the problem.

TW-1, TW-2 C

ONTROL

WARNING ALARMS

Page 83

UGH025-0504 Thermolator TW Series

TROUBLESHOOTING 6-15

TW-1, TW-2 C

ONTROL

OTHER WARNINGS

The Thermolator has detected a problem that could lead to a problem if it is not corrected.

u The Thermolator continues operating. u The control displays a red LED indicating the source of the

problem.

Alarm

The SPI communication link has failed.

DIP Switch Error

Possible cause

The unit is not connected to a host machine.

The network address and baud rate are incorrect.

Something is wrong with the cable.

The controller type DIP switches (7 and 8) inadvertently changed since the last power up sequence.

Solution

If the Thermolator is not connected to a host device, set the SPI address to OFF using the Setpoint adjustment buttons on the control panel.

r Check the network address.

The address may be set to any number from 32 to 254 (a hexadecimal integer between 20 and FE), as long as that number has not been assigned to another machine connected to the same network.

r Make sure the baud rate

(9600, 4800, 2400, or 1200) matches the host machine.

Check the communication cable condition and connections. The cable must conform to SPI standards. Check for loose connections on the motherboard.

Power down the controller and reset the controller type DIP switches (7 and 8) to the previous settings. Refer to TW-1,

TW-2 Control Initial Setup, Section 3 for details on the proper DIP switch settings.

SPI Communication

tyP

SET

Page 84

TW-1, TW-2 C

ONTROL SYSTEM

ALARMS

Alarm

RAM hardware failure.

ROM, checksum failure.

COP failures.

Illegal Opcode.

through

Software cannot write to CPU nonvolatile memory.

Cause

Electrical noise or failed CPU on the motherboard caused system write tests to fail during power up.

The CPU and/or PROM chip (U1 or U2) is not making good contact with its socket, or the PROM chip has failed.

A failed CPU, failed motherboard, software bug or electrical noise caused an internal software error.

The CPU tried to execute an illegal software instruction due to electrical noise or a failed motherboard.

A failed CPU, failed motherboard, software bug or electrical noise caused an internal software error.

The memory has exceeded its usable life or there is a software bug. This error occurs only after changes have been made to nonvolatile memory either through the operator panel or SPI.

Solution

Make sure all connections on the motherboard are solid. Operate unit in a noise free environment. If error persists, contact Conair service.

Make sure the CPU and PROM chips are seated correctly in the sockets. If error persists, contact Conair service.

Cycle power to the unit. If the problem persists, contact Conair service technicians. You may need to replace the motherboard.

Make sure all connections to the motherboard are solid and that the unit is operating in a noise free environment. If error persists, contact Conair service.

Cycle power to the unit. If the problem persists, contact Conair service technicians. You may need to replace the motherboard.

Cycle power to the unit. Contact Conair service if an operating parameter such as the setpoint is not being saved or if this error persists.

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

u The Alarm LED lights and the STOP/RUN LED flashes red. u The Thermolator shuts down or will not start. u The control displays an error code indicating the source of

the problem.

001

ERR

003

ERR

002

ERR

004

ERR

006

ERR

005

ERR

015

ERR

014

ERR

016

ERR

Thermolator TW Series UGH025-0504

6-16 TROUBLESHOOTING

Page 85

UGH025-0504 Thermolator TW Series

TROUBLESHOOTING 6-17

THERMOLATOR WILL NOT POWER UP

If you apply power to the Thermolator and the control panel does not light, you have a problem with the main power circuit or the unit’s microprocessor board.

WARNING: Electrical Shock Hazard Disconnect and lockout the main power supply before proceeding.

Symptom

Applying power does not turn on the Thermolator or light the control panel.

The control panel is lit, but the Thermolator will not operate when RUN is pressed.

Possible cause

Power is not reaching the Thermolator

The unit has blown a fuse.

The incorrect voltage is reaching the Thermolator.

The unit is in Test Mode.

Solution

r Verify that the main power

supply and any customerinstalled electrical disconnect or emergency stop devices are in the ON position.

r Verify correct electrical con-

nections between the unit and the control, and between the unit and the power supply. Replace any damaged wires or cables.

Check Fuse 1 on the motherboard and any fuses or breakers associated with customerinstalled disconnect devices. Replace or reset as required. Identify the cause of the ground fault and correct it. See Check-

ing and Replacing Fuses, Section 6.

Check the electrical requirements on the unit nameplate. Verify correct main supply voltage to the unit and the secondary voltage supply from the transformer to unit components. Replace the transformer, if necessary.

If the Test Mode LED is lit, you must disable Test Mode on the motherboard before resuming operation. See Performing

System Tests, Section 5.

Page 86

REPLACING THE TW T

EMPERATURE

CONTROLLER

Thermolator TW Series UGH025-0504

6-18 TROUBLESHOOTING

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

Disconnect and lockout the main power.

Unscrew the nuts and then remove the control metal.

Disconnect connectors on back of controllers.

Remove controller by squeezing plastic returning clip tabs. Pull out controller.

Reverse order to install new controller.

Page 87

CHECKING AND REPLACING FUSES

UGH025-0504 Thermolator TW Series

TROUBLESHOOTING 6-19

This procedure covers the factory-installed fuses on the unit’s motherboard. If you have installed an electrical disconnect or emergency stop switch, additional fuses and/or breakers may have been used elsewhere in the main power circuit.

To replace a blown fuse:

Disconnect and lockout the main power.

Open the electrical enclosure door.

Turn the screw on the front panel counterclockwise to open.

Replace the fuse. The fuses are located on the mother-

board and are labeled and identified on the orange shield.

Close the electrical enclosure and restart the unit.

If fuse continues to fail:

r Verify that the unit is receiving the correct voltage.

Check the voltage, phasing and amperage ratings on the unit’s nameplate.

r Verify that the unit’s transformer is operating correctly.

Check for proper voltage (120V ±10%) to the voltage sensing device for the fuse location.

r Check all wiring referencing the fusing location for

loose connections, damage or improper grounding. Verify that the correct device is being used for this fuse location. See Disabling or Enabling Output Monitors,

Section 5.

1 2

1 23456

CONFIGURATION

DIP SWITCH

OFF

4 3 2 1

UNLDR 1/ VENT 2 SOL +

UNLDR 1/ VENT 2 SOL UNLDR 2/ COOL 1 SOL + UNLDR 2/ COOL 1 SOL

PUMP

PUMP PUMP OL PUMP OL

6 5 4 3 2 1

4 3 2 1

6 5 4 3 2 1

4 3 2 1

PMP AUX

PMP AUX 1FS/ COMP AUX 1FS/ COMP AUX

PUMPDOWN PUMPDOWN

HEAT/COMP

HEAT/COMP HTS/COMP OL HTS/COMP OL

C NC NO

110V

ALARM

LLS/PURGE 3SOL LLS/PURGE 3SOL +

PURGE 4SOL

PURGE 4 SOL +

3 PHASE INPUT

TCPL'S

SUP RET

AC IN 4

AC IN + 3

AC OUT 2

AC OUT + 1

LLS/WPS

AUTOSTART

HPS/LPS

OPS

FSTAT

65432

432

1 2 3 4 5 6 7 8 1 2 3 4

(-2) CONTROL

OPER PNL CABLE

+ 120 Ohm

+ TR

GND

+ TR

120 Ohm

Fuse 1

Control power

Fuse 5

Vent valve

Fuse 4

Cooling valve

Fuse 2

Pump

Fuse 3

Heater

Fuse 6

Purge valve

IMPORTANT: Always

refer to the wiring diagrams that came with your Thermolator to locate specific electrical components. Illustrations in the User Guide are intended to be representative only.

WARNING:

Shock Hazard

Only qualified service personnel familiar with electrical testing and industrial equipment should examine and correct problems that require opening the unit with power on to diagnose the cause of a problem.

Page 88

Thermolator TW Series UGH025-0504

6-20 TROUBLESHOOTING

RESETTING OVERLOADS

REPLACING PUMP OVERLOAD

Disconnect and lockout the main power.

Open the electrical enclosure door.

Turn the screw on the front panel counterclockwise to open.

Locate the pump overload module attached to

the pump motor starter.

Disconnect the three power leads from the

overload module to the pump motor. Note the placement of each lead and label as needed.

Disconnect auxiliary wiring on

the overload module.

Remove the overload module.

Loosen the three screws that connect the overload module to the motor contactor. Pull the overload module down to release it from the starter.

Reverse these steps to install

the new overload module.

Set the module reset mode to

MAN (manual).

Set the proper FLA trip point.

Do not exceed the FLA for the pump motor.

The pump motor overload is located inside the unit’s electrical enclosure.

Disconnect and lockout the main power.

Open the electrical enclosure door.

Turn the

screw on the front panel counterclockwise to open.

Check the overload.

If the red button is out, the overload has tripped. Press the blue button to reset the overload. Verify that the overload trip point does not exceed the FLA for the pump.

Motor contactor

Motor overload

Page 89

UGH025-0504 Thermolator TW Series

TROUBLESHOOTING 6-21

REPLACING THE MOTHERBOARD

IMPORTANT: Always

refer to the wiring diagrams that came with your Thermolator to locate specific electrical components. Illustrations in the User Guide are intended to be representative only.

Disconnect and lockout the main power supply.

Open the electrical enclosure door.

Turn the screw on the front panel counterclockwise to open.

Mark or label each wire

connected to the motherboard. The orange shield is labeled with the connection information. You must label the wires to ensure they are connected to the correct terminals on the new motherboard.

Disconnect the wires

from the motherboard by pulling the terminal blocks up.

Loosen the screws hold-

ing the orange shield.

Remove the mother

board and shield from the electrical enclosure as a unit.

Remove the mother

board from the shield and replace with the new motherboard.

Reattach the shield

and new motherboard in the electrical enclosure. Tighten the screws.

Reconnect the

terminal blocks and wires to the new board. Make sure you align the terminal blocks with the correct pins on the board. Push the terminal blocks onto the pins, taking care not to bend any pins.

Set dip switches 7 and 8 to the correct unit type.

Set ON for DI and CC models; set off for IC models.

Program output monitors on the new board.

See Disabling or Enabling Output Monitors, Section 5.

1 23456

CONFIGURATION

DIP SWITCH

OFF

4 3 2 1

UNLDR 1/ VENT 2 SOL +

UNLDR 1/ VENT 2 SOL UNLDR 2/ COOL 1 SOL + UNLDR 2/ COOL 1 SOL

PUMP

PUMP PUMP OL PUMP OL

6 5 4 3 2 1

4 3 2 1

6 5 4 3 2 1

4 3 2 1

PMP AUX

PMP AUX 1FS/ COMP AUX 1FS/ COMP AUX

PUMPDOWN PUMPDOWN

HEAT/COMP

HEAT/COMP HTS/COMP OL HTS/COMP OL

C NC NO

110V

ALARM

LLS/PURGE 3SOL LLS/PURGE 3SOL +

PURGE 4SOL

PURGE 4 SOL +

3 PHASE INPUT

TCPL'S

SUP RET

AC IN 4

AC IN + 3

AC OUT 2

AC OUT + 1

LLS/WPS

AUTOSTART

HPS/LPS

OPS

FSTAT

65432

432

1 2 3 4 5 6 7 8 1 2 3 4

(-2) CONTROL

OPER PNL CABLE

+ 120 Ohm

+ TR

GND

+ TR

120 Ohm

1 23456

4 3 2 1

6 5 4 3 2 1

4 3 2 1

6 5 4 3 2 1

4 3 2 1

65432

432

1 2 3 4 5 6 7 8 1 2 3 4

CONFIGURATION

DIP SWITCH

OFF

UNLDR 1/ VENT 2 SOL + UNLDR 1/ VENT 2 SOL UNLDR 2/ COOL 1 SOL + UNLDR 2/ COOL 1 SOL

PUMP

PUMP PUMP OL PUMP OL

PMP AUX

PMP AUX 1FS/ COMP AUX 1FS/ COMP AUX

PUMPDOWN PUMPDOWN

HEAT/COMP

HEAT/COMP HTS/COMP OL HTS/COMP OL

C NC NO

110V

ALARM

LLS/PURGE 3SOL LLS/PURGE 3SOL +

PURGE 4SOL

PURGE 4 SOL +

3 PHASE INPUT

TCPL'S

SUP RET

AC IN 4

AC IN + 3

AC OUT 2

AC OUT + 1

LLS/WPS

AUTOSTART

HPS/LPS

OPS

FSTAT

(-2) CONTROL

OPER PNL CABLE

+ 120 Ohm

+ TR

GND

+ TR

120 Ohm

Page 90

Thermolator TW Series UGH025-0504

6-22 TROUBLESHOOTING

IMPORTANT: Always

refer to the wiring diagrams that came with your Thermolator to locate specific electrical components. Illustrations in the User Guide are intended to be representative only.

REPLACING THE HEATER CONTACTOR

Thermolators use mercury displacement heater contactors. The heater contactors should be replaced if you have checked: l the amp draw on each of the three-phase legs and discov-

ered a voltage imbalance greater than 10%.

l the continuity and found that ohms at the coil equal zero.

To replace the heater contactor:

Disconnect and lockout the main power.

Open the electrical enclosure door.

Turn the screw on the front panel counterclockwise to open.

Disconnect the wires from the heater contactor

Make sure you label the wires to ensure you can connect them correctly to the new contactor.

Remove the contactor

by removing the screws that hold it in place.

Discard old contactor

using the proper disposal procedure. See Material Safety Data Sheet.

Reverse this procedure

to install the new contactor. Make sure the wires are connected correctly.

WARNING: Hazardous Substance

Thermolators use mercury displacement contactors. Mercury is considered a hazardous substance and must be dealt with accordingly. See the Material Safety Data for information on the how to avoid the potential hazards and how to clean up and dispose of mercury if it spills.

WARNING: Electrical Shock Hazard

Only qualified service personnel who have been trained on electrical testing and the procedures for avoiding the hazards should diagnose or correct problems that require opening the unit with power on.

Heater contactor

Page 91

UGH025-0504 Thermolator TW Series

TROUBLESHOOTING 6-23

CHECKING THERMOCOUPLES TW-1 AND TW-2 C

ONTROLS

REPLACING THERMOCOUPLES/

OR PT1000

ENSORS

WARNING: Hot surfaces

Allow the Thermolator to cool to below 100°F (38°C) before servicing the unit.

The Thermolator uses two type ‘K’ thermocouples to monitor supply and return process temperatures. One thermocouple is installed in the wall of the heater tank at the “to process” outlet. The other thermocouple is installed in the wall of the cooling tank at the “from process” inlet.

To check a thermocouple after a probe error:

Disconnect and lockout the main power.

Open the electrical enclosure door.

Turn the

screw on the front panel counterclockwise to open.

Unplug the appropriate thermocouple from

the motherboard and install a jumper on the leads. Refer to the wiring diagrams that came with your unit.

Restart the Thermolator.

u If error message disappears, replace the thermocouple. u If error message does not disappear, replace the moth-

erboard. See Replacing the Motherboard, Section 6.

To replace a thermocouple/or PT1000 Sensors:

Disconnect and lockout the main power.

Shut off the cooling water infeed and drain the

unit. Drain all water using the drain plugs located in the bottom of the unit.

Remove the unit’s top panel

and open the electrical enclosure.

Remove the thermocouple/sensor.

Loosen the compression nut to slide the thermocouple out of the casing. Disconnect the thermocouple wires at the motherboard.

Install the new thermocouple/sensor.

Insert the tip of the new thermocouple at least 1 inch into the tank. tighten the compression nut. Thread the leads through the raceway leading to the electrical enclosure. Attach the thermocouple leads to the motherboard.

1 2

Thermocouple /Sensor

Nut

Page 92

Thermolator TW Series UGH025-0504

6-24 TROUBLESHOOTING

PT100 SENSOR

TEST READINGS

TW CONTROL

°F (°C) Resistance in Ohms 20 (-7) 974

25 (-4) 985

30 (-1) 996

35 (-2) 1007

40 (4) 1017

45 (7) 1028

50 (10) 1039

55 (13) 1050

60 (15) 1061

65 (18) 1071

70 (21) 1082

75 (24) 1093

80 (27) 1103

85 (29) 1115

90 (32) 1125

95 (35) 1136

100 (38) 1146

If you receive a sensor failure SF2 a possible cause may be the process temperature sensor failed. Check with OHM meter and see if the resistance matches the table below. Replace if needed. In addition the sensor wiring may be incorrect or failed. If this is the case check all wiring from terminal strip to sensor in question. Repair as necessary.

Temperature Vs. Resistance readings

Page 93

UGH025-0504 Thermolator TW Series

TROUBLESHOOTING 6-25

Every Thermolator has a solenoid valve assembly that controls the cooling water out flow. Closed circuit (CC) units also have a vent valve assembly. Solenoid valves also are found on the optional purge valve.

Shut off the cooling water infeed.

Drain the unit of all

water through the relief valve port in the rear of the unit. Use a 1/4 inch allen key.

Remove the cooling

water out feed. For closed and isolated circuit models, also remove the cooling water in feed.

Disconnect and lock

out main power.

Remove the top and

side panels of the Thermolator. Lift the top panel straight up, then lift the side panels up.

Remove the cooling

valve from the cooling water out line.

Disassemble the cooling valve.

See Repairing Solenoid Valves and Repairing Motorized Valves, Section 6.

Inspect and clean or repair the valve body

assembly. Remove foreign particles and replace damaged parts as necessary.

Cooling water in

WARNING: Electrical shock and

hot surface hazards

Before 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)

DIRECT INJECTION

CLOSED CIRCUIT

ISOLATED CIRCUIT

Cooling water out

Cooling water in

REPAIRING COOLING VALVES

Page 94

Thermolator TW Series UGH025-0504

6-26 TROUBLESHOOTING

REPAIRING SOLENOID VALVES

Nameplate

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

Retaining Clip*

Retaining Cap*

Sleeve*

Grounding Wire

(Not present on all constructions)

Insulating Washer

Sleeve*

*Indicates Parts Supplied

in Solenoid Enclosure Kit

Coil

Insulating Washer

Spring Washer

Housing* with Nameplate*

Alternate Construction with Nameplate on Housing

*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

Retaining Clip*

Sleeve*

Grounding Wire

(Not present on all constructions)

Sleeve*

Coil

Reassemble the valve and other components.

Reassemble in reverse order. Seal all pipe fittings

with pipe sealant. Check that all flows are in the correct direction. Check for leaks before resuming operation.

Page 95

UGH025-0504 Thermolator TW Series

TROUBLESHOOTING 6-27

REASSEMBLY

MOTORIZED

VALVES

Verify that the valve is in the closed position. The position of the ball opening is indicated by the index on top of the shaft.

Slide the actuator straight down over the valve shaft and onto the mounting plate, with the “R” side facing up. On MS40-703 models, the rotation switch must be in the “R” position.

Align the actuator with the mounting plate, then slide the antirotation clip half way into the slot on the bottom of the actuator.

Tighten the wing nut to secure the anti-rotation clip in place. Be careful not to overtighten the wing nut.

Clip with 2 Holes (NYBA-200)

Using a 10 mm wrench or socket, evenly tighten the two nuts on the shaft clamp, applying 8 to 10 lb-ft (11 to 14 Nm) of torque.

Page 96

Thermolator TW Series UGH025-0504

6-28 TROUBLESHOOTING

WARNING: Electrical shock and

hot surface hazards

Before 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 than 100°F (38°C)

Disconnect and lockout the main power.

Remove the top panel of the Thermolator.

Remove the heater cap.

Use a 1/4-inch open-end wrench to remove the three bolts that hold the cap to the heater tank.

Remove the heater

wiring harness. Label the wiring layout of the heater terminals; wires are labeled 2T1, 2T2, 2T3 and GND.

2 3

Heater cap

REPLACING HEATER ELEMENTS

Continued

Page 97

UGH025-0504 Thermolator TW Series

TROUBLESHOOTING 6-29

IMPORTANT: Always

refer to the wiring diagrams that came with your Thermolator to locate specific electrical components. Illustrations in the User Guide are intended to be representative only.

Unscrew the locking screws on the wiring harness and remove the wires.

Shut off the cooling water in feed.

Drain the Thermolator using the drain plugs

located at the rear of the unit.

Remove the four bolts that hold the heater

element in place. Use a 15/16-inch socket with 1/2-inch drive.

Lift the heating element out of the heater tube.

Lift the element straight up.

Heater cap

Heater element

Heater gasket

Lift the heating element out of the heater tube.

Lift the element straight up.

Replace the heater gasket if it is worn.

Reverse these steps to install the new heater

element and reassemble the unit.

REPLACING HEATER ELEMENTS

CONTINUED

Page 98

Thermolator TW Series UGH025-0504

6-30 TROUBLESHOOTING

REMOVING

THE

PUMP

Disconnect and lockout the main power.

Shut off the

cooling water in feed.

Drain the unit of

all fluid. Remove the relief valve at the rear of the unit using a 1/4inch allen key.

Remove the top

and side panels..

Remove the seal flush

line. Use a 1/2-inch openend wrench to remove the flush line from the connection on the pump adapter.

Remove the pump

assembly bolts. Use a 9/16inch open-end box wrench to remove the bolts holding the pump to the volute. The bolt in the rear will require a 9/16-inch crows foot wrench.

Lift the pump assembly

straight up to remove. The pump can now be replaced or disassembled for repair. Extra long leads so the motor can be removed with disconnecting the wires.

Reverse the steps to

reassemble the unit.

NOTE:

Before restarting, close all drain openings using sealant on the threads and reprime the pump. Do not start until the pump is completely filled with water.

1 2

Cooling water in

DIRECT INJECTION

CLOSED CIRCUIT

ISOLATED CIRCUIT

Cooling water out

Cooling water in

WARNING: Electrical shock and

hot surface hazards

Before 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 than 100°F (38°C)

Pump seal flush line

Pump

assembly

bolts

Volute

Page 99

UGH025-0504 Thermolator TW Series

TROUBLESHOOTING 6-31

DISASSEMBLING

AND

ASSEMBLING

/4- 2 HP PUMPS

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

Remove the impeller nut.

Insert a screwdriver in one of the impeller waterway passages and back off the impeller nut.

Remove the impeller by inserting a screw-

driver in the slot of the motor shaft. Unscrew the impeller while holding the shaft against the rotation.

Remove the seal, gasket case, adapter and

flinger.

Clean the gasket and flange faces, seal seat

cavity and shaft. The shaft shoulder that fits against the impeller must be clean.

Replace the flinger.

Lubricate the seal seat cavity of the adapter and the flinger with soapy water solution before pressing the flinger squarely into the cavity. Do not chip or scratch the lapped seat face.

Remount the adapter to the motor, making

sure the motor shaft does not dislocate or chip the seat of the seal.

Replace the remaining seal components.

Apply a soapy water solution to the motor shaft and the rubber bellows of the rotating seal. Be sure the rotating seal face stays in the holding collar during installation. Do not chip or scratch the lapped seat faces.

Reassemble the remaining components, hold-

ing the shaft against rotation. Remove any burrs caused by the screwdriver on the impeller.

Reattach the pump to the volute case.

Replace any damaged gasket or O-ring between the pump assembly and volute case. Check for free rotation after assembly is completed.

Pump motor

Flinger*

Pump adapter

Gasket, case*

Seal*

Impeller

D washer*

Impeller nut*

*Indicates Parts Supplied

in the Seal Repair Kit

NOTE: Before restarting,

close all drain openings using sealant on the threads and refill the unit with fluid. Do not start the the pump when the unit is dry.

Page 100

Thermolator TW Series UGH025-0504

6-32 TROUBLESHOOTING

Continued

Clean the gasket and flange faces, seal seat

cavity, shaft sleeve and motor shaft. Replace the shaft sleeve if it is damaged or worn.

Replace the flinger.

Lubricate the seal seat cavity of the adapter and the flinger with soapy water solution before pressing the flinger squarely into the cavity. Do not chip or scratch the lapped seat face.

Remount the adapter to the motor.

Make sure the motor shaft does not dislocate or chip the seat of the seal.

Replace the remaining seal components.

Apply a soapy water solution to the motor shaft and the

rubber bellows of the rotating seal. Slide the rotating member of the seal over the shaft sleeve. Replace the seal spring and seal retainer, making sure the rotating seal face stays in the holding collar during installation. Do not chip or scratch the lapped seat faces.

Place the key in the key seat and slide the

impeller on the shaft. Replace the impeller retaining nut. Remove any burrs caused by the screwdriver on the impeller.

Pump motor

Flinger*

Pump adapter

Gasket, case*

Seal*

Impeller

O-ring, shaft*

Impeller retainer*

*Indicates Parts Supplied

in Repair Kit

Shaft* sleeve

Seal retainer*

Key*

Wear ring

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

Remove the impeller retaining assembly. Insert a

screwdriver in one of the impeller waterway passages to hold the impeller steady while removing the retainer.

Remove the impeller being careful not to lose

any parts. If the impeller is difficult to remove, you may need to use a bearing puller.

Remove the seal, adapter, shaft and flinger.

DISASSEMBLING

AND

ASSEMBLING

3 - 7.5 HP PUMPS

Conair Thermolator TW-1, Thermolator TW-2, Thermolator TW User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual