Conair Thermolator TW-S, Thermolator TW-P User Manual

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USER GUIDE

UGH056-0917

Thermolator® TW-S and TW-P

Temperature Control Units

TW-S TW-P

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

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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: UGH056-0917

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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Table of Contents

1-1 Introduction

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

How to Use the Lockout Device ....................................................................... 1-5

2-1 Description

What is the Thermolator TW-P ......................................................................... 2-2

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

How the TW-P Direct Injection Works ............................................................... 2-3

How the Closed Circuit Works .......................................................................... 2-4

How the Closed Circuit Separate Source Works ............................................... 2-5

TW-P Control Features vs TW-V and TW-S ....................................................... 2-6

Speciﬁcations: TW-P........................................................................................ 2-7

TW-P Features and Options ............................................................................. 2-8

Options ........................................................................................................... 2-8

3-1 Installation

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

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

Connecting Process and Water Supply Lines Without Purge ............................. 3-4

Mold Purge Valve Connections ......................................................................... 3-5

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

Testing the Installation..................................................................................... 3-7

Initial Setup ..................................................................................................... 3-8

Operating Mode ............................................................................................ 3-10

Temperature Units ......................................................................................... 3-11

Setpoint ........................................................................................................ 3-12

Alarm Points .................................................................................................. 3-12

Table of Contents I i

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4-1 Operation

The TW-P Control ............................................................................................ 4-2

Default Display ................................................................................................ 4-3

Starting the Thermolator .................................................................................. 4-4

Stopping the Thermolator ................................................................................ 4-5

Using the Optional Mold Purge Option ............................................................. 4-6

Conair TW-P Thermolator ................................................................................ 4-7

5-1 Maintenance

Maintenance of your Thermolator .................................................................... 5-2

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

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

Removing the Pump Motor and Seal (1/2 to 3 Hp units) ................................... 5-4

Reassembling the Pump Motor and Seal (1/2 to 3 Hp units) ............................. 5-7

Removing the Pump Motor and Seal (5 to 10 Hp units) .................................... 5-9

Reassembling Pump Motor and Seal (5 to 10 Hp units ................................... 5-11

6-1 Troubleshooting

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

A Few Words of Caution ................................................................................... 6-3

Identifying the Cause of a Problem .................................................................. 6-4

Controller Alarms ............................................................................................. 6-5

Controller Control Fault Logic ........................................................................ 6-14

Unit Faults ..................................................................................................... 6-15

Unit Will Not Power Up ................................................................................... 6-26

Troubleshooting ............................................................................................. 6-27

Replacing the Heater Contactor ..................................................................... 6-29

Checking the RTD .......................................................................................... 6-30

ii I Table of Contents

Replacing the RTD ......................................................................................... 6-32

Repairing Cooling Valves ............................................................................... 6-33

Disassembly of Alternate Direct Acting Solenoid Valves .................................. 6-34

Alternate Pilot Operated Solenoid Valves ........................................................ 6-35

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Replacing Immersion Heaters ........................................................................ 6-36

Removing the Pump ...................................................................................... 6-38

A Appendix

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

Warranty Information ....................................................................................... A-2

B Appendix

PID Parameters ............................................................................................... B-1

Setting the Security Passcode ......................................................................... B-4

C Appendix

Plumbing Diagram........................................................................................... C-1

Plumbing Curves ............................................................................................. C-4

D Appendix

Service Parts ................................................................................................... D-1

E Appendix

External Interfaces .......................................................................................... E-1

F Appendix

Pressure Switch Settings ..................................................................................F-1

G Appendix

Mold Purge Installation Instructions ................................................... G-1

H Appendix

Flowmeter Installation Instructions .................................................... H-1

Table of Contents I iii

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iv I Table of Contents

Page 7

Introduction

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

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

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

Foreword ............................................................ 1-3

SECTION

Introduction

ATTENTION: Read This So No One Gets Hurt .............. 1-4

How to Use the Lockout Device .............................. 1-5

Introduction I 1-1

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Purpose of the User Guide

This User Guide describes the Conair Thermolator® TW-S and TW-P and explains stepby-step how to install and operate 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.

How the Guide is Organized

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 indicate tasks or steps to be performed by the user.

A diamond indicates the equipment’s response to an action performed by the user or a situation.

An open box marks items in a checklist.

A circle marks items in a list.

•

Indicates a tip. A tip is used to provide you with a suggestion that will help you with the

maintenance and the operation of this equipment.

Indicates a note. A note is used to provide additional information about the steps you are following throughout the manual.

Your Responsibility as a User

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

• Thorough view of this User Guide, paying particular attention to hazard warnings, appendices, and related diagrams.

• Thorough review of the equipment itself, with careful attention to voltage sources, intended use, and warning labels.

• Thorough review of instruction manuals for associated equipment.

• Step-by-step adherence to instructions outlined in this User Guide.

1-2 I Introduction

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Foreword

The Thermolator® typically consists of a ﬂuid pump, electric immersion heater, and temperature control valve in a compact packaged cabinet for easy location in industrial applications where ﬂuid temperature control is required.

This manual is to serve as a guide for installing, operating, and maintaining the equipment. Improper installation can lead to poor performance and/or equipment damage. We recommend the use of qualiﬁed installers and service technicians for all installation and maintenance of this equipment.

This manual is for our standard product. The information in this manual is general in nature. Unit-speciﬁc drawings and supplemental documents are included with the equipment as needed. Additional copies of documents are available upon request. We strive to maintain an accurate record of all equipment during the course of its useful life.

Due to the ever-changing nature of applicable codes, ordinances, and other local laws pertaining to the use and operation of this equipment, we do not reference them in this manual. There is no substitute for common sense and good operating practices when placing any mechanical equipment into operation. We encourage all personnel to familiarize themselves with this manual’s contents. Failure to do so may unnecessarily prolong equipment down time.

Follow good piping practices and the information in this manual to ensure successful installation and operation of this equipment.

We trust your equipment will have a long and useful life. If you should have any questions, please contact our Service Department specifying the serial number and model number of the unit as indicated on the nameplate.

Introduction

Contact Conair Parts and Service Phone: 800-458-1960 From outside of the United States, Call: 814 437 6861

Introduction I 1-3

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ATTENTION: Read This So No One Gets Hurt

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.

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 machine.

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

WARNING: Voltage hazard

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

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 severe personal injury and erratic machine operation.

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

WARNING: Compressed air hazard

If you use compressed air, you must wear eye protection and observe all OSHA and other safety regulations pertaining to the use of compressed air. Bleed off pressure before servicing equipment.

CAUTION: Hot Surfaces

Surface temperatures inside the Thermolator can exceed 300° F {149° C}. Always allow the unit to cool below 100° F {38º C} before opening, servicing, or disassembling the unit.

1-4 I Introduction

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How to Use the Lockout Device

CAUTION: Before performing maintenance or repairs on this product, you should

disconnect and lockout electrical power sources to prevent injury from unexpected energization or start-up. A lockable device may be provided to isolate this product from potentially hazardous electricity.

WARNING: Before removing lockout devices and returning switches to the ON position, make sure that all personnel are clear of the machine, tools have been removed and all safety guards reinstalled.

Lockout is the preferred method of isolating machines or equipment from energy sources. Your Conair product may be equipped with the lockout device pictured below. To use the lockout device:

1 Stop or turn off the equipment.

2 Isolate the equipment from the electric power.

3 Turn the rotary disconnect switch to the OFF, or “O” position

4 Secure the device with an assigned lock or tag.

5 The equipment is now locked out.

Introduction

If the machine has no included lockout device, perform the same procedure at the upstream device as part of premises electrical system. Incoming cooling water and compressed air (if purge) are additional energy sources that need to be controlled.

Introduction I 1-5

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1-6 I Introduction

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Description

What is the Thermolator TW-S and TW-P? ................ 2-2

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

How the TW-S and TW-P Series Direct Injection Works 2-3

SECTION

Description

How the Closed Circuit Works ................................ 2-4

How the Closed Circuit Separate Source Works ......... 2-5

How the TW-P Direct Injection Works ....................... 2-5

TW-S Control Features vs TW-V and TW-P ................ 2-6

TW-P Control Features vs TW-V and TW-S ................ 2-7

Specifications: TW-S............................................. 2-8

Specifications: TW-P ............................................. 2-9

Description I 2-1

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What is the Thermolator TW-S and TW-P

The Thermolator TW-S and TW-P Series circulates 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.

The TW-S and TW-P Series is available in single or multiple-zone conﬁgurations for process heating and cooling. Two-zone models can control up to two temperatures at different locations in the process. Two-zone models have common cooling water manifolds and electrical connections.

Contact Conair Customer Service 1 800 458 1960. From outside of the United States, call: 814 437 6861

Typical Applications

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

TW 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:

• Process temperatures up to 250°F {121° C} - with options up to 300° F {149° C}.

• Use with chiller water or properly treated and ﬁltered tower or city water.

Direct injection models may be used with glycol/water process loop mixtures, as long as the glycol does not exceed 50% of the mixture. If your application requires a higher percentage of glycol, or if you have a contaminated cooling water supply, ask your Conair representative about our closed-circuit or isolated circuit Thermolator TW-S and TW-P models.

IMPORTANT: Do not use deionized water or glycol mixtures containing additives in the Thermolator. Softened water or glycol mixtures with additives, such as automotive fluids, can damage the Thermolator. Glycol/water process loop mixtures should use only industrial-grade ethylene or propylene glycol.

Contact Conair for more information about recommendations for your product.

2-2 I Description

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How the TW-S and TW-P Series Direct Injection Works

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

1 The temperature of the process ﬂuid is

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

Description

From Process

Cooling Water In

Cooling Water Out

To Process RTD

To Process

From Process RTD

Cooling Valve

Relief Valve

Heater

Mixing Tank

(or Optional 2nd Heater)

Low Pressure Switch

Bypass/ De-aeration

Process

Pressure

Gauge

2 The temperature of the process ﬂuid is

measured as it ﬂows into the mixing tank through the “From Process” line B.

3 If the “To Process” temperature is above

the setpoint value, the cooling valve opens. Cool water enters the bottom of the mixing tank via the “Cooling In” line C. Warm water ﬂows out of the mixing tank via the “Cooling Out” line D.

4 If the “To Process” temperature is below

the setpoint, the heater elements inside the heater tank are energized.

5 The pump moves water from the mixing

tank into the heater tank. Pressure is measured before and after the pump with pressure gauges E and F. Note: Depending on your model, you may have an additional heater in the mixing tank.

From

Process

Pressure

Gauge

Pump

TW-S Direct Injection

Description I 2-3

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How the Closed Circuit Works

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. A brazed-plate heat exchanger replaces the mixing tank used on direct injection units.

1 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 A to the mold or process. The ﬂuid returns to the unit through the “From Process” line B for reheating or cooling.

2 If the temperature is above the setpoint value, the cool-

ing valve opens. Cool water enters the heat exchanger via the “Cooling In” line. Process ﬂuid is always being circulated through the process side of the heat exchanger. The process ﬂuid is indirectly cooled via conduction from the colder water now running through the cooling side of the heat exchanger. If the measured temperature is below the setpoint, the heater elements inside the heater tank are energized.

Optional From Process RTD

3 The pump moves water from the heat exchanger to the

heater tank. Pressure is measured before and after the pump with pressure gauge E and F.

2-4 I Description

TW-S Closed Circuit

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How the Closed Circuit Separate Source Works

Closed Circuit Separate Source 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 never mixed with process ﬂuid. Fluid to ﬁll the process loop is provided by a “separate source” A brazed plate heat exchanger replaces the mixing tank used on direct injection units.

1 The temperature of the process ﬂuid is measured as it

Description

2 Alternatively, the temperature of the process ﬂuid may

be measured as it ﬂows into the mixing tank through the “From Process” line B.

3 If the temperature is above the setpoint value, the cooling

valve opens. Cool water enters the heat exchanger via the “Cooling In” line. Process ﬂuid is always being circulated through the process side of the heat exchanger. The process ﬂuid is indirectly cooled via transmission from the colder water now running through the cooling side of the heat exchanger. If the measured temperature is below the setpoint, the heater elements inside the heater tank are energized.

4 The pump moves water from the heat exchanger to the

heater tank. Pressure is measured before and after the pump with pressure gauge E and F.

TW-P Closed Circuit Separate Source

Description I 2-5

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TW-S Control Features vs TW-V and TW-P

Control features on the TW-S Series Thermolators

Model TW-S

Direct Injection Closed Circuit - Common Source Closed Circuit - Separate Source

Construction

Standard Pump Range

Standard Heater Range 0 to 48 KW Cast Heater / Pump Incoloy Heaters Silicon Carbide Seals Pressure Gauges 250°F Setpoint Range 300°F Setpoint Range

Controls

PID Control Setpoint / Actual Display Password Protection Modbus RTU via RS-485 SPI via RS-485 Retransmit Process Temp (4-20mA) Hand Held Remote Auto Restart Capability High Temperature Safety Mold Purge Phase Detection Circuit Heat Error for Heater Malfunction Remote Start/Stop 120°F Air Purge Cancel Quick Access Cool Down Mode

Status / Alarm Lights

Panel Mounted Status Lights 7 LEDs Panel Mounted Alarm Lights 3 LEDs Audible Alarm Strobe Light

2-6 I Description



3/4 to 10 Hp

{0.56 to 7.45 KW}

    

  



  



The TW-S Control

Standard



Optional

PID Control

Phase detection indicates incorrect pump rotation or an open electrical leg.

Control features on the TW-P and TW-V Series Thermolators

Model TW-P TW-V

Direct Injection Closed Circuit - Common Source Closed Circuit - Separate Source

Construction

Standard Pump Range

Standard Heater Range 0 to 48 KW 12 KW Cast Heater / Pump Incoloy Heaters Silicon Carbide Seals Pressure Gauges 250°F Setpoint Range 300°F Setpoint Range

Controls

Status / Alarm Lights

Panel Mounted Status Lights 12 LEDs 1 LED Panel Mounted Alarm Lights 5 LEDs 1 LED Audible Alarm Strobe Light

 

3/4 to 10 Hp

{0.56 to 7.45 KW}

         

    



    



3/4 to 10 Hp

{0.56 to 7.45 KW}

Page 19

TW-P Control Features vs TW-V and TW-S

Control Power

Autostart Signal

Pump

Heat

Cool

Coolant Pressure

Temperature Limit

Flow GPM (flash)

Mold

Purge

Rapid

Cool

Process

Cool Down

Electrical Phase Error

Heat Error

Process Cool Down

Mold Purge

Rapid Cool

Communications

Remote Heat/Cool

Program Mode

Description

Control features on the TW-P Series Thermolators

Model TW-P

Direct Injection Closed Circuit - Common Source Closed Circuit - Separate Source

Construction

Standard Pump Range

Standard Heater Range 0 to 48 KW Cast Heater / Pump Incoloy Heaters Silicon Carbide Seals Pressure Gauges 250°F Setpoint Range 300°F Setpoint Range

Controls

Status / Alarm Lights

Panel Mounted Status Lights 12 LEDs Panel Mounted Alarm Lights 5 LEDs Audible Alarm Strobe Light



3/4 to 10 Hp

{0.56 to 7.45 KW}

    

  



    



Standard



Optional

* 4-20mA

PID Control

Purge On/ Off button included on control.

Phase detection indicates incorrect pump rotation or an open electrical leg.

Remote Start/ Stop works with external timers or switches for convenient preheating of molds.

The TW-P Control

Control features on the TW-S and TW-V Series Thermolators

Model TW-S TW-V

Direct Injection Closed Circuit - Common Source Closed Circuit - Separate Source

Construction

Standard Pump Range

Standard Heater Range 0 to 48 KW 12 KW Cast Heater / Pump Incoloy Heaters Silicon Carbide Seals Pressure Gauges 250°F Setpoint Range 300°F Setpoint Range

Controls

Status / Alarm Lights

Panel Mounted Status Lights 7 LEDs 1 LED Panel Mounted Alarm Lights 3 LEDs 1 LED Audible Alarm Strobe Light

 

3/4 to 10 Hp

{0.56 to 7.45 KW}

         

    



  



3/4 to 10 Hp

{0.56 to 7.45 KW}

Description I 2-7

Page 20

Specifications: TW-S

Models

TW-S (direct injection)

‡

Performance Characteristics

Minimum setpoint temperature °F {°C} 40 {4} Maximum setpoint temperature °F {°C} 250 {121}, (300 {149} optional) Minimum operating temperature °F {°C} Approximately 20° {11°} above the cooling water inlet temperature* Available pump sizes 0.75, 1, 2, 3, 5, 7.5, 10 Hp {0.56, 0.75, 1.49, 2.24, 3.73, 5.59, or 7.46 kW} Available heater sizes 9, 12, 18, 24, 36 or 48 kW Connections to/from process NPT (female) 1.50 inches Connections in/out cooling water NPT (female) 1.00 inches

Pump Performance - Consult your Conair representative for pump performance characteristics at other operating points.

Pump

Nominal ﬂow gpm {lpm} 50 {189} 55 {208} 75 {284} 85 {322} 100 {379} 120 {454} 150 {568} Pressure@ nominal ﬂow psi {kg/cm2} 20 {1.4} 25 {1.7} 30 {2.1} 32 {2.2} 46 {3.2} 56 {3.9} 65 {4.5}

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} 10 Hp {7.46 kW}

Dimensions inches {mm}

Cabinet Style Single Zone (A)

Dual Zone (B)

Height 28.31 {719} 29.00 {734}

Width 14.00 {356} 28.34 {720}

Depth 25.75 {654} 26.06 {662}

†

Shipping weight ranges lb {kg} Weights vary depending on cabinet size and options.

Single Zone Dual Zone

Pump Minimum Maximum Minimum Maximum

0.75 Hp {0.56 kW} 240 {109} 280 {127} 491 {223} 576 {261} 1 Hp {0.75 kW} 245 {111} 290 {132} 499 {226} 584 {265} 2 Hp {1.49 kW} 248 {113} 298 {131} 515 {234} 590 {268} 3 Hp {2.24 kW} 259 {118} 299 {136} 538 {244} 623 {283} 5 Hp {3.73 kW} 302 {137} 352 {160} 629 {285} 699 {317}

7.5 Hp {5.59 kW} 317 {144} 362 {164} 649 {294} 729 {331} 10 Hp {7.46 kW} 329 {149} 379 {172} 683 {310} 763 {346}

Total Full Load Amps per zone

Heater 9 kW 12 kW 18 kW Voltage

208/3/60 230/3/60 380/3/60 400/3/50 460/3/60 575/3/60 208/3/60 230/3/60 380/3/60 400/3/50 460/3/60 575/3/60 208/3/60 230/3/60 380/3/60 400/3/50 460/3/60 575/3/60

Pump size

0.75 Hp {0.56 kW} 25.9 15.0 12.9 10.5 33.4 19.3 16.7 13.5 48.5 28.0 24.2 19.5

1.0 Hp {0.75 kW} 26.8 15.2 15.3 13.3 10.6 34.3 19.5 19.6 17.1 13.6 49.4 28.2 28.3 24.5 19.6

2.0 Hp {1.49 kW} 28.9 16.6 16.7 14.3 11.6 36.4 20.9 21.0 18.1 14.6 51.5 29.6 29.7 25.6 20.6

3.0 Hp {2.24 kW} 31.7 13.4 18.0 15.4 12.5 39.2 22.4 22.3 19.2 15.5 54.3 31.1 31.0 26.7 21.5

5.0 Hp {3.73 kW} 36.3 20.7 18.2 17.7 14.2 43.8 25.0 22.5 21.5 17.2 58.9 33.7 31.2 29.0 23.2

7.5 Hp {5.59 kW} 42.1 24.9 20.5 20.3 16.3 49.6 29.2 24.8 24.1 19.3 64.7 37.9 33.5 31.6 25.3

10.0 Hp {7.46 kW}

50.3 28.9 24.8 24.1 18.9 57.8 33.2 29.1 27.9 21.9 72.9 41.9 37.8 35.4 27.9

Total Full Load Amps per zone

Heater 24 kW 36 kW 48 kW Voltage

Pump size

0.75 Hp {0.56 kW} 63.6 36.6 31.7 25.6 93.7 54.0 46.8 37.6 N/A 61.9 49.7

1.0 Hp {0.75 kW} 64.5 36.8 36.9 32.1 25.7 94.6 54.2 54.3 47.2 37.7 N/A 62.3 49.8

2.0 Hp {1.49 kW} 66.6 38.2 38.3 33.1 26.7 96.7 55.6 55.7 48.2 38.7 N/A 63.3 50.8

3.0 Hp {2.24 kW} 69.4 39.7 39.6 34.2 27.6 99.5 57.1 57.0 49.3 39.6 N/A 64.4 51.7

5.0 Hp {3.73 kW} 74.0 42.3 39.8 36.5 29.3 104.1 59.7 57.2 51.6 41.3 N/A 66.7 53.4

7.5 Hp {5.59 kW} 79.8 46.5 42.1 39.1 31.4 109.9 63.9 59.5 54.2 43.4 N/A 69.3 55.5

10.0 Hp {7.46 kW}

208/3/60 230/3/60 380/3/60 400/3/50 460/3/60 575/3/60 208/3/60 230/3/60 380/3/60 400/3/50 460/3/60 575/3/60 208/3/60 230/3/60 380/3/60 400/3/50 460/3/60 575/3/60

88.0 50.5 46.4 42.9 34.0 118.1 67.9 63.8 58.0 46.0 N/A 73.1 58.1

Speciﬁcation Notes

* Lower operating temperatures can be obtained with larger cooling valves.

†

Available in TW-S and TW-P models only.

‡

Direct Inject (DI) cooling injects cooling water directly into the process loop upon

demand.

2-8 I Description

FLA data for reference purposes only. Does not include any options or accessories

on equipment. For full FLA detail for power circuit design of speciﬁc machines and systems, refer to the electrical diagrams of the equipment order and the nameplate applied to the machine.

Speciﬁcations may change without notice. Consult with a Conair representative for the

most current information.

Page 21

Specifications: TW-P

Models

Performance Characteristics

Minimum setpoint temperature °F {°C} 40 {4} Maximum setpoint temperature °F {°C} 250 {121}, (300 {149} optional) 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} (varies) Available pump sizes 0.75, 1, 2, 3, 5, 7.5, 10 Hp {0.56, 0.75, 1.49, 2.24, 3.73, 5.59, or 7.46 kW} Available heater sizes 6, 9, 12, 18, 24, 36 or 48 kW 9, 12, 18, 24, or 36 kW Connections to/from process NPT (female) 1.50 inches Connections in/out cooling water NPT (female) 1.00 inches

TW-P (direct injection)

‡

TW-P (closed circuit)

Pump Performance - Consult your Conair representative for pump performance characteristics at other operating points.

Pump

Nominal ﬂow gpm {lpm} 50 {189} 55 {208} 75 {284} 85 {322} 100 {379} 120 {454} 150 {568} Pressure @ nominal ﬂow psi {kg/cm2} 20 {1.4} 25 {1.7} 30 {2.1} 32 {2.2} 46 {3.2} 56 {3.9} 65 {4.5}

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} 10 Hp {7.46 kW}

Dimensions inches {mm}

Cabinet Style Single Zone (A)

Height 28.43 {722} 29.00 {734}

Width 14.00 {356} 28.34 {720}

Depth 25.75 {654} 26.06 {662}

Dual Zone (B)

†

TW-S and

TW-P only

Shipping weight ranges lb {kg} Weights vary depending on cabinet size, options,and cooling type (DI or CC).

Single Zone Dual Zone

Pump Minimum Maximum Minimum Maximum

0.75 Hp {0.56 kW} 240 {109} 280 {127} 491 {223} 576 {261} 1 Hp {0.75 kW} 245 {111} 290 {132} 499 {226} 584 {265} 2 Hp {1.49 kW} 248 {113} 298 {135} 515 {234} 590 {268} 3 Hp {2.24 kW} 259 {118} 299 {136} 538 {244} 623 {283} 5 Hp {3.73 kW} 302 {137} 352 {160} 629 {285} 699 {317}

7.5 Hp {5.59 kW} 317 {144} 362 {164} 649 {294} 729 {331} 10 Hp {7.46 kW} 329 {149} 379 {172} 683 {310} 763 {346}

Total Full Load Amps per zone **

Heater 9 kW 12 kW 18 kW Voltage

Pump size

0.75 Hp {0.56 kW} 25.9 15.0 12.9 10.5 33.4 19.3 16.7 13.5 48.5 28.0 24.2 19.5

1.0 Hp {0.75 kW} 26.8 15.2 15.3 13.3 10.6 34.3 19.5 19.6 17.1 13.6 49.4 28.2 28.3 24.5 19.6

2.0 Hp {1.49 kW} 28.9 16.6 16.7 14.3 11.6 36.4 20.9 21.0 18.1 14.6 51.5 29.6 29.7 25.6 20.6

3.0 Hp {2.24 kW} 31.7 13.4 18.0 15.4 12.5 39.2 22.4 22.3 19.2 15.5 54.3 31.1 31.0 26.7 21.5

5.0 Hp {3.73 kW} 36.3 20.7 18.2 17.7 14.2 43.8 25.0 22.5 21.5 17.2 58.9 33.7 31.2 29.0 23.2

7.5 Hp {5.59 kW} 42.1 24.9 20.5 20.3 16.3 49.6 29.2 24.8 24.1 19.3 64.7 37.9 33.5 31.6 25.3

10.0 Hp {7.46 kW}

208/3/60 230/3/60 380/3/60 400/3/50 460/3/60 575/3/60 208/3/60 230/3/60 380/3/60 400/3/50 460/3/60 575/3/60 208/3/60 230/3/60 380/3/60 400/3/50 460/3/60 575/3/60

50.3 28.9 24.8 24.1 18.9 57.8 33.2 29.1 27.9 21.9 72.9 41.9 37.8 35.4 27.9

Total Full Load Amps per zone **

Heater 24 kW 36 kW 48 kW Voltage

Pump size

0.75 Hp {0.56 kW} 63.6 36.6 31.7 25.6 93.7 54.0 46.8 37.6 N/A 61.9 49.7

1.0 Hp {0.75 kW} 64.5 36.8 36.9 32.1 25.7 94.6 54.2 54.3 47.2 37.7 N/A 62.3 49.8

2.0 Hp {1.49 kW} 66.6 38.2 38.3 33.1 26.7 96.7 55.6 55.7 48.2 38.7 N/A 63.3 50.8

3.0 Hp {2.24 kW} 69.4 39.7 39.6 34.2 27.6 99.5 57.1 57.0 49.3 39.6 N/A 64.4 51.7

5.0 Hp {3.73 kW} 74.0 42.3 39.8 36.5 29.3 104.1 59.7 57.2 51.6 41.3 N/A 66.7 53.4

7.5 Hp {5.59 kW} 79.8 46.5 42.1 39.1 31.4 109.9 63.9 59.5 54.2 43.4 N/A 69.3 55.5

10.0 Hp {7.46 kW}

208/3/60 230/3/60 380/3/60 400/3/50 460/3/60 575/3/60 208/3/60 230/3/60 380/3/60 400/3/50 460/3/60 575/3/60 208/3/60 230/3/60 380/3/60 400/3/50 460/3/60 575/3/60

88.0 50.5 46.4 42.9 34.0 118.1 67.9 63.8 58.0 46.0 N/A 73.1 58.1

Description

†

Speciﬁcation Notes

* Lower operating temperatures can be obtained with larger cooling valves.

†

Available in TW-S and TW-P models only.

‡

Direct Inject (DI) cooling injects cooling water directly into the process loop upon

demand.

Closed Circuit (CC) cooling injects cooling water into the process loop only during the

initial ﬁlling or when make-up water is needed.

** FLA data for reference purposes only. Does not include any options or accessories

on equipment. For full FLA detail for power circuit design of speciﬁc machines and systems, refer to the electrical diagrams of the equipment order and the nameplate applied to the machine.

Speciﬁcations may change without notice. Consult with a Conair representative for the most current information.

Description I 2-9

Page 22

TW-S and TW-P Features and Options

Incoloy heaters

minimize chemical and high temperature damage, and maximizes life.

Two-piece cast

construction

High efficiency pumps

from 3/4 to 10 Hp. Silicon carbide seals are standard.

Built-in sediment trap

settles contaminants away from the pump seals.

Options

Modulating Valve

This option eliminates thermal shock from your process circuit by modulating the cooling water. If Modulating valve option is not chosen, the Solenoid valve replaces it.

Compressed Air Mold Purge (Available with TW-P only) This option quickly evacuates fluid from the process circuit, allowing for faster, cleaner disconnection of the temperature controller from molds and hoses.

Alarm packages The Thermolator control includes an output relay that can be connected to an optional external alarm package to call attention to alarm conditions.

Solenoid Valve

2-10 I Description

Stacking Rack

Save floor space by stacking Thermolators two-high. The stacking rack can be used only with single-zone models with a height of less than 30 inches{262 mm} high cabinets.

Page 23

Installation

SECTION

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

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

Rigging .............................................................. 3-4

Fluid Distribution Piping ........................................ 3-4

Installation - Electrical ........................................ 3-5

Connecting Process and Water Supply Lines

without Purge ...................................................... 3-6

Optional Mold Purge Valve Connections ................... 3-7

Connecting the Main Power Source ......................... 3-8

Testing the Installation ......................................... 3-9

Initial Setup .......................................................3-10

Installation

Temperature Units ...............................................3-11

Setpoint ............................................................3-12

Alarm Points.......................................................3-13

Installation I 3-1

Page 24

NOTE: If your TW-P was ordered with the remote HMI option, the remote HMI may arrive in a separate box.

Unpacking the Boxes

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

CAUTION: Lifting

To avoid personal injury or damage to the Thermolator, lift the unit using a forklift or hoist with straps that have been positioned at the center of gravity.

1 Carefully remove the Thermolator and components from their shipping containers.

2 Remove all packing material, protective paper, tape, and plastic. Compare contents

to the shipping papers to ensure that you have all the parts.

3 Carefully inspect all components to make sure no damage occurred during shipping.

Check all wire terminal connections, bolts, and any other electrical connections, which may have come loose during shipping.

4 Record serial numbers and speciﬁcations in the blanks provided on the back of the

User Guide’s title page. This information will be helpful if you ever need service or parts.

5 You are now ready to begin installation. See Installation Section entitled,

Preparing for Installation.

NOTE: If the temperature control unit is stored prior to installation, it is important to protect it from damage. Blow out any water from the unit to protect it from damage from freezing. Cover the equipment to keep dirt and debris from accumulating on it. Units should not be stored in areas warmer than 145°F {63°C}.

3-2 I Installation

Page 25

Preparing for Installation

Mold Purge

Rapid Cool

Process Cool Down

Control Power

Autostart Signal

Pump

Heat

Cool

Coolant Pressure

Temperature Limit

Electrical Phase Error

Heat Error

Process Cool Down

Rapid Cool

Communications

Remote Heat/Cool

Program Mode

Mold Purge

Flow GPM (flash)

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

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

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

1 Position the Thermolator as close to the process machine as possible.

Installation

2 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 unit for required voltage, phase, frequency, and full load amps. Check the last page of the electrical power prints for the disconnect fuse size and minimum wire connection size. All wiring should be completed by qualiﬁed personnel and should

comply with your region’s electrical codes.

r A clean, well-ventilated environment. The room temperature should not

exceed 104° F {40° C} with 95% non-condensing humidity and should not fall below 32° F {0° C}.

r Minimum clearance for safe operation and maintenance. The diagram at

the right shows minimum clearance for operation. You also need enough clearance in rear for water hookups. For maintenance, you should move the Thermolator to provide at least 36 inches {91 cm} on any side of the Thermolator. Additionally, your required electrical codes may require a larger service area in front of the electrical panel.

r A source of water for cooling. City, tower or chiller water may be

used, as long as the supply pressure is at least 25 psi and not more than 95 psi for most units; refer to the appendix for more information on 48 kW and 300° F

{149° C} units.

Alternate locations

Process Machine

12 inches {305 mm}

Thermolator

12 inches {305 mm}

20 inches {508 mm}

3 Install plumbing for process and cooling lines.

You will need two 11/2-inch NPT male ﬁttings for the process inlet and outlet and two 1-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.

Installation I 3-3

Page 26

Rigging

The unit has a structural steel base with casters to facilitate easy movement and positioning. Follow proper rigging methods to prevent damage to components. Avoid impact loading caused by sudden jerking when lifting or lowering the unit. Use pads where abrasive surface contact may occur. Use the frame supporting the unit for positioning it with a crane or a forklift.

Fluid Distribution Piping

Proper insulation of any cooling ﬂuid system where the supply cooling ﬂuid temperature is below the dew point is crucial to prevent condensation. In most cases this will apply to systems where the supply temperature is 55°F {13°C} or colder. The formation of condensation on water piping caused by the state change of the water from gas to liquid adds a substantial heat load and becomes an additional burden for the cooling system.

The importance of properly sized piping between the cooling system and the temperature control unit and between the temperature control unit and the process cannot be overemphasized. See the ASHRAE Handbook or other suitable design guide for proper pipe sizing. In general, run full size piping out to the process and then reduce the pipe size to match the connections on the process equipment. One of the most common causes of unsatisfactory unit performance is poor piping system design. Avoid long lengths of hoses, quick disconnect ﬁttings, and manifolds wherever possible as they offer high resistance to water ﬂow. When manifolds are required, install them as close to the use point as possible. Provide ﬂow-balancing valves at each machine to assure adequate water distribution in the entire system. We recommend shut-off valves at each machine to allow for isolation of the unit.

3-4 I Installation

Page 27

Installation - Electrical

All wiring must comply with local codes and the National Electric Code (NEC). Full Load Amperes (FLA) and other unit electrical data are on the unit nameplate. A unit speciﬁc electrical schematic ships with the unit. Measure each leg of the main power supply voltage at the main power source. Voltage must be within the voltage utilization range given on the drawings included with the unit. If the measured voltage on any leg is not within the speciﬁed range, notify the supplier and correct before operating the unit. Voltage imbalance must not exceed two percent. Excessive voltage imbalance between the phases of a three-phase system can cause motors to overheat and eventually fail. Voltage imbalance is determined using the following calculations:

%Imbalance = (V

= (V1 + V2 + V3) / 3

avg

Vx = phase with greatest difference from V

– Vx) x 100 / V

avg

For example, if the three measured voltages were 442, 460, and 454 volts, the average would be:

(442 + 460 + 454) / 3 = 452

The percentage of imbalance is then:

(452 – 442) x 100 / 452 = 2.2 %

This exceeds the maximum allowable of 2%. There is a terminal block for main power connection to the main power source. The main power source should be connected to the terminal block through an appropriate disconnect switch. There is a separate lug in the main control panel for grounding the unit. Check the electrical phase sequence at installation and prior to start-up. Operation of the unit with incorrect electrical phase sequencing will result in improper pump performance. Check the phasing with a phase sequence meter prior to applying power. The proper sequence should read “ABC” on the meter. If the meter reads “CBA”, open the main power disconnect and switch two line leads on the line power terminal blocks (or the unit mounted disconnect). Do not interchange any load leads that are from the unit contactors or the motor terminals. .

Installation

Installation I 3-5

Page 28

Tools for Installation:

r Pipe wrench large

enough for a 2-inch pipe

r Premium quality

Teﬂon thread sealant

NOTE: Conair recommends 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.

Connecting Process and Water Supply Lines Without Purge

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.

1 Remove the shipping pipe plug from the female connections on the back of the

Thermolator.

2 Install pipe to the rear of the Thermolator. Use male 1

process connections and male 1-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.

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

directions.

4 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 over-tighten!

/2-inch NPT piping for

Cooling Valve

and

From Process

connection in this area

To Process connection in this area

Cooling water out

Cooling water in

DIRECT INJECTION

3-6 I Installation

Page 29

Optional Mold Purge Valve Connections

A mold purge valve is available as an option. This valve quickly evacuates ﬂuid from the process circuit, allowing faster disconnection of the temperature controller from molds and hoses. A manual purge button controls this valve.

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 supply of non-lubricated compressed air.

1 Remove the shipping pipe plug from the female connections on the back of the

Thermolator.

2 Install an external ball valve on the cooling water inlet of the Thermolator. This

valve is required when a purge valve is used.

3 Install pipe to the rear of the Thermolator. Use male 1

/2-inch NPT piping for

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

directions.

5 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!

TIP: Conair recommends or-

dering the purge valve with the Thermolator so that wiring and installation is completed at the factory. However, aftermarket addition of the purge valve is possible.

Installation

6 Connect the purge valve to the compressed air supply. The air pressure should not

exceed 100 psi.

NOTE: For information about how to add a purge valve to your Thermolator if you did not order it equipped that way from the factory, contact Conair Service.

NOTE: See Appendix G for Mold Purge Installation Instruction Sheet

Contact Conair Parts and Service Phone: 800-458-1960 From outside of the United States, Call: 814 437 6861

Installation I 3-7

Page 30

Connecting the Main Power Source

Before beginning, note the electrical speciﬁcations on the serial tag mounted to the side of the unit. The electrical connection 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 connection should run through a fused disconnect sized for the amperage noted on the serial tag and conforming to all local and national codes, including Article 250 of the National Electric Code.

WARNING: Electrical hazard

Before performing maintenance or repairs on this product, disconnect and lock out electrical power sources to prevent injury from unexpected energization or start-up. A lockable device must be used to isolate this product from potentially hazardous electricity.

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

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

Optional

Disconnect

Switch

IMPORTANT: Always refer to the wiring diagrams that came with your temperature control unit before making electrical connections. The diagrams show the minimum size main power cable required for your unit, and 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.

r Verify that resistance to ground

on each phase is at least 1 mega ohm (use a multi-meter, not a megger for this measurement).

1 Open the unit’s electrical enclosure. Removing

the top panel is recommended. The Thermolator comes from the factory with a knockout for 1/2 inch conduit. A knockout punch should be used if necessary to enlarge the hole for larger diameter conduits.

2 Insert the main power wires through the conduit in the right side of the

enclosure. See electrical prints for recommended wire size.

 NOTE: If using a ﬂexible cord, secure the wire with a rubber

compression ﬁtting or strain relief.

3 Connect the power wires to the terminals

indicated on the wiring diagram that came with your machine. The Thermolator comes pre-wired expecting clockwise (L1-L2-L3) phase rotation.

4 Check every terminal screw to make sure wires are

secure. Gently tug each wire. If a wire is loose, use a screwdriver or allen wrench to tighten the terminal.

5 Connect the ground wire to the grounding lug shown in the

wiring diagram shipped with your unit.

3-8 I Installation

Page 31

Testing the Installation

WARNING: Only qualified personnel should perform this procedure.

Part 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.

1 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 on standard 250° F {121° C} units less than 48kW. Refer

to the appendix for PSI requirements for units with 48kW heaters and 300° F {149° C} capabilities.

Installation

2 Apply power to the unit. The temperature controller display lights up to indicate that

the control has power. All LED segments on the display will light for a few seconds while the control performs a self-test. The control then displays the software version, followed by temperature display.

3 Check the rotation of the pump on the TW-S only. (The TW-P has a built-in phase

rotation monitor.) Remove the top access panel and a side panel.

Press the RUN button, and wait until the pump starts. It will take approximately 30 seconds to complete vent cycle.

When the pump starts, quickly press the STOP button and look at the pump shaft. With a ﬂashlight, verify that the pump rotation matches the direction indicated on the rotation sticker on the side of the pump motor.

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 incoming power distribution block.

Return to step 2 and check rotation again.

4 Replace the top/side access panel.

5 Press the RUN button

If everything is working correctly:

• The venting and/or pump LED illuminates.

Control Power

Autostart Signal

Pump

Heat

Cool

Coolant Pressure

Process

Cool Down

Temperature Limit

Electrical Phase Error

Heat Error

Process Cool Down

Mold Purge

Rapid Cool

Communications

Remote Heat/Cool

Program Mode

Flow GPM (flash)

Mold

Purge

Rapid

Cool

Tools Required

r Flashlight

• The unit initiates a 30-second venting sequence. The pump starts automatically when the venting sequence is over.

• Normal operation begins. The heater turns on if the process temperature is below setpoint. The cooling valve is activated if the process temperature is above setpoint.

 NOTE: If the coolant pressure low LED illuminates, verify that the cooling water supply is connected properly

and that the water pressure is at least 25 PSI or greater except for 48 kw or 300° F {149° C} units. Refer to

the Appendix for more information.

If everything tested correctly, proceed to the Initial Setup instructions on the next page. If something did not work correctly, refer to the Troubleshooting section of this user

guide.

Installation I 3-9

Page 32

Initial Setup

(Continued)

r Operating Mode r Temperature Units r Setpoint r Alarm Points

CAUTION: The Thermolator will not operate correctly if certain factory-set

parameters are changed. Parameters should only be changed by qualified technical personnel who are familiar with the operation of this type of equipment. If the Thermolator does not appear to be working correctly, verify the parameters against the list of factory settings.

For a complete list of the factory-set parameters see Default Parameters in the appendix of

this user guide.

All parameters can be changed using the keypad and the menu system.

Raise Key

Used to increase values or toggle between setting choices.

Control Power

Autostart Signal

Flow GPM (flash)

Mold Purge

Pump

Heat

Cool

Coolant Pressure

Temperature Limit

Electrical Phase Error

Heat Error

Process

Cool Down

Process Cool Down

Mold Purge

Rapid Cool

Communications

Remote Heat/Cool

Program Mode

Rapid Cool

Lower Key

Used to decrease values or toggle between setting choices.

Conguration Menu

Select Key

Used to select a parameter for editing, or save the new value of a changed parameter.

3-10 I Installation

Page 33

Temperature Units

Function

To select the desired temperature units for your system (°F vs. °C), follow this procedure:

1 Stop the Thermolator or ensure that you are on the home screen by pressing the

STOP button.

2 Enter the user conﬁguration menu by holding the “Function”

seconds.

If the passcode is at its default “0”, simply push “Select” . If the passcode has been changed to something else, use the “Up” and

“Down” buttons to scroll to the correct passcode, and then push “Select” .

button for 5

3 Repeatedly push “Select” to scroll through available user parameters until Unt

(Units) is displayed in the upper display (about 2 presses).

In the lower display, use the “Up” or “Down” buttons to select F for a Fahrenheit or  for Celsius.

4 Push “Select” to save the changed parameter. Push “STOP” to exit.

Installation

Installation I 3-11

Page 34

Setpoint

To select the proper setpoint of the system, follow this procedure:

1 From the home screen you should observe the current setpoint in green in the up-

per display and the actual process temperature in the lower window.

2 Change the setpoint using the “Up” or “Down” buttons. The new

value will automatically be implemented a few seconds after the up or down button is released.

Setpoint value

Process value

Flow GPM (flash)

Mold

Purge

Rapid

Control Power

Autostart Signal

Pump

Heat

Cool

Coolant Pressure

Temperature Limit

Electrical Phase Error

Heat Error

Process

Cool

Cool Down

Process Cool Down

Mold Purge

Rapid Cool

Communications

Remote Heat/Cool

Program Mode

Adjust setpoint upwards

Adjust setpoint downwards

 NOTE: From the factory, the TW-P will control the “To Process” or “Supply” ﬂuid to the setpoint.

3-12 I Installation

Page 35

Alarm Points

Function

To select the desired alarm points for your system (low alarm and high alarm), follow this procedure:

1 Stop the Thermolator or ensure that you are on the home screen by pressing the

STOP button.

2 Enter the user conﬁguration menu by holding the “Function”

button for 5

seconds.

If the passcode is at its default “0”, simply push “Select” . If the passcode has been changed to something else, use the “Up” and

“Down” buttons to scroll to the correct passcode, and then push “Select” .

3 Repeatedly push “Select” to scroll through available user parameters until

the desired parameter is shown in the upper display.

In the lower display, use the “Up” or “Down” buttons to select the desired setting. See the following table for a list of relevant parameters.

Display Description Default Permissible Range

The deviation alarms below can be used to create a permissible operating temperature window around the setpoint. Actual process temperature

outside of this window for a certain amount of time will create a deviation alarm.



h

Deviation delays below modify the deviation alarms above. You can select how long you want the system to tolerate a temperature excursion

outside of the deviation window before alarming.





h

S

O

These parameters function as absolute temperature alarms. Any excursion beyond these limits will create an immediate alarm. Do not set these

within your normal warm-up or operating ranges or you will experience nuisance alarms.

PbE

PE

SU

hSU

Low deviation alarm limit

High deviation alarm limit

Machine startup “ignore deviation” delay

Alarm delay for low deviation

Alarm delay for high deviation

Alarm deviation alarm after start

Alarm output

Low pressure bypass enabled

Panel temperature alarm

User low safety limit alarm

User high safety limit alarm





 S

EN

2

 to  (degrees) below setpoint

 to  (degrees) above setpoint

 to  (minutes)

 to  minutes ( to  minutes on program versions prior to version 1.33)

 to  minutes on program versions 1.33 and later only)

Disabled ( S )or Enabled ( EN) on program version 1.33 and later only

Disabled ( S )or Enabled ( EN).

Disabled ( S )or Enabled ( EN)

Between factory low and high limits.

Installation

4 Push “Select” to save the changed parameters. Push “STOP” to exit.

Installation I 3-13

Page 36

3-14 I

Page 37

Operation

The TW-S Control ................................................. 4-2

The TW-P Control ................................................. 4-3

Controller Operating Buttons .................................. 4-4

Temperature Displays ........................................... 4-5

Operating Lights .................................................. 4-5

SECTION

Operation

Default Display .................................................... 4-6

Starting the Thermolator ....................................... 4-7

Stopping the Thermolator .....................................4-13

Program Menu ....................................................4-14

Program Menu Items ............................................4-15

Process Cool Down Sequence Initiation ..................4-16

Pump Running Hour Display ..................................4-16

SPI Communications (Optional) ..............................4-16

SPI Option Parameters .........................................4-17

Modbus RTU (Optional) .........................................4-18

Modbus Option Parameters ...................................4-18

Modbus Registers................................................4-19

Using the Mold Purge Option .................................4-19

Conair TW-P Thermolator ......................................4-20

Operation I 4-1

Page 38

Setpoint Value Display

The window displays the ﬂuid temperature setpoint during normal operation.

Process Value Display

The window displays the actual temperature of ﬂuid entering the “To Process” line.

The TW-S Control

Raise and Lower Key

Used to enter the setpoint temperature, index through the operating modes or change other parameter values.

Press to increase a value.

Press to decrease a value.

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

Select Key

Used to edit a parameter or save a changed parameter.

Run

Press to begin normal operation.

Audible Alarm (Optional)

Start Button

Press and hold to begin normal operation. The button lights when the unit is running after vent cycle has completed.

 Note: You must hold the button during entire unit cycle.

Status Lights

The lights indicate the operating status of the listed components. = Off or inactive = On or active (1): More Cool (2): Less Cool (5): Heat

Stop Pump Button

Press to stop the Thermolator. Push again to de-assert and allow restart.

4-2 I Operation

Page 39

The TW-P Control

Setpoint Value Display

The window displays the ﬂuid temperature setpoint during normal operation.

Process Value Display

The window displays the actual temperature of ﬂuid entering the “To Process” line.

Mold Purge Button

(optional)

The purge uses compressed air to clear ﬂuid from the mold and lines before a mold change. Press and hold the purge while evacuating all ﬂuid from mold and line. The purge button is inactive when the TW is running.

Flow GPM (flash)

Mold

Purge

Rapid

Cool

Process

Cool Down

Raise and Lower Key

Used to enter the setpoint temperature, index through the operating modes or change other parameter values.

Press to increase a value.

Press to decrease a value.

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

Control Power

Autostart Signal

Pump

Heat

Cool

Coolant Pressure

Temperature Limit

Electrical Phase Error

Heat Error

Process Cool Down

Mold Purge

Rapid Cool

Communications

Remote Heat/Cool

Program Mode

Select Key

Used to edit a parameter or save a changed parameter.

Operation

WARNING: Shut off the supply to cooling water inlet before purging.

Run

Press to begin normal operation.

Audible Alarm (Optional)

Stop Button

Press to stop the Thermolator.

Start Button

Press and hold to begin normal operation. The button lights when the unit is running after vent cycle has completed.

 Note: You must hold the button during entire unit cycle.

Status Lights

The lights indicate the operating status of the listed components. = Off or inactive = Problem or Warning = Operational = Operational

Operation I 4-3

Page 40

Controller Operating Buttons

Button Description of Operation

Start

Stop

Pressing the Start button initiates a vent sequence. The vent sequence removes air that may have separated out from the water to

prevent improper operation and premature heater failure. When initiated, the vent sequence opens the cooling valve for 30 seconds

to allow air to escape then runs the pump for 30 seconds while the cooling valve is open to remove any remaining air from the sys-

tem. Once the vent sequence is complete, the cooling valve closes, the pump remains running, and normal operation begins. When

the unit is running the Run indicating light is on and green. If the auto start feature is enabled it will have precedence over the start

button. See the Program Menu section for instructions on how to enable or disable the auto start feature. The vent sequence cancel

prevents the vent sequence from occurring when the unit has been operating and the ﬂuid temperature is elevated. The factory

default value for the vent sequence cancel is 120°F {49°C}. See the Program Menu section for instructions on how to change the

vent sequence cancel temperature. The Start button also performs an enter function while in the programming menu.

Pressing the Stop button clears all faults and stops the pump. With the auto start function enabled and an auto start signal is pres-

ent, pressing the stop button will not stop the unit. The Stop button also performs a cancel function while in the programming menu.

Alarm Reset

Down

Display/

Program

Mold Purge

(Optional)

(TW-P Only)

Rapid Cool

(Optional)

(TW-P Only)

When an alarm condition is present, the alarm light is on and red. The ﬁrst Alarm Reset button press will silence the alarm horn

(optional), open the remote alarm contact (optional), and the alarm light changes from red to yellow. The alarm horn (optional) and/

or remote alarm contact (optional) remain disabled until a subsequent alarm occurs. A second press of the Alarm Reset button

resets the state from Alarm to Normal Operation.

The Up button raises the set point temperature. Pressing the Up button and releasing it increases the set point temperature by one

degree. Pressing the Up button and holding it increases the set point temperature until reaching the maximum allowable set point

temperature. In addition to adjusting the set point temperature, the Up button adjusts various alarms and set point values when the

unit in the programming mode.

The Down button decreases the set point temperature. Pressing the Down button and releasing it decreases the set point tem-

perature by one degree. Pressing the Down button and holding it decreases the set point temperature until reaching the minimum

allowable set point temperature. In addition to adjusting the set point temperature, the Down button adjusts various alarms and set

point values when the unit is in the programming mode.

Pressing the Display/Program button changes the temperature displayed in the Process screen from supply to return. When the

display is set to supply temperature, an orange indicating light is on in the lower right corner of the Process temperature display.

When the display is set to return temperature, there is no orange indicating light in the lower right corner of the Process tempera-

ture display. To toggle the Process temperature display from supply to return temperature, press and release the Display/Program

button. The display will return to the default Supply temperature automatically after 5 seconds without a button press. In addition to

switching between the supply and return process temperature displays, the Display/Program button initiates and navigates through

the program menu. See the Program Menu section for more detail.

The Mold Purge button initiates a mold water purge if this option is present and enabled. The mold purge option allows compressed

air to purge the circuit of water by forcing it out through the cooling valve. To initiate a mold purge sequence stop the unit then

press and release the mold purge button. During a mold purge, the cooling water out valve opens, the mold purge compressed air

solenoid valve opens, and the cooling water inlet valve closes. The mold purge sequence is 1 minute long. To stop the mold purge

sequence before it is completed, press the Mold Purge button again or press the Stop button. See the Program Menu section for

instructions on how to enable or disable this feature.

The Rapid Cool button opens the solenoid valve if this option is present and enabled. Pressing the Rapid Cool button initiates a

Rapid Cool sequence. The sequence opens the Rapid Cool valve, opens the vent/cooling valve, and disables the heater. The se-

quence is 1 minute long. To stop the Rapid Cool sequence before it is completed, press the button again, or press the Stop button.

See the Program Menu section for instructions on how to enable or disable this feature.

Process

Cool Down

(Optional)

Note: To initiate a Process Cool Down sequence on a unit with the standard controller press and hold down the Run button, then press the Stop button and then release both buttons.

4-4 I Operation

 NOTE: Rapid Cool option is not available with 48 kW.

The Process Cool Down button initiates a cool-down sequence if the process supply water is above 90°F {32°C}. The Process Cool

Down sequence reduces the water temperature before the unit shuts off to extend the life of the pump seal. To initiate a Process

Cool Down sequence, press and release the Process Cool Down button. During this sequence, the cooling valve opens and the

pump runs for 120 seconds or until the temperature of the water reaches 90°F {32°C}, whichever occurs ﬁrst. During the Process

Cool Down sequence the Set Point display temporarily toggles between the target value 90°F {32°C} and current set point and the

Pump, Cool, and Process Cool Down lights ﬂash green. After the Process Cool Down sequence is complete, the unit stops, the set

point temperature displays in the Set Point display, and the Process Cool Down light remains solid green to indicate the comple-

tion of the sequence. Pressing the Start and/or Stop buttons during a Process Cool Down sequence stops the sequence. See the

Program Menu section for instructions on how to enable or disable this feature.

Page 41

Temperature Displays

Display Description of Operation

Setpoint

Actual

The Setpoint display normally shows the set point temperature. A decimal point in the lower right corner of this display

indicates the temperature unit of measure is set to °F, no decimal point indicates the temperature unit of measure is set to °C.

See the Program Menu section to change the temperature scale units of measure. This display also shows alarm codes and

programming information.

The Actual Temperature display normally shows supply temperature. A decimal point in the lower right corner of the display

indicates the temperature displayed is the supply temperature, no decimal point indicates the temperature displayed is the

return temperature. To change the display from supply to return temperature, press and release the Display/Program button.

The display will return to the default Supply temperature automatically after 5 seconds without a button press. This display also

shows alarm codes and programming information.

Operating Lights

Display Description of Operation

Control Power

The Control Power light is on and green when 24VDC control voltage is present.

Autostart Signal

Pump

Heat

Cool

Coolant Pressure

Temperature

Limit

Electrical Phase

Error (Optional)

Heat Error

(Optional)

The Autostart Signal light is green when closed (run), yellow when open (stop), and unlit if this feature is disabled. This feature

allows starting and stopping of the unit by a remote contact closure. From the factory, the Autostart feature is disabled. See the

Program Menu section for instructions on how to enable or disable the Autostart feature. Do not introduce any external voltage

to the Autostart contacts; this will result in damage to the controller.

The Pump light is solid green when the pump is running and ﬂashes red if the pump motor overload trips.

The Heat light is on and green when the heating is required.

The Cool light is on and green while in normal running operation when the cooling valve is open. The light ﬂashes green during

an Autovent sequence or Process cool-down sequence.

The Coolant Pressure In light will ﬂash red if the inlet cooling water pressure drops below the set point of the low-pressure

safety switch. If a low-pressure condition occurs, the unit will automatically stop and remain de-energized until the cooling

water pressure is above the cut-in set point of the pressure switch. The light is solid green if the Coolant Inlet Pressure is satis-

factory. It will ﬂash green while in the Purge mode.

The Temperature Limit light ﬂashes yellow if a high or low temperature limit warning occurs and ﬂashes red if a high or low

temperature limit safety occurs. A temperature limit safety stops the unit. Pushing the Alarm Reset button will reset this alarm.

The Electrical Phase Error light ﬂashes red when a line voltage problem exists. This error indicates a loss of phase, phase

reversal, or phase imbalance.

The Heat Error light is solid red when the controller calls for heat and heating does not occur. The Heat Error light ﬂashes red

when the controller does not call for heat but heating occurs. Both conditions cause the unit to stop.

Operation

Process Cool

Down (Optional)

Mold Purge

(Optional)

The Process Cool Down light ﬂashes green when the unit is executing a Process Cool Down sequence. The Cool and Pump

lights will also ﬂash green during a seal saver sequence. After the Process Cool Down sequence is complete, the unit stops

and the Process Cool Down light remains green to indicate the completion of the sequence. See the Process Cool Down But-

ton section for a description of the Process Cool Down function and operation.

The Mold Purge light ﬂashes green when the unit is executing a purge sequence. The Cool light will also ﬂash green during a

mold purge sequence. After the Mold Purge sequence is complete, the unit stops and the Mold Purge light remains green to

indicate the completion of the sequence. See the Mold Purge Button section for a description of the Mold Purge function and

operation. See the Program Menu section for instructions on how to enable or disable this feature.

(Continued)

Operation I 4-5

Page 42

Operating Lights

Display Description of Operation

Rapid Cool

(Optional)

Communications

(Optional)

The Rapid Cool light ﬂashes green when the unit is executing a Rapid Cool sequence. The Cool light will also ﬂash green dur-

ing a rapid cool sequence. After the Rapid Cool sequence is complete, the unit stops and the Rapid Cool light remains green

to indicate the completion of the sequence. See the Rapid Cool Button section for a description of the Rapid Cool function and

operation. See the Program Menu section for instructions on how to enable or disable this feature.

The Communications light ﬂashes green when the unit is properly transmitting and receiving a communication signal. See the

Program Menu section for instructions on how to enable or disable this feature.

(Continued)

Remote Heat/Cool

(Optional)

Program Mode

Requires the Premium Controller option (TW-P).

Requires the Premium Controller option (TW-P) as well as the individual option for this function.

The Remote Heat/Cool light is on and yellow when this option is enabled. This feature allows the heating and cooling to be

turned on and off by remote contact closures. Switching a contact from open to close activates the heat or cool function as-

signed to the contact. Switching the contact from closed to open deactivates the individual heat or cool function assigned to the

contact. When enabled the controller does not perform any heat or cool functions and relies exclusively on the external contact

closures for these functions; however, the unit maintains all warnings and safety functions. From the factory, the Remote Heat/

Cool feature is disabled. See the Program Menu section for instructions on how to enable or disable this feature. Do not intro-

duce any external voltage to the Remote Heat/Cool contacts; this will result in damage to the controller.

The Program Mode light ﬂashes yellow when the control system is in the programming menu.

Default Display

These items are shown by default on the controller. Use the “Up” and

“Down” buttons to change the setpoint.

DISPLAY

EXAMPLE





ITEM UNITS DESCRIPTION

Active Process Value (shown

on lower display in red)

Active Set Point

(shown on upper display in

green)

°F or °C The current temperature of the process ﬂuid.

°F or °C The temperature that the temperature control-

ler is attempting to reach by either heating or

cooling the process ﬂuid.

 NOTE: The active process value can be changed by pushing the “Display”

Display

button. The default

process value can be changed in the user parameter menu.

4-6 I Operation

Page 43

Starting the Thermolator

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

1 Turn on the water supply to the Thermolator. The supply pressure must be at least

25 psi for most units. Refer to the appendix G for more information on 48 kw and 300°

F {149° C} units. Check for leaks in the cooling water and process ﬂuid lines before

continuing.

2 Turn on main power to the Thermolator.

• The controller display and “Control Power” LED will illuminate to indicate the control has power.

• The controller will show the ﬁrmware version on the lower display while show- ing “tcp” on the upper display. After a few seconds, process temperature will be displayed (red, bottom display) and setpoint will be shown (green, top display).

3 Set the temperature setpoint to 40° F (4.4° C) if the Thermolator’s process lines

were recently reconﬁgured, or if you suspect excessive air is in the process lines.

Press to increase or to decrease the temperature setting. This will provide additional ﬂushing and de-aeration in the process lines via the cooling valve.

NOTE: All LEDs will ﬂash to test their operation.

Operation

4 Press RUN .

The unit initiates a 30-second (or as otherwise deﬁned by user parameter) venting sequence. The Venting LED illuminates.

• The pump starts after the venting cycle is over. The Pump LED illuminates when the pump is running.

• 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.

 NOTE: Both venting stages will be skipped if the process temperature is above the vent bypass temperature,

and the Thermolator will consequently start the pump immediately in the “RUNNING” state.

5 Set the setpoint to the desired temperature, Shown in green on the top display.

Press to increase or to decrease the temperature setpoint. If you followed step 3, wait until process lines are de-aerated before raising setpoints.

6 If the Alarm LED turns on, press “Silence/Reset” to silence the optional

audible alarm.

Refer to the Troubleshooting section for more information.

 NOTE: If the coolant pressure

low LED illuminates, verify that the cooling water supply is connected properly and that the water pressure is at least 25 PSI or greater except for 48

kw or 300

Refer to the Appendix for more information.

° F {149° C} units.

Operation I 4-7

Page 44

Start-up

Every unit is factory set to deliver water in accordance with the standard operating speciﬁcations for that particular unit. Due to variables involved with different applications and different installations, minor adjustments may be required during the initial start-up to ensure proper operation. We recommend a qualiﬁed technician perform the start-up and that they follow the start-up procedure in sequence. The following serves as a checklist for the initial start-up and for subsequent start-ups if the unit is out of service for a prolonged time.

WARNING: Electrical hazard

WARNING:

This equipment contains hot water or coolant under pressure. Accidental release of this hot fluid may result in steam formation and can cause personal injury and or property damage.

WARNING:

This equipment may contain fan blades or other sharp edges. Make sure all fan guards and other protective shields are securely in place.

WARNING:

The exposed surfaces of motors, heater tubes, and other fluid circuit components can be very hot and can cause burns if touched with unprotected hands

CAUTION: Disconnect and lock out incoming power before installing, servic-

ing, or maintaining the equipment. Connecting power to the main terminal block energizes the entire electric circuitry of the unit. A power supply provides 24 VDC control power. Electric power at the main disconnect should be shut off before opening access panels for repair or maintenance.

CAUTION: Wear eye protection when installing, maintaining, or repairing the

equipment to protect against any sparks, debris, or fluid leaks.

CAUTION: Wear protective gloves when installing, maintaining, or repairing

the equipment to protect against any sparks, debris, or fluid leaks.

CAUTION: To prevent improper pump performance due to reverse rotation,

connect L1-L2-L3 in the A-B-C phase sequence.

4-8 I Operation

(Continued)

Page 45

Start-up

(Continued)

CAUTION: Do not shut off To Process, From Process, Cooling Water In, or

Cooling Water out valves while this equipment is operating. Equipment failure and/or serious injury could result.

CAUTION: Always keep the cover in place while operating this equipment.

Internal surfaces may be extremely hot. Only qualified personnel should remove this cover.

CAUTION: Ground the unit properly in compliance with local and national

codes.

Step 1 – Connecting Main Power

Connect main power properly ensuring it matches the voltage shown on the nameplate of the unit. Check the electrical phase sequence prior to start-up. The proper sequence is “ABC”. If the phasing is incorrect, open the main power disconnect and switch two line leads on the main power terminal blocks (or the unit mounted disconnect). All electrical components are in-phase at the factory. Do not interchange any load leads that are from the unit contactors or the motor terminals. After conﬁrming proper power connection and grounding exist, turn the main power on.

Operation

Step 2 – Fill Coolant Circuit

Check to make sure all piping connections are secure. All ﬂuid lines and connectors should be rated for 150 psi {10.3 bar}at the maximum operating temperature except for 7½ hp and 10 hp units with the 300°F {149°C} option that require lines and connectors rated for at least 175 psi {12.1 bar}. We recommend the cooling source supply and return lines are of metal composition (black steel, galvanized or copper).

Make sure that the cooling source is the appropriate temperature and pressure for your application. In most cases, the cooling source is between 40°F and 85°F {4°C and 29°C}. The cooling source ﬂuid pressure must be above the set point of the pressure switch in order for the unit to start. For most applications, the design cooling source supply pressure is between 25 psi and 50 psi {1.7 and 3.4 bar} Units with the 300°F {148.89°C} operating range option require an inlet cooling source pressure of 75 psi {5.2 bar}. If the total pressure in the unit (cooling source inlet pressure plus the pump pressure) exceeds 150 psi {10.3} the pressure relief valve in the unit will open. If this becomes an issue, install a pressure-regulating valve (Part #9616548 available from our Parts Department) on the supply line to help regulate the pressure to ensure it does not exceed the pressure rating of the pressure relief valve. For further assistance in installing a pressure-regulating valve, please contact our Service Department (800-458-1960 or 1-814-437-6861 from outside of the United States).

Contact Conair Parts and Service Phone: 800-458-1960 From outside of the United States, Call: 814 437 6861

(Continued)

Operation I 4-9

Page 46

Start-up

(Continued)

System Fill Water Chemistry Requirements

The properties of water make it ideal for heat transfer applications. It is safe, non-ﬂammable, non-poisonous, easy to handle, widely available, and inexpensive in most industrialized areas.

When using water as a heat transfer ﬂuid it is important to keep it within certain chemistry limits to avoid unwanted side effects. Water is a “universal solvent” because it can dissolve many solid substances and absorb gases. As a result, water can cause the corrosion of metals used in a cooling system. Often water is in an open system (exposed to air) and when the water evaporates, the dissolved minerals remain in the process ﬂuid. When the concentration exceeds the solubility of some minerals, scale forms. The life giving properties of water can also encourage biological growth that can foul heat transfer surfaces.

To avoid the unwanted side effects associated with water cooling, proper chemical treatment and preventive maintenance is required for continuous plant productivity.

Unwanted Side Effects of Improper Water Quality

• Corrosion

• Scale

• Fouling

• Biological Contamination

Cooling Water Chemistry Properties

• Electrical Conductivity

• pH

• Alkalinity

• Total Hardness

• Dissolved gases

The complex nature of water chemistry requires a specialist to evaluate and implement appropriate sensing, measurement and treatment needed for satisfactory performance and life. The recommendations of the specialist may include ﬁltration, monitoring, treatment and control devices. With the ever-changing regulations on water usage and treatment chemicals, the information is usually up-to-date when a specialist in the industry is involved. The table below shows the list of water characteristics and quality limitations.

4-10 I Operation

(Continued)

Page 47

Start-up

(Continued)

Fill Water Chemistry Requirements

Water Characteristic Quality Limitation

Alkalinity (HCO3-) 70-300 ppm

Aluminum (Al) Less than 0.2 ppm

Ammonium (NH3) Less than 2 ppm

Chlorides (Cl-) Less than 300 ppm

Electrical Conductivity 10-500µS/cm

Free (aggressive) Carbon Dioxide (CO2)

Free Chlorine(Cl2) Less than 1 PPM

HCO3-/SO42- Greater than 1.0

Hydrogen Sulﬁde (H2S) Less than 0.05 ppm

Iron (Fe) Less than 0.2 ppm

Manganese (Mn) Less than 0.1 ppm

Nitrate (NO3) Less than 100 ppm

pH 7.5-9.0

Sulfate (SO42-) Less than 70 ppm

Total Hardness (dH)k 4.0-8.5

†

Dissolved carbon dioxide calculation is from the pH and total alkalinity values shown below or measured on the site

using a test kit. Dissolved Carbon Dioxide, PPM = TA x 2

†

Less than 5 ppm

[(6.3-pH)/0.3]

where TA = Total Alkalinity, PPM as CaCO

Operation

CAUTION: When your application requires the use of glycol, use industrial

grade glycol specifically designed for heat transfer systems and equipment. Never use glycol designed for automotive applications. Automotive glycols typically have additives engineered to benefit the materials and conditions found in an automotive engine; however, these additives can gel and foul heat exchange surfaces and result in loss of performance or even failure of the unit. In addition, these additives can react with the materials of the pump shaft seals resulting in leaks or premature pump failures.

WARNING:

Ethylene Glycol is flammable at higher temperatures in a vapor state. Carefully handle this material and keep away from open flames or other possible ignition sources.

(Continued)

Operation I 4-11

Page 48

Start-up

(Continued)

Step 3 – Initial Unit Operation

Enter the set point temperature. Refer to the Control Panel Operation section for further information.

Start the unit by pressing the Start button on the control panel. Pressing the Start button enables the microprocessor control functions, initiates an Auto-vent sequence, and turns on the Run indicating light which is green when on.

The Auto Vent sequence removes air that may have separated out from the water or been entrapped in the water circuit for some reason. Air in the system can lead to improper operation and premature heater failure. When initiated, the Auto Vent sequence opens the cooling valve for 30 seconds to allow air to escape. This allows the majority of the air to escape from the system. For further air purging, the Auto Vent sequence energizes the pump for 30 seconds while the cooling valve is open to remove any remaining air from the system. While in the vent sequence, the Pump and Cool lights will ﬂash. Once the Auto Vent sequence is complete, the cooling valve is closed, the pump remains energized, and normal operation initiates.

Check the rotation of the pump by visually conﬁrming the motor shaft rotation matches the directional arrow sticker on the motor case. If the pump is running backwards, switch two of the main power leads, after shutting off the disconnect switch.

The unit is now ready for service.

4-12 I Operation

Page 49

Stopping the Thermolator

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}.

You must shut down the Thermolator whenever you:

• Change the water hookups.

• Shut down the process machine.

• Purge the process circuit of the water or ﬂuid.

• Perform routine or preventative maintenance.

• See an alarm condition that requires troubleshooting.

• Relocate, ship or store the unit.

To shut down the unit during a normal interruption in production process, where no maintenance will be performed:

1 Press STOP .

To shut down the unit to change water hookups:

1 Change setpoint to 80° F {27° C} and allow the Thermolator to cool itself to

less than 100° F {38° C}.

2 Press STOP .

3 Shut off the cooling water supply, and relieve any pressure in the unit (see

pressure gauge) by lifting the relief valve lever; then drain the unit of all ﬂuid. The cooling water inlet hose can be removed to provide additional draining.

4 Once the unit is cool, remove the water hookups.

To shut down the unit for relocation or storage:

1 Change setpoint to 80° F {27° C} and allow Thermolator to cool itself to less

than 100° F {38° C}.

2 Press STOP .

Operation

3 Shut off the cooling water supply, and relieve any pressure in the unit (see

pressure gauge) by lifting the relief valve lever; then drain the unit of all ﬂuid. The cooling water inlet hose must be removed to provide maximum draining.

4 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.

Operation I 4-13

Page 50

Program Menu

Access to the program menu is password protected to prevent unintended alteration to the program settings and parameters. To access the programming menu the unit must be in a stopped state.

To enter the program menu stop the unit then press and hold the Display/Program button for 10 continuous seconds to put the controller in program mode. The Program

Mode light ﬂashes yellow and the display will show PAS on the Process display and 000 on the Set Point display. The unit is now ready to have the password entered. From the factory, the password is set to 000.

5 Use the Up or Down arrow buttons to increase the numeric value on the Set

Point display until the correct password value is shown.

6 To enter the password, press and release the Start button. If an incorrect password

is entered the Set Point display shows no and the Process display shows PAS. After 5 seconds, the unit will go back to the password entry mode and display PAS on the Process display and “blanks” on the Set Point display. If no activity occurs for another 5 seconds, the controller exits the programming mode and returns to the Stopped state.

7 Once in the program menu, use the Display/Program button to scroll through

the different adjustable parameters (see Program Menu Items table).

8 To change an item, press the Display/Program button until the item code dis-

plays in the Process display. Pressing the Alarm Reset button and Display/Program button at the same time will reverse the direction the Display/Program button indexes through the menu items.

9 Once the desired menu item code displays in the Process display, use the Up and

Down arrow buttons to adjust the value shown in the Set Point display until the desired value is shown. Press the Start button to enter the display value. Press the Stop button to cancel and revert to the previously value.

10 There is a Master Reset function to restore all User menu parameters to their factory

default values. To initiate a Master Reset the unit must be in a stopped state. Once the unit is stopped, press and hold the Alarm Silence/Reset button and Stop button simultaneously for 10 consecutive seconds until PRG is displayed on the Set Point display and RSt is displayed on the Process display. To conﬁrm a Master Reset is desired, press and release the Start button and the system will perform a Master Reset and reboot. The Master Reset is aborted after the PRG is displayed on the Set Point display and RSt is displayed on the Process display by turning the control power off or taking no action for 10 consecutive seconds.

4-14 I Operation

Page 51

Program Menu Items

Item Name Item

Code

Default

Valve

Range

Alarm delay for high deviation alarm AdH 30 0 to 60 minutes (10 to 60 minutes on program

versions prior to version 1.33)

Alarm delay for low deviation alarm AdL 30 0 to 60 minutes (10 to 60 minutes on program

versions prior to version 1.33)

Alarm deviation alarm delay after start ADS 30 0 to 30 minutes on program version 1.33 and later

only

Alarm output AdO DIS Disabled (DIS) or Enabled (EnA) on program

versions 1.33 and later only

Autostart enable ASE ENA Disabled (DIS) or Enabled (EnA)

Brownout monitor brn EnA Disabled (DIS) or Enabled (EnA)

Communications Baud rate

Communications Modbus ID

Communications SPI address

Communications type

bAU 96 12 to 96

bId 1 1 to 247

S PA 32 32 to 63

COt OFF OFF, Retransmit (rEt), SPI (SPI), ModBus (bUS),

Handheld Remote (Han)

Crash Cool enabled

CCE DIS Disabled (DIS) or Enabled (EnA)

Derivative time dEr 5 0 to 200

Display units Unt F F or C

High deviation alarm limit HId 10 5 to 100 degrees above set point

Integral time Int 25 1 to 800

Low deviation alarm limit Lod 10 5 to 100 degrees below set point

Low pressure bypass enabled pbE dIS Disabled (DIS) or Enabled (EnA)

Panel Temperature Alarm PA e EnA Disabled (DIS) or Enabled (EnA)

Panel Temperature Readout Pte Display only

Proportional band bnd 20 1 to 300

Proportional band ratio Pbr 5 1 to 10

Pump run hours PrH 0 0 to 999 (x100)

Purge enabled (optional)

Remote heat/cool enabled

Remote Setpoint enabled

Remote Setpoint high limit

Remote Setpoint low limit

Retransmit high limit

Retransmit low limit

PuE DIS Disabled (DIS) or Enabled (EnA)

rHC DIS Disabled (DIS) or Enabled (EnA)

rSE DIS Disabled (DIS) or Enabled (EnA)

rSH 260 rSL to 999

rSL 10 -99 to rSH

rEH 260 rEL to 999

rEL 10 -99 to rEH

Return Temperature Probe Enable SSE EnA Disabled (DIS) or Enabled (EnA)

Seal-Saver enabled SSE EnA Disabled (DIS) or Enabled (EnA)

User high safety limit alarm HSU 260 Between factory low and high limits

User low safety limit alarm LSU 22 Between factory low and high limits

User password UPA 000 0 to 999

Vent sequence cancel temperature SCt 120 Between factory low and high limits

Requires the Premium Controller option (TW-P) as well as the individual option for this function.

Operation

Operation I 4-15

Page 52

Process Cool Down Sequence Initiation

The Process Cool Down sequence reduces the water temperature before the unit shuts off to extend the life of the pump seal. See the Program Menu section for instructions on how to enable or disable this feature. During this sequence, the cooling valve opens and the pump runs for 120 seconds or until the temperature reaches 90°F {32°C}, whichever occurs ﬁrst. During the Process Cool Down sequence the Set Point display temporarily toggles between the target value 90°F and current set point and the Pump, Cool, and Process Cool Down lights ﬂash green. After the Process Cool Down sequence is complete, the unit stops, the set point temperature displays in the Set Point display, and the Process Cool Down light remains solid green to indicate the completion of the sequence. Pressing the Start and/or Stop buttons during a Process Cool Down cool-down sequence stops the sequence.

To initiate a Process Cool Down sequence on units with the Premium Controller simply press and release the Process Cool Down button. To initiate a sequence on units with the standard controller, press and hold the Start button, then press the Stop button and release both buttons. The Process Cool Down sequence begins if the process supply temperature is above 90°F {32°C}.

Pump Running Hour Display

The total accumulated pump running hours are stored for maintenance purposes. See the Program Menu section to display the pump running hours. Running hours are in units of hundreds so a display value of 10 means 1,000 hours. To reset the pump running hours, press the Start and Alarm Reset buttons at the same time and hold for 3 seconds.

SPI Communications (Optional)

Several members of SPI : The Plastics Industry Trade Association developed a communications standard for plastic processing equipment to communicate using the Serial Peripheral Interface bus (SPI bus), which coincidently has the same abbreviation as the trade association. This option includes an expansion module and a RS-485 communication port on the unit. The communication hardware ﬁrmware is SPI 3.01 standard compliant.

To activate or deactivate this feature use the program menu Communication Type function. In addition to activating the communication type, a baud rate and SPI address must be set using the Communication Baud Rate and SPI Address function. If multiple pieces of equipment are on the same network, the base address of each machine has to be unique.

4-16 I Operation

Page 53

SPI Option Parameters

Command Poll Select Description

Echo 20 20 20 21 Controller integrity command used to accept and retain data and provide it in response to

a poll inquiry in an open 4-byte ASCII format with ASCII units.

Version 20 22 Controller version command used to provide a version number following format: AABB,

where AA=SPI assigned version level, BB=vendor assigned version level in an open

4-byte ASCII format with ASCII units.

Set Point Process Temperature 20 30 20 31 Target supply coolant temperature leaving the unit in a numeric format in °F.

Alarm, High Temperature Deviation 20 32 20 33 Value in conjunction with the process set point that determines the high alarm tempera-

ture in a numeric format in °F must always be positive.

Alarm, Low Temperature Deviation 20 34 20 35 Value in conjunction with the process set point that determines the low alarm tempera-

ture in a numeric format in °F must always be positive.

Status, Process 20 40 Process status in a 16-bit format as follows:

0=controlling

1=an alarm is present

2=an alarm affecting the process has occurred (high or low temperature deviation)

3=an alarm affecting the machine has occurred (probe fault or pump fault)

4=the controller has exceeded its over set point deviation

5=the controller has exceeded its below set point deviation.

Status, Machine 1

Status, Machine 2 20 44 Machine status in a 16-bit format as follows:

Mode, Machine 20 48 20 40 Machine mode in two 8-bit bytes. When polling 20 48 bit 0 indicated the machine is off. 20

Temperature, To Process (Supply) 20 70 Returns the process supply temperature in a numeric format in °F.

Temperature, To Process (Return) 20 72 Returns the process return temperature in a numeric format in °F.

20 42 Machine status in a 16-bit format as follows:

0=controlling

1=an alarm is present

2=an alarm affecting the process has occurred (high or low temperature deviation)

3=an alarm affecting the machine operation has occurred (probe fault or pump fault)

4=the controller has exceeded its over set point deviation

5=the controller has exceeded its below set point deviation.

0=controlling

1=an alarm is present

2=an alarm affecting the process has occurred (high or low temperature deviation)

3=a sensor error has been detected

4=an alarm affecting the machine operation has occurred.:

40 bit 0 commands the unit to be turned on or off (on when high or off when low). 20 40

bit 1 is used to recognized the alarm condition.

Operation

Operation I 4-17

Page 54

Modbus RTU (Optional)

The Modbus RTU option provides a RS-485 communications port for Modbus RTU communications. Note the ModBus Parity = None, Stop Bits = 1, and default Baud Rate = 9,600.

Modbus Option Parameters

4002 Machine State R Integer 0=Off, 1=Stop, 2=Run, 3=Run Fault 2, 4=Run

Fault 3, 5=Fault 1, 6=Factory Menu, 7=User

Menu, 8=Get User Password, 9=Master Reset

4007 Derivative R/W Integer

4008 Integral R/W Integer

4009 Heat Cycle Rate R

4010 Cool Cycle Rate R

4011 Low Alarm Delay R Integer

4012 High Alarm Delay R Integer

4013 Temperature Display Units R Integer 0 = °F, 1 = °C

4015 Brownout Enabled R Integer 0 = Disabled, 1 = Enabled

4017 Process Cool Down Enabled R 0 = Disabled, 1 = Enabled

4018 Remote Heat Cool Enabled R 0 = Disabled, 1 = Enabled

4019 Mold Purge Enabled R 0 = Disabled, 1 = Enabled

4020 Rapid Cool Enabled R 0 = Disabled, 1 = Enabled

4024 Remote Setpoint Enabled R Integer 0 = Disabled, 1 = Enabled

4025 Autostart Enabled R Integer 0 = Disabled, 1 = Enabled

4027 Communication BAUD Rate R/W Integer 0 = 1200, 1 = 2400, 2 = 4800, 3 = 9600

4028 MODBUS Identiﬁcation R/W Integer

4030 SPI Communications Address R/W Integer

4038 PID OUT R -100 to 100 PID algorithm output

4039 MODBUS Command R/W Integer 0 = Do Nothing, 1 = Start, 2 = Stop

8002 Supply Fluid Temperature (°C) R Floating Point Error Hi = 9.9E05, Error Low = -9.9E05

8004 Return Fluid Temperature (°C) R Floating Point Error Hi = 9.9E05, Error Low = -9.9E05

8010 Low Temperature Deviation (°C) R/W Floating Point

8012 High Temperature Deviation (°C) R/W Floating Point

8014 Low Setpoint Limit Temperature (°C) R Floating Point

8016 High Setpoint Limit Temperature (°C) R Floating Point

8018 Supply Temperature Retransmit Range Low (°C) R Floating Point

8020 Supply Temperature Retransmit Range High (°C) R Floating Point

8022 Low Temperature Safety – User Set (°C) R/W Floating Point

8024 High Temperature Safety – User Set (°C) R/W Floating Point

8026 Proportional Band (°C) R/W Floating Point

8002 Supply Fluid Temperature (°C) R Floating Point Error Hi = 9.9E05, Error Low = -9.9E05

8004 Return Fluid Temperature (°C) R Floating Point Error Hi = 9.9E05, Error Low = -9.9E05

8010 Low Temperature Deviation (°C) R/W Floating Point

8012 High Temperature Deviation (°C) R/W Floating Point

8014 Low Setpoint Limit Temperature (°C) R Floating Point

8016 High Setpoint Limit Temperature (°C) R Floating Point

4-18 I Operation

(Continued)

Page 55

Modbus Option Parameters

8018 Supply Temperature Retransmit Range Low (°C) R Floating Point

8020 Supply Temperature Retransmit Range High (°C) R Floating Point

8022 Low Temperature Safety – User Set (°C) R/W Floating Point

8024 High Temperature Safety – User Set (°C) R/W Floating Point

8026 Proportional Band (°C) R/W Floating Point

8052 Pump Running Hours R Floating Point

8054 Setpoint Temperature (°C) R/W Floating Point

8056 Low Temperature Safety – Factory Set (°C) R Floating Point

8058 High Temperature Safety – Factory Set (°C) R Floating Point

8070 Supply Temperature Input Offset R Floating Point

8072 Return Temperature Input Offset R Floating Point

8074 Remote Setpoint Temperature Input Offset R Floating Point

8080 Remote Setpoint Limit Temperature (°C) R Floating Point

8082 Remote Setpoint High Temperature Limit (°C) R Floating Point

(Continued)

Operation

Modbus Registers

The following is a list of Modbus Registers that are remotely available.

Notes:

• There is a limitation on the maximum Modbus block size of 40 for integers and 20 for ﬂoats.

• Additional settings include:

– Baud: Set by parameter bU, 9600 baud by default.

– Parity: None

– Data bits: 8

– Stop bits: 1

– Flow control: None

• It is common for external software to apply an address offset of “1”, so you may need to add “1” to the Modbus addresses based on the software in the remote system.

• In newer versions of Modbus, you may have to append a “4” or a “40” preﬁx on the registers listed.

For example, to get to “MACHINE STATE” in register 4002, you may have to access register 4002, 4003, 44002, 44003, 404002, or 404003. Once you test your system and get a valid response, you will know the rules to consistently apply to your system for all addresses.

Operation I 4-19

Page 56

Using the Optional Mold Purge Option

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

Control Power

Autostart Signal

Pump

Heat

Cool

Coolant Pressure

Flow GPM (flash)

Mold

Purge

Rapid Cool

Process

Cool Down

Temperature Limit

Electrical Phase Error

Heat Error

Process Cool Down

Mold Purge

Rapid Cool

Communications

Remote Heat/Cool

Program Mode

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.

1 Press STOP to stop the Thermolator.

2 Shut off the cooling water supply valve.

3 Press MOLD PURGE

• The “Purge” LED lights.

• The cooling valve is opened.

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.

4 Release MOLD PURGE

to start purging.

to stop purging.

4-20 I Operation

Page 57

Conair TW-P Thermolator

Normal Operation

For normal operation of the TW-P Thermolator, set the setpoint on the temperature

controller using the and buttons. On the display, the lower red display shows the current temperature, and the upper green display shows the setpoint. In the right-hand column, the various LEDs describe the status of the machine.

Adjust setpoint upwards

Setpoint value

Process value

Flow GPM (flash)

Mold

Purge

Rapid Cool

Process

Cool Down

Control Power

Autostart Signal

Pump

Heat

Cool

Coolant Pressure

Temperature Limit

Electrical Phase Error

Heat Error

Process Cool Down

Mold Purge

Rapid Cool

Communications

Remote Heat/Cool

Program Mode

Adjust setpoint downwards

Operation

(Continued)

Operation I 4-21

Page 58

4-22 I Operation

Page 59

Maintenance

Maintenance of your Thermolator ............................ 5-2

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

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

SECTION

Removing the Pump Motor and Seal

(1/2 to 2 Hp, any frequency and 3 HP, 60 Hz units) .............. 5-4

Reassembling the Pump Motor and Seal

(1/2 to 2 Hp, any frequency and 3 HP, 60 Hz units) .............. 5-7

Removing the Pump Motor and Seal

(3 Hp, 50Hz and 5 to 10 Hp, any frequency units) ................ 5-9

Reassembling Pump Motor and Seal

(3 Hp, 50Hz and 5 to 10 Hp, any frequency units) ...............5-11

Reset Pump Overload ...........................................5-12

Replacing the Controller Boards ............................5-13

Maintenance

Maintenance I 5-1

Page 60

Maintenance of your Thermolator

Depending on which features, options, and additions you ordered with your Thermolator, your maintenance procedures and necessities may differ from what is shown in this user guide. Please note that all illustrations, photos, and instructions are based on a typical conﬁguration of a Thermolator. Always refer to the wiring diagrams and other documentation - including manuals from the manufacturer of any valves, heat exchangers, and parts used on your Thermolator - when completing any maintenance or troubleshooting tasks.

Contact Conair Parts and Service Phone: 800-458-1960 From outside of the United States, Call: 814 437 6861

If you have any questions or concerns about your Thermolator, feel free to call Conair’s Parts and Service departments for assistance.

Preventative Maintenance Schedule

Once the unit is in service, we suggest following the maintenance procedures as closely as possible. The importance of a properly established preventive maintenance program cannot be overemphasized. Taking the time to follow these simple procedures will result in substantially reduced downtime, reduced repair costs, and an extended useful lifetime for the unit. Thermolator TW water temperature controllers are essentially maintenance-free. However, to maintain the best performance, we recommend the following maintenance schedule.

• Daily or as often as necessary

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.

r Keep the unit and the area around it clean.

Check for and remove lint, dust, or other obstructions on the unit, especially around air vent areas. Keep ﬂoor around the unit dry. The Thermolator exchanges air from in front of, underneath, on top and beside the unit, so make sure that nothing is against the front, bottom, top or sides of the unit that would stop proper ventilation around the unit.

• Quarterly (every 3 months) or as often as necessary

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 RTD connections. Replace any wire that appears damaged or has worn or cracked

insulation.

5-2 I Maintenance

• Every ﬁve years

r Replace cooling fan in electrical cabinet.

Page 61

Accessing the Thermolator Enclosure

Depending on which features, options, and additions you ordered with your Thermolator, your Thermolator may appear different and operate differently from the illustrations and photos shown in this user guide.

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:

1 Remove the top panel.

2 Remove each side panel by lifting straight up.

 NOTE: The side panels ﬁt into slots at the bottom. Note how they ﬁt so that reassembly will be easy.

3 Set the top panel and side panels out of the way for maintenance procedures.

Note that the right side and left side panels are unique and will only ﬁt on the unit in their appropriate position.

Maintenance

Cont rol Power

Auto

sta

rt Sign

Pump

Heat

Cool

Coolant Pressur

Temperature Limit

F l o w GPM (

flash)

Elect

rical Phase Err

Heat Erro

Proc

ess Cool Down

Mold

Rapid

Process

Purge

ol Down

ld Purge

Rapid C

ool

Commu

nic ations

Remo

te Heat/Cool

Prog

ram Mode

Maintenance I 5-3

Page 62

Tools Required

r 9/16-inch wrench

r Flat-blade screwdriver

r 5/8 inch deep socket

r Press for removal of

pump seal

Removing the Pump Motor and Seal

(1/2 to 2 Hp, any frequency and 3 HP, 60 Hz units)

Motor

Motor Bolts

Pipe Plug

Loc Tite

Time Required

45 Minutes

Casing Bolts

Mechanical Seal

Impeller

Impeller Locknut

Casing O-Ring

Casing

Pump O-Rings

If the pump motor or seal ever needs to be replaced, the following procedure can be used on all models with 1/2 to 3 Hp motors for disassembly:

Motor Adapter

1 Using a 9/16-inch wrench, remove the four (4) casing bolts that hold the motor and

impeller adapter assembly to the Thermolator.

2 Remove the motor and adapter from the pump adapter to volute.

Contact Conair Parts and Service Phone: 800-458-1960 From outside of the United States, Call: 814 437 6861

5-4 I Maintenance

3 Remove the casing O-ring. Inspect for damage or wear. If in good condition, set

aside for re-use. If a new part is needed, contact Conair Parts and request part number 267204-0160-02

(Continued)

Page 63

Removing the Pump Motor and Seal

(1/2 to 2 Hp, any frequency and 3 HP, 60 Hz units)

4 Remove the dust cap from the bell end motor housing to expose the motor shaft.

5 Using a locking pair of pliers, grip

the ﬂat sides of the motor shaft.

(Continued)

6 Remove impeller lock nut using a

5/8 inch deep socket. The lock nut is secured in place with a high performance thread locker. A signiﬁcant amount of torque will be required to break it free. Use the locking pliers at the other end of the shaft to prevent shaft rotation when removing the lock nut and impeller. Standard clockwise thread is used.

7 Unscrew the impeller from the shaft.

Maintenance

(Continued)

Maintenance I 5-5

Page 64

Removing the Pump Motor and Seal

(1/2 to 2 Hp, any frequency and 3 HP, 60 Hz units)

(Continued)

8 Slide the rotating half of the shaft seal off of the shaft. Be careful not to contami-

nate, chip, or scratch seal surfaces if it is to be re-used. Set seal half aside for re-use if appropriate.

9 Using a 9/16-inch wrench, remove the four (4) casing bolts.

5-6 I Maintenance

10 Slide motor adapter off of motor shaft.

11 Press stationary half of

pump seal out of motor adapter, being careful not to damage rubber diametral seal or rotating/ non-rotating seal interface surface. Set seal half aside for re-use if appropriate.

Page 65

Reassembling the Pump Motor and Seal

(1/2 to 2 Hp, any frequency and 3 HP, 60 Hz units)

The following procedure can be used on all models with 1/2 to 3 Hp motors for reassembly:

1 Gently press stationary

half of pump seal into motor adapter being careful

to not damage rotating / non-rotating seal interface surface.

2 Slide motor adapter as-

sembly on to motor shaft.

3 Install and tighten the 4 bolts to 20 ft-lbs {27.12 N·m}. While tightening the bolts,

be careful to maintain the motor adapter perpendicular to the shaft.

Tools Required

r 9/16-inch wrench

r Flat-blade screwdriver

r 5/8 inch deep socket

r Blue Loc-Tite ® (271)

Time Required

25 Minutes

Maintenance

4 Slide the rotating portion of the shaft seal onto the shaft with the spring on the

impeller side.

(Continued)

Maintenance I 5-7

Page 66

Reassembling the Pump Motor and Seal

(1/2 to 2 Hp, any freq. and 3 HP, 60 Hz units)(Cont.)

5 Align the impeller and screw on to shaft.

6 Place a small amount of Blue Loc-Tite #271 on the shaft end thread.

5-8 I Maintenance

7 Install the impeller jam nut on the shaft, and tighten to 12 ft-lbs {16.27 N·m}.

Use a locking pair of pliers to grip the ﬂat side of the shaft at the motor bell end. Re-install dust cap if removed during disassembly.

8 Place pump to adapter

o-ring on motor adapter.

Locate the o-ring as far up the adapter as possible such that it sits tight to the angle formed by the mounting ﬂange.

9 Locate the motor and motor adapter assembly on the pump volute. Install the 4

bolts, tightening to 20 ft-lbs {27.12 N·m}.

Page 67

Removing the Pump Motor and Seal

(3 Hp, 50Hz and 5 to 10 Hp, any frequency units)

Motor

Motor Bolts

Shaft Key

Tools Required

r 9/16-inch wrench

r Flat-blade screwdriver

r 9/16-inch deep socket

Time Required

20 Minutes

Casing Bolts

Mechanical Seal

Impeller

Impeller Washer

O-Ring

Loc-Tite

The following procedure can be used on all models with 5 to 10 hp pump motors for disassembly:

Impeller Bolt

Casing

Motor Adapter

Shaft Sleeve

1 Remove eight (8) pump casing bolts using a 9/16-inch wrench.

2 Remove motor and adapter from casing.

3 Inspect pump casing to adapter o-ring for damage. If appropriate obtain replace-

ment part number 267204-0265-02.

4 Remove impeller bolt and washer using a 9/16-inch deep socket. The bolt is

secured in place with a high performance thread locker. A signiﬁcant amount of torque will be required to break it free. The impeller may be clamped on the smallest diameter round section behind the witness line of the casing interface only. Do not damage the outside surface where the close clearance between the casing and impeller exists.

Maintenance

Contact Conair Parts and Service Phone: 800-458-1960 From outside of the United States, Call: 814 437 6861

(Continued)

Maintenance I 5-9

Page 68

Removing the Pump Motor and Seal

(3 Hp, 50Hz and 5 to 10 Hp, any frequency units)

(Continued)

This area interfaces with volute

Witness line

Clamp in this region if needed

5 Unscrew impeller from shaft.

6 Slide rotating half of shaft seal off of shaft. Be careful not to contaminate, chip or

scratch seal surfaces if it is to be re-used. Set seal half aside for re-use if appropriate.

7 Slide shaft sleeve off of shaft.

8 Remove 4 motor bolts using 9/16-inch wrench.

9 Slide motor adapter off of motor shaft.

10 Press stationary half of pump seal out of motor adapter being careful not to dam-

age rubber diametral seal or rotating / non-rotating seal interface surface. Set seal half aside for re-use if appropriate.

5-10 I Maintenance

Page 69

Reassembling Pump Motor and Seal

(3 Hp, 50Hz and 5 to 10 Hp, any frequency units)

The following procedure can be used on all models with 5 to 10 Hp motors for disassembly:

1 Gently press stationary half of pump seal into motor adapter being careful not

damage rotating / non-rotating seal interface surface.

2 Slide motor adapter assembly on to motor shaft.

3 Install and tighten the four (4) bolts to 37 ft lbs {50.12 N·m}. Holding the motor

adapter on to the motor being careful to maintain the adapter perpendicular to the shaft.

4 Slide the shaft sleeve over top of shaft.

5 Slide the rotating portion of the shaft seal on to the shaft with the spring on the

impeller side.

6 Align the impeller and screw on to shaft.

7 Place a small amount of Blue Loc-Tite #271 on the impeller bolt thread.

8 Install the impeller bolt and washer on the shaft, tighten to 20 ft-lbs {27.12 N·m}.

9 Place pump to adapter o-ring on motor adapter if removed. Locate the o-ring in

the groove on the adapter without residual twist.

10 Locate the motor and motor adapter assembly on the pump casing. Install the

eight (8 )bolts, tightening to 37 ft-lbs {50.12 N·m}.

Tools Required

r 9/16-inch wrench

r Flat-blade screwdriver

r 9/16-inch deep socket

r Blue Loc-Tite ® (271)

Time Required

60 Minutes

Maintenance

Maintenance I 5-11

Page 70

Tools Required

r Phillips

Screwdriver

Resetting Pump Overload

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

1 Disconnect and lockout the main power.

2 Open the electrical enclosure door. Turn the screw on

the front panel counterclockwise to open.

3 Check the overload. Press the blue button to attempt

to reset the overload. If it clicks, the overload was tripped. Verify that the overload trip point is set as speciﬁed by the electrical power prints.

Replacing Pump Overload

1 Disconnect and lockout the main power.

2 Open the electrical enclosure door. Turn the screw on the front panel counterclock-

wise to open.

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

4 Disconnect the three power leads from

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

5 Disconnect auxiliary wiring on the

overload module.

6 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.

7 Reverse these steps to install the new

overload module.

8 Set the module reset mode to M for

manual.

9 Set the proper FLA trip point. Trip

point will be shown on electrical prints

Motor Contactor

Motor Overload

10 Push reset button on overload to ensure

it is not in the tripped state.

5-12 I Maintenance

11 Verify that pump rotation is correct (see Installation section of this manual).

Page 71

Replacing the Controller Boards

The controller boards used in the Thermolator TW-P can be replaced if necessary. Two main circuit boards make up the controller. One is the display board that contains all the numeric displays, LEDs and pushbuttons. The other is the main board that contains the microprocessor, inputs, outputs, and option daughter cards. They are connected with a 20-conductor ribbon cable. Any or all can be independently replaced.

To remove controller:

1 Disconnect and lockout the main power supply.

2 If replacing the main board, remove all terminal strips. If the daughter cards are

to not be replaced, use a pair of needle-nose pliers to release the daughter cards from the plastic standoffs. Unplug ribbon cable.

If replacing the HMI board, unplug ribbon cable from the back.

3 Remove the four mounting screws holding the board in place.

4 Remove the board to be replaced.

To reinstall the controller:

5 If replacing the main board and/or any of the daughter cards, please check care-

fully that all the jumpers and DIP switches on the new part are set exactly the same as the old part. If the old part is not available for reference, all factory jumper

settings are shown on the electrical control prints.

6 If replacing the main board, insert all terminal strips. Replace all daughter cards

on plastic standoffs. Take care to ensure that daughter card connections to the main board are properly aligned. Reattach ribbon cable.

If replacing HMI board, reattach ribbon cable from the back.

7 Replace the four mounting screws as shown in the pictures above in step 3.

8 The user parameters are stored on the main board, and will be set to their fac-

tory defaults. If the main board was replaced, please be sure to re-conﬁgure parameters to control operation of the TCU as desired.

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.

Maintenance

Contact Conair Parts and Service Phone: 800-458-1960 From outside of the United States, Call: 814 437 6861

Maintenance I 5-13

Page 72

5-14 I Maintenance

Page 73

Troubleshooting

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

A Few Words of Caution......................................... 6-3

Identifying the Cause of a Problem ......................... 6-4

SECTION

Controller Alarms ................................................. 6-5

Controller Control Fault Logic ...............................6-14

Unit Faults .........................................................6-15

Unit Will Not Power Up .........................................6-26

Troubleshooting ..................................................6-27

Replacing the Heater Contactor .............................6-29

Checking the RTD ................................................6-30

Replacing the RTD ...............................................6-32

Repairing Cooling Valves ......................................6-33

Disassembly of Alternate Direct Acting Solenoid

Valves ...............................................................6-34

Troubleshooting

Alternate Pilot Operated Solenoid Valves .................6-35

Replacing Immersion Heaters ................................6-36

Removing the Pump .............................................6-38

Troubleshooting I 6-1

Page 74

Before Beginning

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

Before you begin troubleshooting:

Additional manuals and prints for your Conair equipment may be ordered through the Customer Service or Parts Department for a nominal fee. Most manuals can be downloaded free of charge from the product section of the Conair website.www.conairgroup.com

r Find any wiring, parts, and assembly diagrams that were shipped with your equip-

ment. These are the best reference for correcting a problem. The diagrams will note any custom features or options not covered in this User Guide.

r Verify that you have all instructional materials related to the Thermolator. Additional

details about troubleshooting and repairing speciﬁc components are found in these materials.

r Check that you have manual for other equipment connected in the system. Trouble-

shooting may require investigating other equipment attached to, or connected with the Thermolator.

6-2 I Troubleshooting

Page 75

A Few Words of Caution

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

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

All wiring, disconnects, and fuses should be installed and adjusted by qualified electrical technicians in accordance with electrical codes in your region. Always maintain a safe ground. Do not operate the equipment at power levels other than what is specified on the machine serial tag and data plate.

WARNING: Electrical hazard

Before performing maintenance or repairs on this product, disconnect and lock out electrical power sources to prevent injury from unexpected energization or start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity.

WARNING: Compressed air hazard

If you use compressed air, you must wear eye protection and observe all OSHA and other safety regulations pertaining to the use of compressed air. Bleed off pressure before servicing equipment.

WARNING: Hot surface and liquid 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}.

Troubleshooting

Troubleshooting I 6-3

Page 76

Identifying the Cause of a Problem

NOTE: Additional troubleshooting help can be found in the documentation manuals included with this User Guide.

The Troubleshooting section covers problems directly related to the operation and maintenance of the TW-P. This section does not provide solutions to problems that originate with other equipment. Additional troubleshooting help can be found in manuals supplied with the other equipment.

Illuminated alarm LEDs 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.

Control Power

Autostart Signal

Pump

Heat

Cool

Flow GPM (flash)

Mold

Purge

Rapid

Cool

Process

Cool Down

Coolant Pressure

Temperature Limit

Electrical Phase Error

Heat Error

Process Cool Down

Mold Purge

Rapid Cool

Communications

Remote Heat/Cool

Program Mode

Standard Indicator

Lights and Alarm

Codes

Refer to Controller Alarms in this Section.

Visual + Audible Alarm (Optional) and Illuminated Fault Light

Refer to Mechanical/Electrical Problems in this section.

When an Alarm condition occurs:

1 Press Fault to silence optional audible alarm.

2 Note any indicator lights or error messages to help determine the cause of the problem.

3 Note what the machine was doing prior or during the alarm occurrence. (Was it starting

up, running steadily, etc.?)

4 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.

5 Determine and ﬁx the cause of the alarm.

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

Also disconnect air and water supply lines as needed.

6-4 I Troubleshooting

Page 77

Controller Alarms

Control Power

Autostart Signal

Pump

Heat

Cool

When an alarm occurs, the Thermolator has detected a problem with the process. Without correction, the TCU will not be able to produce process ﬂuid of the correct temperature. Under certain conditions, an alarm could lead to equipment damage or personal injury if it is not corrected.

• The controller displays an error code indicating the cause of the problem.

• If the optional alarm package is installed, the Fault strobe will illuminate and the audible alarm will activate.

Alarm Possible Cause Solution

Coolant Pressure Lo

Low Coolant Inlet Pressure

The TCU ﬂuid circuit does not have enough pressure to operate the pump or heater.

WARNING: Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

u COOLANT PRESSURE

LOW LED illuminates. Optional strobe, sounds, dry contacts actuated.

u Pump temporarily turns off. u Heater temporarily turns off. u Cooling valve continues to

regulate.

This alarm will automatically reset when system pressure returns. When it does, the TCU will automatically resume normal operation.

Is fresh water turned on to the TCU?

Does your facility have the required water pressure to run the TCU? Normally this is 25psi, but may be signiﬁcantly higher on certain models.

Is the pressure switch faulty? Upgrade your facility plumbing

Be sure to turn on the water supply before starting the TCU. The pressure status can be observed on the COOLANT PRESSURE LOW LED even when the TCU is not running.

Observe the pressure indicated on the pressure gauges. Compare this to the minimum required operating pressure for your speciﬁc TCU model.

if necessary, or add an external booster pump

If you are sure that sufﬁcient water pressure is present, test the pressure switch with a VOM. Low pressure should allow the switch to open, whereas high pressure should cause it to close.

(Continued)

Troubleshooting

Troubleshooting I 6-5

Page 78

Controller Alarms

Control Power

Autostart Signal

Pump

Heat

Cool

Function

Display

Mold

Purge

Supply Return

Control Power

Autostart Signal

Pump

Heat

Cool

Coolant Pressure Low

Venting

Program Mode

(Continued)

• The controller displays an error code indicating the cause of the problem.

• If the optional alarm package is installed, the Fault strobe will illuminate and the audible alarm will activate.

Alarm Possible Cause Solution

Coolant Pressure Lo

Cool

Down

Alarm

Coolant Pressure Low Timeout

The TCU has experienced either;

1. Too many low pressure alarms within a certain time period.

2. The TCU has remained temporarily shut down with a low pressure alarm for too long.

WARNING: Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

Water pressure in your building is only marginally acceptable to run the TCU. Any small ﬂuctuations can cause the TCU to cycle on and off repeatedly.

Other equipment fed from the same water line as the TCU is consuming signiﬁcant water ﬂow at intermittent intervals. Due to the high demand, pressure at the TCU temporarily drops.

Observe the building water pressure over time. If it drops below the minimum require pressure, you will need to upgrade your facility plumbing, or add an external booster pump.

If permitted by the manufacturer of the other equipment, install ﬂow reducers to the other equipment so that ﬂow is restricted to a reasonable level and sufﬁcient pressure is retained for the TCU.

6-6 I Troubleshooting

u ALARM LED ﬂashes in

conjunction with COOLANT PRESSURE LOW LED.

u Optional strobe, sounds, dry

contacts actuated.

u Pump turns off. u Heater turns off. u Cooling valve closes.

Once you have corrected the problem, push the alarm silence/reset button to clear this alarm. Then push the RUN button to restart the TCU.

(Continued)

Page 79

Controller Alarms

• The controller displays an error code indicating the cause of the problem.

• If the optional alarm package is installed, the Fault strobe will illuminate and the audible alarm will activate.

(Continued)

Alarm Possible Cause Solution

2 2

H

Deviation Alarm – Over Setpoint

The process temperature has exceeded the allowable deviation window for a certain amount of time.

WARNING: Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

u ALARM LED ﬂashes in con-

u Optional strobe, sounder, dry

u Pump continues to run nor-

u Heater continues to run

u Cooling valve continues to

This alarm will automatically reset when the problem is corrected.



22

juction with an alternating actual temperature display.

contacts actuated.

mally.

normally.

run normally.

Has water stopped ﬂowing throughout the unit or between supply outlet and return inlet?

Did the cooling valve fail closed?

Is the temperature difference between the cooling water supply and the setpoint too small?

Is the cooling valve under-sized for the application?

Is the high process temperature alarm too sensitive?

Is the high deviation temperature alarm delay too short?

Verify that the unit is running and that the pump is working. Check for closed or defective cooling or vent valves and plugged lines. See Repairing Cooling

Valves.

Check for external closed valve on the process ﬂuid going to external equipment. Check for a plugged pipe.

Check the cooling valves. See

Repairing Cooling Valves or the Motorized Cooling Valve instructions.

The temperature difference should be at least 25° F {14° C} to achieve proper cooling. Increase the process setpoint, decrease the cooling water supply temperature or increase the cooling water supply pressure.

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

Modify the High Deviation Alarm trigger point by increasing parameter H.

Modify the High Deviation Alarm Delay by increasing parameter H.

Troubleshooting

Is the initial deviation alarm delay parameter too short?

Are the algorithm and PID parameters set correctly?

Modify the “Startup Ignore Deviation Delay” by increasing parameter .

Check the algorithm/PID parameters, including: t, Pb, E, n, PbH, EH, nH, and Pbr.

(Continued)

Troubleshooting I 6-7

Page 80

Controller Alarms

• The controller displays an error code indicating the cause of the problem.

• If the optional alarm package is installed, the Fault strobe will illuminate and the audible alarm will activate.

(Continued)

Alarm Possible Cause Solution

2 2



Deviation Alarm – Under Setpoint

The process temperature has dropped below the allowable deviation window for a certain amount of time.

WARNING: Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

u ALARM LED ﬂashes in con-

u Optional strobe, sounder, dry

u Pump continues to run nor-

u Heater continues to run

u Cooling valve continues to

This alarm will automatically reset when the problem is corrected.





juction with an alternating actual temperature display.

contacts actuated.

mally.

normally.

run normally.

Is the cooling valve stuck open or leaking water?

Did a heater element fail or open?

Did a heater contactor fail open? Replace the contactor if defective.

Is the low process temperature alarm too sensitive?

Is the low deviation temperature alarm delay too short?

Is the initial deviation alarm delay parameter too short?

Is the Thermolator under-sized for the application?

Is the Thermolator or equipment to which it is attached leaking?

Are the algorithm and PID parameters set correctly?

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 Cooling Valves.

With the unit powered down: Check for loose connections on heater wiring. Check resistance between the phase legs on the output side of the heater contactor (or SSR if present). Readings should be within 0.25 ohms of each other. Replace the heater, if necessary. See Replacing

Heater Elements.

See Replacing the Heater Contactor.

Modify the Low Deviation Alarm trigger point by increasing parameter .

Modify the Low Deviation Alarm trigger point by increasing parameter .

Modify the “Startup Ignore Deviation Delay” by increasing parameter.

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

Verify that there are no water leaks. Fix as necessary.

Check the algorithm/PID parameters: t, Pb, E,n, PbH, EH,nH, and Pbr.

6-8 I Troubleshooting

(Continued)

Page 81

Controller Alarms

• The controller displays an error code indicating the cause of the problem.

• If the optional alarm package is installed, the Fault strobe will illuminate and the audible alarm will activate.

(Continued)

Alarm Possible Cause Solution

22 22

HSU

User Temperature – High Limit

The process temperature has risen beyond the user-conﬁgured maximum high limit.

WARNING: Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

This alarm can be reset by pushing the Alarm Silence/Reset button once the temperature returns to an acceptable level.



24

u ALARM LED ﬂashes in con-

junction with an alternating actual temperature display.

u Optional strobe, sounder, dry

contacts actuated.

u Pump continues to run nor-

mally.

u Heater continues to run

normally.

u Cooling valve continues to

run normally.

Has water stopped ﬂowing thought the unit or between the supply outlet and return inlet?

Did the cooling valve fail closed?

Is the temperature difference between the cooling water supply and the setpoint too small?

Has the heater contactor failed with the contacts welded closed?

Is the cooling valve under-sized for the application?

Is the high process temperature alarm too sensitive?

Is the cooling water return line plugged?

Has the cooling water return pressure risen?

Has the cooling water supply pressure dropped?

Verify that the unit is running and that the pump is working. Check for closed or defective cooling or vent valves and plugged lines. See Repairing Cooling

Valves.

Check for external closed valve on the process ﬂuid going to external equipment. Check for a plugged pipe.

Check the cooling valve. See

Repairing Cooling Valves or the Motorized Cooling Valve instructions.

The temperature difference should be at least 25°F {14°C} to achieve proper cooling. Increase the process setpoint, decrease the cooling water supply temperature or increase the cooling water supply pressure.

Replace the contactor if defective.

See Replacing the Heater Contactor.

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

Increase the alarm trigger point

HSU. The recommended setting

is the setpoint plus 2° F {4° C} to 10°F {18° C}.

Verify the free ﬂow of water out of the unit.

Check the water return pressure with valve.

Check the water supply pressure. If equipped, verify that strainer is not clogged.

Troubleshooting

(Continued)

Troubleshooting I 6-9

Page 82

Controller Alarms

• The controller displays an error code indicating the cause of the problem.

• If the optional alarm package is installed, the Fault strobe will illuminate and the audible alarm will activate.

(Continued)

Alarm Possible Cause Solution

Contact Conair Parts and Service Phone: 800-458-1960 From outside of the United States, Call: 814 437 6861

22 22

HSF

Factory Temperature – High Limit

The process temperature has risen beyond the factory-conﬁgured maximum high limit.

WARNING: Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.



2

u ALARM LED ﬂashes in con-

junction with an alternating actual temperature display.

u Optional strobe, sounder, dry

contacts actuated.

u Pump continues to run nor-

mally.

u Heater continues to run

normally.

u Cooling valve continues to

run normally.

Has water stopped ﬂowing thought the unit or between the supply outlet and return inlet?

Did the cooling valve fail closed?

Has the heater contactor failed with the contacts welded closed?

Is the cooling valve under-sized for the application?

Verify that the unit is running and that the pump is working. Check for closed or defective cooling or vent valves and plugged lines. See Repairing Cooling

Valves.

Check for external closed valve on the process ﬂuid going to external equipment. Check for a plugged pipe.

Check the cooling valve. See

Repairing Cooling Valves or the Motorized Cooling Valve instructions.

Replace the contactor if defective.

See Replacing the Heater Contactor.

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

This alarm can be reset by pushing the Alarm Silence/Reset button once the temperature returns to an acceptable level.

6-10 I Troubleshooting

Is the cooling water return line plugged?

Has the cooling water return pressure risen?

Has the cooling water supply pressure dropped?

Verify the free ﬂow of water out of the unit.

Check the water return pressure with valve.

Check the water supply pressure. If equipped, verify that strainer is not clogged.

(Continued)

Page 83

Controller Alarms

• The controller displays an error code indicating the cause of the problem.

• If the optional alarm package is installed, the Fault strobe will illuminate and the audible alarm will activate.

(Continued)

Alarm Possible Cause Solution

8 8

SU

User Temperature – Low Limit

The process temperature has risen beyond the user-conﬁgured minimum low limit.

WARNING: Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

u ALARM LED ﬂashes in con-

u Optional strobe, sounder, dry

u Pump continues to run nor-

u Heater continues to run

u Cooling valve continues to

This alarm can be reset by pushing the Alarm Silence/Reset button once the temperature returns to an acceptable level.





juction with an alternating actual temperature display.

contacts actuated.

mally.

normally.

run normally.

Is the cooling valve stuck open or leaking water?

Did a heater element fail or open?

Did the heater contactor fail open?

Is the low process temperature alarm too sensitive?

Is the Thermolator under-sized for the application?

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 Cooling Valves.

Heater Elements.

Replace the contactor if defective.

See Replacing the Heater Contactor.

Decrease the alarm trigger point

SU. The recommended setting

is the setpoint minus 2°F {4°C} to 10°F {18°C}. Replace the contactor if defective. See Replacing the

Heater Contactor.

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

Troubleshooting

Is the Thermolator or equipment to which it is attached leaking?

Verify that there are no water leaks. Fix as necessary.

(Continued)

Troubleshooting I 6-11

Page 84

Controller Alarms

• The controller displays an error code indicating the cause of the problem.

• If the optional alarm package is installed, the Fault strobe will illuminate and the audible alarm will activate.

(Continued)

Alarm Possible Cause Solution

8 8

SF

Factory Temperature – Low Limit

The process temperature has risen beyond the factory-conﬁgured minimum low limit.

WARNING: Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

u ALARM LED ﬂashes in con-

u Optional strobe, sounder, dry

u Pump continues to run nor-

u Heater continues to run

u Cooling valve continues to





juction with an alternating actual temperature display.

contacts actuated.

mally.

normally.

run normally.

Is the cooling valve stuck open or leaking water?

Did a heater element fail or open?

Did the heater contactor fail open?

Is the Thermolator under-sized for the application?

Is the Thermolator or equipment to which it is attached leaking?

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 Cooling Valves.

Heater Elements.

Replace the contactor if defective. See Replacing the

Heater Contactor.

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

Verify that there are no water leaks. Fix as necessary.

This alarm can be reset by pushing the Alarm Silence/Reset button once the temperature returns to an acceptable level.

6-12 I Troubleshooting

Page 85

Controller Alarms

• The controller displays an error code indicating the cause of the problem.

• If the optional alarm package is installed, the Fault strobe will illuminate and the audible alarm will activate.

Alarm Possible Cause Solution

F 8

8

Low Flow

The optional ﬂowmeter has detected ﬂow below the userconﬁgured low ﬂow limit.

u “FLL” is displayed in the

u Pump continues to run nor-

u Heater continues to run

u Cooling valve continues to

u Alarm LED, optional strobe,

This alarm will automatically reset once ﬂow is above the low ﬂow limit.



8

setpoint display.

mally.

normally.

run normally.

sounder, dry contacs are all not actuated.

Is a valve closed in the process loop?

Is there some kind of blockage in the process loop?

Did the process loop change in length or conﬁguration that now provides more ﬂow resistance to the pump?

Is the user-conﬁgured low-ﬂow limit set too high?

Examine the process loop and look for blockages, closed valves, etc.

Modify the Flowmeter Alarm Threshold by decreasing parameter F.

Troubleshooting

Troubleshooting I 6-13

Page 86

Controller Control Fault Logic

Fault Alarm Indication Pump

Shut

Off

Low Coolant Inlet Pressure

Temperature Limit Safety

The Coolant Pressure In Light ﬂashes red Yes Yes Yes No No Yes

The Set Point and Process Temperatures Flash

Ye s Ye s Ye s Ye s No Yes

and the Temperature Limit Light ﬂashes red

Temperature Limit Warning

Pump Motor Overload

Supply Probe Fault Hi

The Temperature Limit Light ﬂashes yellow No No No Ye s No Yes

The Pump Light ﬂashes red Ye s Yes Yes Yes Ye s Ye s

The Set Point Temperature Display shows PRS

Ye s Ye s Ye s Ye s No Yes

and the Process Temperature Display shows EH

Supply Probe Fault Lo

The Set Point Temperature Display shows PRS

Ye s Ye s Ye s Ye s No Yes

and the Process Temperature Display shows E

Return Probe Fault Hi

The Set Point Temperature Display shows PRR

Ye s Ye s Ye s Ye s No Yes

and the Process Temperature Display shows EH

Return Probe Fault Lo

The Set Point Temperature Display shows PRr

Ye s Ye s Ye s Ye s No Yes

and the Process Temperature Display shows E

Heater

Shut

Off

Unit

Shut

Off

Alarm

Reset

Required

Manual

Reset

Required

Remote

Alarm

Activated

Brownout

The Set Point Temperature Display shows Brn

and the Process Temperature Display shows Out

3-Phase Power Error

(Optional)

Heater Contactor Error

(Optional)

Pressing the Alarm Silence/Reset resets alarm.

A manual reset of the pump motor thermal overload is required to reset this alarm.

Activates the alarm horn and closes the alarm contact (optional).

Requires the Premium Controller option (TW-P).

The Electrical Phase Error light ﬂashes red Yes Yes Yes Yes No Ye s

The Heat Error light ﬂashes red Ye s Yes Yes Yes No Ye s

Ye s Ye s Ye s Ye s No Yes

6-14 I Troubleshooting

Page 87

Unit Faults

The Thermolator has detected a problem with the internal components, wiring, electrical power, or operating environment. Without correction, the fault could lead to equipment damage or personal injury if it is not corrected.

• The controller displays an error code indicating the cause of the problem.

• The TCU may take automatic control actions, based on the nature of the fault, to best protect the op- erator and the TCU until the fault is corrected.

• If the optional alarm package is installed, the fault strobe will illuminate and the audible alarm will activate.

• Some faults require a power cycle to reset.

Fault Possible Cause Solution

tcU

ht

Hardware Over-Temperature Trip

The temperature of the process ﬂuid bypass tube has exceeded the maximum permissible operating temperature. For models with SSR’s, this fault can also refer to an overheated SSR heatsink.

WARNING: Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

u ALARM LED illuminated. u Optional strobe, sounder,

dry contacts actuated.

u Pump locks on. u Heater locks off. u Cooling valve locks open.

Has water stopped ﬂowing through the unit or between the supply outlet and return inlet?

Has the heater contactor (or SSR) failed with the contacts welded closed?

If SSR Model: Has the heatsink fan failed or is the air pathway blocked?

Has the optional high temperature switch failed?

Verify that the unit is running and that the pump is working. Check for closed or defective cooling or vent valves and plugged lines. See Repairing

Cooling Valves.

Check for external closed valve on the process ﬂuid going to external equipment.

Replace the contactor if defective. See Replacing the Heater

Contactor.

Replace the fan or clear the blocked air pathway. Reset the heatsink thermostat by depressing the button on the top of it.

Verify that the switch is closed near room temperature with a VOM. If not, replace the optional temperature limit switch.

Troubleshooting

Power must be cycled to reset this fault.

(Continued)

Troubleshooting I 6-15

Page 88

Unit Faults

• The controller displays an error code indicating the cause of the problem.

• The TCU may take automatic control actions, based on the nature of the fault, to best protect the op- erator and the TCU until the fault is corrected.

• If the optional alarm package is installed, the fault strobe will illuminate and the audible alarm will activate.

• Some faults require a power cycle to reset.

(Continued)

Fault Possible Cause Solution

br

ht

Controller Board Overheated

The temperature of the controller board has exceeded the maximum permissible operating temperature. This is probably due to excessive temperature inside the electrical control enclosure.

WARNING: : Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

u ALARM LED illuminated. u Optional strobe, sounder,

dry contacts actuated.

u Pump operates normally. u Heater operates normally. u Cooling valve operates

normally.

Have the cooling vents on the TCU been blocked?

Is the TCU operating in an ambient environment outside its maximum permissible limits (max of 104°F {40°C}?

Has the enclosure cooling fan failed or is the air pathway blocked?

Check for blocked or plugged cooling vents.

Relocate the TCU or provide additional external ventilation or cooling.

Replace the fan or clear the blocked air pathway.

This fault can be reset by pushing the Alarm Silence/Reset button once the controller board temperature returns to an acceptable level.

6-16 I Troubleshooting

(Continued)

Page 89

Unit Faults

• The controller displays an error code indicating the cause of the problem.

• The TCU may take automatic control actions, based on the nature of the fault, to best protect the op- erator and the TCU until the fault is corrected.

• If the optional alarm package is installed, the fault strobe will illuminate and the audible alarm will activate.

• Some faults require a power cycle to reset.

(Continued)

Fault Possible Cause Solution

PUP

Is enough restriction provided in the ﬂuid circuit loop?



Pump Overload

The pump is pulling more electrical current than its maximum ratings permit. This is probably due to excessive mechanical loading of the motor.

WARNING: : Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

u ALARM LED illuminated. u Optional strobe, sounder,

dry contacts actuated.

u Pump shuts off. u Heater shuts off. u Cooling valve closes.

The reset button on the overload must be depressed to clear this fault. See Resetting Pump

Overload section.

* % Voltage imbalance = 100 x (Maximum deviation from average voltage) / (average voltage)

Is there mechanical binding due to a physical jam/obstruction in the pump casing volute?

Have the bearings in the motor failed, causing excessive mechanical loading or misalignment?

Is the correct voltage supplied to the pump motor?

Is a phase open? Check voltage, L1 to L2, L2

Is the motor overload faulty or set incorrectly?

Install a ﬂow-reducing oriﬁce or introduce some additional ﬁttings/smaller diameter piping.

Remove the endcap from the motor and check that the shaft is free to rotate. If not, see Removing the

Pump and Motor.

Remove the endcap from the motor and check that the shaft is free to rotate. If not, see Removing the

Pump and Motor.

Supply voltage should match the rating on the pump nameplate ±10%. If voltage is correct, check wiring connections.

to L3, L3 to L1. All should be within 3% voltage imbalance*.

Disconnect the power and open the electrical enclosure. Verify that the overload is set to trip at the proper amperage, which is speciﬁed on the electrical power prints. Manually trip and reset the overload. If the problem continues, replace the overload. See Re-

setting and Replacing Overloads.

Troubleshooting

(Continued)

Troubleshooting I 6-17

Page 90

Unit Faults

• The controller displays an error code indicating the cause of the problem.

• The TCU may take automatic control actions, based on the nature of the fault, to best protect the op- erator and the TCU until the fault is corrected.

(Continued)

• If the optional alarm package is installed, the fault strobe will illuminate and the audible alarm will activate.

• Some faults require a power cycle to reset.

NOTE: Although somewhat counter-intuitive, restrictions in the ﬂuid make it easier for the motor to pump the ﬂuid, and therefore require less electrical current.

Fault Possible Cause Solution

htr

Er

Heater Contactor is Welded Closed

The heater contactor is NOT disconnecting the heater when told to open by the controller. The heater is likely running continuously.

 Note: This fault is only valid for

units with electromechanical contactors. Mercury or SSR heater controls do not produce this error.

WARNING: Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

u ALARM LED illuminated. u Optional strobe, sounder,

dry contacts actuated.

u Pump locks on. u Heater locks off (although it

is probably still active due to malfunction).

u Cooling valve locks open.

Have the electromechanical heater contactor contacts welded shut and are preventing the contactor from mechanically shuttling to an open position?

Is a fault in the control wiring or controller outputs continuously powering the heater contactor coil?

Replace the heater contactor.

Ensure that the application is a cooling-based application and will only require heater operation for initial machine warm up. For applications requiring continuous heating regulation, contact Conair customer service and inquire about Mercury or SSR upgrade kits for the heater contactor.

Contact Conair Parts and Service Phone: 800-458-1960 From outside of the United States, Call: 814 437 6861

Test voltage between the A1 and A2 terminals (coil) on the heater contactor. If 120VAC is found, the contactor is probably not defective. Troubleshoot the problem by searching for the source of this voltage.

Power must be cycled to reset this fault.

6-18 I Troubleshooting

(Continued)

Page 91

Unit Faults

• The controller displays an error code indicating the cause of the problem.

• The TCU may take automatic control actions, based on the nature of the fault, to best protect the op- erator and the TCU until the fault is corrected.

• If the optional alarm package is installed, the fault strobe will illuminate and the audible alarm will activate.

• Some faults require a power cycle to reset.

(Continued)

Fault Possible Cause Solution

htr

Er2

Heater Contactor is NOT Closing

The heater contactor is NOT closing when told to open by the controller. The heater is likely not able to run.

 Note: This fault is only valid for

units with electromechanical contactors. Mercury or SSR heater controls do not produce this error.

WARNING: Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

u ALARM LED illuminated. u Optional strobe, sounder,

dry contacts actuated.

u Pump locks on. u Heater locks off. u Cooling valve locks open.

Power must be cycled to reset this fault.

Has the electromechanical heater contactor become jammed and is being prevented from mechanically shuttling to a closed position?

Is a fault in the control wiring or controller outputs failing to provide power to the heater contactor coil?

Replace the heater contactor.

Contact Conair Parts and Service Phone: 800-458-1960 From outside of the United States, Call: 814 437 6861

Test voltage between the A1 and A2 terminals (coil) on the heater contactor. If 120VAC is never found, the contactor is probably not defective. Troubleshoot the problem by searching for why the control signal is not reaching the heater contactor coil.

Troubleshooting

(Continued)

Troubleshooting I 6-19

Page 92

Unit Faults

• The controller displays an error code indicating the cause of the problem.

• The TCU may take automatic control actions, based on the nature of the fault, to best protect the op- erator and the TCU until the fault is corrected.

• If the optional alarm package is installed, the fault strobe will illuminate and the audible alarm will activate.

• Some faults require a power cycle to reset.

(Continued)

Fault Possible Cause Solution

brn

Ut

Brownout

The TCU experienced a loss of power while it was running.

 Note: This fault can be selectively

enabled/disabled in the user menu under parameter brn.

WARNING: Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

u ALARM LED illuminated. u Optional strobe, sounder,

dry contacts actuated.

u Pump turns off. u Heater turns off. u Cooling valve closes.

Did your facility experience a power outage?

Is there a disturbance or voltage imbalance in your electrical system?

Ensure that no other connected equipment has been adversely affected by the power outage.

Push the Fault Silence/Reset button, and then push the Run button to restart the TCU.

Have a qualiﬁed electrician review your facility wiring and electrical power. Correct any issues so that the voltage provided to the TCU is as required.

Push the Fault Silence/Reset button to reset this fault.

6-20 I Troubleshooting

(Continued)

Page 93

Unit Faults

• The controller displays an error code indicating the cause of the problem.

• The TCU may take automatic control actions, based on the nature of the fault, to best protect the op- erator and the TCU until the fault is corrected.

• If the optional alarm package is installed, the fault strobe will illuminate and the audible alarm will activate.

• Some faults require a power cycle to reset.

(Continued)

Fault Possible Cause Solution

NOTE: This feature is an option and not present on all models.

Ph

Err

Phase Loss/Rotation Error

The three-phase electrical power being provided to the TCU is either missing a leg, or has incorrect phase rotation direction (TCU is factory-wired for clockwise, L1-L2-L3, phase rotation). This fault is only present on TCU’s that have the optional three-phase monitor included.

WARNING: Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

u ALARM LED illuminated. u Optional strobe, sounder,

dry contacts actuated.

u Pump locks off. u Heater locks off. u Cooling valve locks closed.

Do you have a dead/low leg in the incoming three phase power?

If a portable installation, are different parts of your factory phased differently?

Have a qualiﬁed electrician check your three-phase power, and correct any problems.

Ensure consistent phasing throughout your facility.

--Or-Reverse any two incoming power legs on the TW-P. See Connecting

the Main Power Source.

Check for proper rotation of pump. See Testing the Installa-

tion.

Troubleshooting

Power must be cycled to reset this fault.

(Continued)

Troubleshooting I 6-21

Page 94

Unit Faults

• The controller displays an error code indicating the cause of the problem.

• The TCU may take automatic control actions, based on the nature of the fault, to best protect the op- erator and the TCU until the fault is corrected.

• If the optional alarm package is installed, the fault strobe will illuminate and the audible alarm will activate.

• Some faults require a power cycle to reset.

(Continued)

Fault Possible Cause Solution

Pr

EH

Supply Probe Fault Hi

The “To Process” RTD is malfunctioning or has a break in the wiring.

WARNING: Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

u ALARM LED ﬂashes in

conjunction with SUPPLY LED.

u Optional strobe, sounder,

dry contacts actuated.

u Pump turns off. u Heater turns off. u Cooling valve closes.

Do you have a break in your RTD wiring? Do you have a loose wire?

Has the RTD itself failed or sustained physical damage?

Check the RTD loop wiring with a VOM. See Checking the RTD.

Test the RTD with a VOM. See

Checking the RTD.

If damaged, replace the RTD.

This fault will automatically reset when the problem is corrected.

6-22 I Troubleshooting

(Continued)

Page 95

Unit Faults

• The controller displays an error code indicating the cause of the problem.

• The TCU may take automatic control actions, based on the nature of the fault, to best protect the op- erator and the TCU until the fault is corrected.

• If the optional alarm package is installed, the fault strobe will illuminate and the audible alarm will activate.

• Some faults require a power cycle to reset.

(Continued)

Fault Possible Cause Solution

Pr

E

Supply Probe Fault Low

The “To Process” RTD is malfunctioning or has a short circuit.

WARNING: Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

u ALARM LED ﬂashes in

conjunction with SUPPLY LED.

u Optional strobe, sounder,

dry contacts actuated.

u Pump turns off. u Heater turns off. u Cooling valve closes.

Do you have a short circuit in your RTD wiring?

Has the RTD itself failed or sustained physical damage?

Check the RTD loop wiring with a VOM. See Checking the RTD.

Test the RTD with a VOM. See

Checking the RTD.

If damaged, replace the RTD.

Troubleshooting

This fault will automatically reset when the problem is corrected.

(Continued)

Troubleshooting I 6-23

Page 96

Unit Faults

• The controller displays an error code indicating the cause of the problem.

• The TCU may take automatic control actions, based on the nature of the fault, to best protect the op- erator and the TCU until the fault is corrected.

• If the optional alarm package is installed, the fault strobe will illuminate and the audible alarm will activate.

• Some faults require a power cycle to reset.

(Continued)

Fault Possible Cause Solution

Prr

EH

Return Probe Fault Hi

The “To Process” RTD is malfunctioning or has a break in the wiring.

WARNING: Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

u ALARM LED ﬂashes in

conjunction with SUPPLY LED.

u Optional strobe, sounder,

dry contacts actuated.

u Pump turns off. u Heater turns off. u Cooling valve closes.

Do you have a break in your RTD wiring?

Do you have a loose wire?

Has the RTD itself failed or sustained physical damage?

Check the RTD loop wiring with a VOM. See Checking the RTD.

Test the RTD with a VOM. See

Checking the RTD.

If damaged, replace the RTD.

This fault will automatically reset when the problem is corrected.

6-24 I Troubleshooting

(Continued)

Page 97

Unit Faults

• The controller displays an error code indicating the cause of the problem.

• The TCU may take automatic control actions, based on the nature of the fault, to best protect the op- erator and the TCU until the fault is corrected.

• If the optional alarm package is installed, the fault strobe will illuminate and the audible alarm will activate.

• Some faults require a power cycle to reset.

(Continued)

Fault Possible Cause Solution

Prr

E

Return Probe Fault Low

The “To Process” RTD is malfunctioning or has a short circuit.

WARNING: Only qualified electrical service personnel should examine and correct problems that require opening the unit’s electrical enclosure or checking electrical current.

u ALARM LED ﬂashes in

conjunction with RETURN LED.

u Optional strobe, sounder,

dry contacts actuated.

u Pump turns off. u Heater turns off. u Cooling valve closes.

Do you have a break in your RTD wiring?

Has the RTD itself failed or sustained physical damage?

Check the RTD loop wiring with a VOM. See Checking the RTD.

Test the RTD with a VOM. See

Checking the RTD.

If damaged, replace the RTD.

Troubleshooting

This fault will automatically reset when the problem is corrected.

Troubleshooting I 6-25

Page 98

Unit Will Not Power Up

If you press the control power button and the control panel does not light, you have a problem with the main power circuit or the unit’s temperature controller.

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

Symptom Possible Cause Solution

Applying power does not illuminate the temperature controller display.

Is power reaching the Thermolator?

Is the correct voltage reaching the Thermolator?

Verify that the main power supply and any customer-installed electrical disconnect or emergency stop devices are in the ON position. Verify correct electrical connec-

tions between the unit and the power supply. Replace any damaged wires or cables.

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

6-26 I Troubleshooting

Page 99

Troubleshooting

Symptom Possible Cause Solution

Alternating overheating and overcooling or rapid cycling from heat to cool.

Unable to heat properly. Cooling valve is stuck in the open

Poor water ﬂow. Check connectors and increase

Poor connection or failure of RTD.

Failure of the microprocessor. Replace controller.

position.

size if necessary. If there are a large number of hoses and/or they are long, try to shorten hose runs and use as large of a hose as possible to minimize water-circuit pressure drop. If quick disconnects with check valves are used, remove the check valves to reduce pressure drop through water circuit.

Check connection, replace if necessary.

Flush out the cooling valve by adjusting the Set Point up and down several times to open and close the cooling valve. If this does not work, stop the unit and turn off the electric power, shut off the cooling source, and take the valve apart for cleaning or replacement.

Troubleshooting

Leaking connection and/or the manual pressure relief valve is in an open condition.

Immersion heater is inoperative Have a qualiﬁed electrician check

Microprocessor controller failure. Replace controller.

Failure of RTD. Replace RTD.

Check for leaks and replace any faulty valves.

to see if the heater and/or heater contactor are functioning correctly and replace any defective components.

(Continued)

Troubleshooting I 6-27

Page 100

IMPORTANT: Always refer to the wiring

Troubleshooting

(Continued)

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

Symptom Possible Cause Solution

Unable to cool properly. Cooling water supply is not suf-

ﬁcient.

Check to make sure the cooling water supply is of sufﬁcient temperature, volume and pressure for the unit.

Drain (cooling water return line) is not sufﬁcient.

Check the drain (cooling water return line) to ensure there is no restriction preventing water ﬂow to the drain (cooling water return line).

Cooling valve is inoperative. Check the drain (cooling water

return line) and see if you can feel or hear a change in the ﬂow as the cooling valve open and closes. If you cannot hear or feel the ﬂow it is likely the valve has failed. Replace valve if necessary.

Plugged heat exchanger (only

Clean or replace heat exchanger. on models with heat exchanger option).

High backpressure in the cooling

Reduce backpressure. water system

Heater failure. Unit not ﬁlled with water. Fill unit with water.

6-28 I Troubleshooting

Faulty heater. Replace heater.

Plugged heater tube / ﬂow restriction.

Pressure relief valve leaks. The combined pressure of the

incoming cooling water pressure and the unit pump pressure exceeds the pressure rating of the pressure relief valve.

Pressure relief valve stuck in open position.

Clear obstruction.

Install a pressure-reducing valve

on the incoming cooling water

line. Review the start-up proce-

dure for cooling water pressure

requirements at various operating

temperatures.

Replace valve.

Conair Thermolator TW-S, Thermolator TW-P User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual