Conair Thermolater vacuTrac, VTR1-DI, VTR2-DI User Manual
USERGUIDE
UGH003-0102
Thermolater® vacuTrac
Positive/Negative Pressure Water Temperature
Controller with TW-1 or TW-2 Microprocessor
www.conairgroup.com
Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861
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spaces provided.
It’s a good idea to record the model and serial number(s) of your equi pment and the date you
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number, to provide help for the specific equipment you installed.
Please keep this User Guide and all manuals, engine ering prints and parts lists together for
documentation of your equipment.
Date:
ual Number: UGH003-0102
Man
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.
Copyright 2002 l Conair l All rights reserved
Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861
TEMPERATURE CONTROL UNITS
Thermolator®vacuTrac (VTR1-DI and VTR2-DI)
Positive/Negative Pressure
One Conair Drive ● Pittsburgh, PA 15202 ● 412-312-6000 ● FAX 412-312-6227 ● www.conairnet.com
TPHM011/1101
Keep your operation up and running with the
Thermolator vacuTrac water temperature controller. This
positive/negative pressure unit can be used as a temporary fix for a leaky mold or bad O-rings.
The vacuTrac is equipped with a manual three-way
ball valve that allows you to change the unit from positive pressure to negative pressure by moving the valve
handle on the back of the unit counterclockwise.
Changing the unit to operate with negative pressure
allows the unit to draw air into the mold effectively stopping leaks.
■ INCOLO Y HEATERS
Standard on the vacuTrac, Incoloy heaters resist damage
from high temperatures and chemicals.
■THREE-WAY B ALL VALVE
Quick and easy changeover from standard positive pressure
to negative pressure operation.
■ LIFT-OFF ACCESS PANELS
Convenient, tool-free access to internal components.The
cabinet lifts away for easy maintenance and servicing.
■ STA TE-OF-THE-ART CONTROLS
Easy to use microprocessor controls provide accurate temperature control. Auto-tuning of the PID control parameter
provides uniform temperature control regardless of light or
heavy external loading.
■COMP ACT ,STURDY DESIGN
Small footprint. Designed for efficient use of your valuable
floor space.
CONTROL
TEMPERATURE
AND STOP
MOLD LEAKS
Single or dual zone models available
Use the vacuTrac to produce negative pressure in the from process
lines. Otherwise, the unit functions
like a direct injection temperature
control unit and can be used when
your application requires process
temperatures up to 180° F.
The unit is equipped with a highcapacity, heavy-duty jet pump/venturi. Choose 9 or 12 kW heaters
and pumps from 2 to 7.5 Hp.
Specify single zone if you need
one temperature throughout your
mold, or dual zone if two different
setpoints are required.
You have a choice of two
advanced microprocessor control
systems. Other options include bell,
strobe or piezo horn for alarm conditions.
TPHF017/1101
FEATURES
One Conair Drive ● Pittsburgh, PA 15202 ● 412-312-6000 ● FAX 412-312-6227 ● www.conairnet.com
TEMPERATURE CONTROL UNITS
Thermolator®vacuTrac (VTR1-DI and VTR2-D2)
Positive/Negative T emperature Controller
FEATURES
Expansion/fluid reservoir
accepts thermal expansion
of fluid when heated.
High efficiency pump
pushes fluid through
the system.
Air/water separation
tank allows entrapped
air to escape to the
expansion tank.
Pressure relief valve
prevents system
over pressurization.
Venting line prevents
trapped air in system.
Cooling check valve
prevents coolant back
flow into the vacuTrac.
Level switches
control tank fluid level.
Make-up solenoid valve
maintains tank level.
Cooling solenoid valve
lets hot fluid out of system.
Vacuum generating jet
pump/venturi
To process
pressure gauge
Three-way ball valve
diverts flow to
generate vaccuum.
From process
pressure gauge
Overflow connection
relieves system static
pressure.
Cooling water outlet
Cooling water inlet
Positive/negative pressure
units use a jet pump/venturi to
produce negative pressure in
the “from process” lines.
Water at positive pressure
will leak out of mold cracks or
bad o-rings. During negative
pressure operation, however,
air is drawn through the lines,
and the mold operates without
leaking. A manual three-way
ball valve can be closed to
make these units into standard direct injection units.
Because the units use water
and vent to the atmosphere,
they have a maximum process
temperature of 180° F.
From Process
Pressure Gauge
From Process
Cooling In
and Make-Up
Manual Three-Way
Ball Valve
To Process
Pressure Gauge
To Process
Cooling Out
Vent and Overflow
Connection
3 Gallon
Reservoir
Union
Make-Up Solenoid
Process Piping
Cooling Water/Make-Up Piping
Make-Up Switch
Low Level Switch
Jet Pump/
Venturi
Valve
Supply
Temperature
Thermocouple
Check
Valve
Cooling
Solenoid
Valve
Union
Return
Temperature
Thermocouple
Drain
Drain
Air
Vent
Line
Air/Water
Separation
Tank
Pressure
Relief
Valve
Heater Tank
(9 or 12 kW)
Pump
Note:
Maximum Set
Point is 180°F
TPHO017/1101
FEATURES
One Conair Drive ● Pittsburgh, PA 15202 ● 412-312-6000 ● FAX 412-312-6227 ● www.conairnet.com
TEMPERATURE CONTROL UNITS
Thermolator® vacuTrac (VTR1-DI and VTR2-D2)
Positive/Negative Pressure
CONTROLS
vacuTrac Plus Control (TW-2)
Includes all of the features of the standard
vacuTrac control, PLUS:
● Autostart capability for convenient pre-
heating of molds.Works with external
timers or switches.
● Choice of temperature control points
allows you to monitor and control from the
process supply or process return temperature, or from an average of the two.
● Phase detection circuit indicates incorrect
pump rotation or an open electrical leg.
● Remote control up to 50 feet.Magnetic
panel back allows you to place the controls
where you need them. Comes with 15-foot
cable.Lengths of 30 or 50 feet optional.
Note:The purge option is not available on
the vacuTrac positive/negative pressure
water temperature controllers.
vacuTrac Control (TW-1)
Our waterproof, durable control is operator
friendly and smart. Standard features:
● Automatic fine-tuning of PID control para-
meters provides uniform temperature control
regardless of external loading.
● Adjustable high/low deviation warnings
track with your setpoint temperature. Preprogrammed acceleration feature speeds up
setting parameters.
● 18 operating and fault indicator lights,
including 7 bi-color LEDs, tell you the status
of critical components and parameters.
● Password entr y prevents unauthorized or
accidental changes to operating parameters.
● RS485 communication using SPI protocol.
Baud rates and addresses are programmable on the operator panel.
OPTIONS
Alarm packages
Call attention to alarm conditions
with a light and horn package.
One Conair Drive ● Pittsburgh, PA 15202 ● 412-312-6000 ● FAX 412-312-6227 ● www.conairnet.com
TPHS017/1101
SPECIFICATIONS
TEMPERATURE CONTROL UNITS
Thermolator®vacuTrac (VTR1-DI and VTR2-DI)
Positive/Negative Pressure
VTR1-DI (single zone) VTR2-DI (dual zone)
VTR1-DI rear view and connections
MODELS
VTR1-DI VTR2-DI
Performance Characteristics
Minimum setpoint 32 °F {0 °C} 32 °F {0 °C}
Maximum setpoint 180 °F {82 °C} 180 °F {82 °C}
Pump Performance per zone
Pump Size Hp {kW}
2 {1.49} 3 {2.24} 5 {3.73} 7.5 {5.59} 2 {1.49} 3 {2.24} 5 {3.73} 7.5 {5.59}
Nominal flow gpm {l/min}
55 {208} 80 {303} 100 {379} 115 {435} 55 {208} 80 {303} 100 {379} 115 {435}
Pressure @ nominal flow psi {bar}
31 {2.2} 35 {2.5} 43 {3} 51 {3.6} 31 {2.2} 35 {2.5} 43 {3} 51 {3.6}
Dimensions inches {mm}
A -Height
43 {1090} 43 {1090}
B- Width
14 {355} 28 {710}
C- Depth
31.5 {800} 31.5 {800}
Weight Ib {kg}
Operating
300 {136} 305 {138} 310 {141} 320 {145} 600 {272} 610 {277} 620 {281} 640 {290}
Shipping
470 {213} 475 {216} 480 {218} 490 {222} 770 {349} 780 {354} 790 {358} 810 {367}
Water Connections NPT inches (Female)
To/From Process 1.25 1.25
Cooling Water Inlet/Outlet 0.75 0.75
ELECTRICAL REQUIREMENTS - full load amps
†
VTR1-DI VTR2-DI
Heater 9 kW 12 kW 9 kW 12 kW
Voltage
208V 230V 460V 575V 208V 230V 460V 575V 208V 230V 460V 575V 208V 230V 460V 575V
Pump sizes
2 Hp {1.49 kW} 31.8 28.8 14.4 11.5 40.2 36.4 18.2 14.6 63.6 57.6 28.8 23.0 80.4 72.8 36.4 29.1
3 Hp {2.24 kW} 34.7 31.4 15.7 12.6 43.1 39.0 19.5 15.6 69.3 62.8 31.4 25.1 86.1 78.0 39.0 31.2
5 Hp {3.73 kW} 38.5 34.8 17.4 13.9 46.8 42.4 21.2 17.0 76.9 69.9 34.8 27.8 93.7 84.8 42.4 33.9
7.5 Hp {5.59 kW} 45.7 41.4 20.7 16.6 54.1 49.0 24.5 19.6 91.5 82.8 41.4 33.1 108.3 98.0 49.0 39.2
SPECIFICATIONS NOTES:
†
All voltages are 3 phase, 60 Hz.
Specifications can change without notice. Check with a Conair representative for the most current information.
A
B
CONAIR THERMOLATOR VTR POSITIVE/NEGATIVE OPERATION
1.0 PROCESS WATER CONNECTIONS
PROCESS CONNECTIONS
Connect the FROM PROCESS and TO PROCESS connections on the back of the Thermolator using 1-
1/4”
NPT piping. Viewed from the rear, the FROM PROCESS connection is located on the left hand side of the
unit, and is clearly marked “FROM PROCESS”. The TO PROCESS connection is located on the right hand
side of the unit, and is marked “TO PROCESS” in close proximity on the back panel.
OVERFLOW/VENT CONNECTION
Connect the OVERFLOW/VENT piping on the reservoir tank, located at the top rear of the unit, to an open
drain or vented, covered container. This connection must be piped with a clean break in order to prevent
back flow and pressure in the PROCESS piping. This is where a VTR vents air out of the PROCESS piping
since the unit is operating at times in a vacuum mode, and can be introducing small amounts of air into
the PROCESS piping.
Note: Always use a back-up wrench to support the piping when making connections to the unit.
1.1 COOLING/MAKE-UP WATER CONNECTIONS
COOLING CONNECTIONS
Connect the COOLING WATER IN /MAKE-UP and COOLING WATER OUT piping to the Thermolator using ¾”
NPT pipe. Viewed from the rear, the COOLING IN /MAKE-UP hookup is in the lower left hand side through
the back panel and is marked “COOLING WATER IN”. The COOLING WATER OUT hookup is in the lower
right hand side through the back panel and is marked “COOLING WATER OUT”.
Note: The cooling water out connection is piped with a swing check that must not be turned on to its
side when the connection is made.
1.2 COOLING/MAKE-UP WATER PRESSURES
COOLING /MAKE-UP SUPPLY & RETURN WATER PRESSURES
Cooling /make-up SUPPLY and RETURN water pressure must have net pressures of between 25 PSI and 75
PSI. A net pressure less than 25 PSI may not provide sufficient cooling for the process. The net pressure
is the difference between the cooling SUPPLY and RETURN pressures.
1.3 SEQUENCE OF OPERATION
SEQUENCE OF OPERATION
VTR1 units control process water temperature. When the controller signals the unit to heat, the electric
immersion heater is energized raising the PROCESS water temperature. When the controller signals the
unit to cool, the COOLING WATER OUT (1/4”) solenoid valve is energized. This allows the hot PROCESS
water out of the process piping. When sufficient water has been pumped out of the unit, the MAKE-UP
water level float switch will make, opening the COOLING/MAKE-UP (3/8”) solenoid valve, replacing the
hot discharged water with cooler water.
This unit’s operation is similar to a TW-DI unit except that a VTR unit has a reservoir tank that is open to
the atmosphere, which allows a maximum 180° F PROCESS water temperature.
Notes: 1. The DIN units do not have pressure switches. They use float switches instead
2. The make up water level float switch is the higher one in the reservoir tank. The low
water level cut-out float switch is the lower one in the reservoir tank.
3. Anytime the three phase power is turned on to the unit the cooling/make-up water is
(3/8”) solenoid valve may energize.
The VTR unit operates in either a positive or negative pressure mode. Upon energizing the unit, if the
make-up level float switch is in the made position, the COOLING/MAKE–UP water in (3/8”) solenoid valve
will open and begin to fill the unit’s PROCESS piping and reservoir tank. As the water level rises in the
reservoir tank, or if it is sufficiently full to begin with, the low water level float switch will make, turning
off the (LOW WATER PRESSURE) light on the operator panel.
STARTING UP THE UNIT
The start button may now be pressed to energize the unit. The negative pressure mode of operation is
initiated by turning the 3-way valve (See Figure 1.) at the back of the unit counter clock-wise. Negative
pressure in the process piping is caused by diverting some of the flow from the pump through the eductor.
The water bypassed to the eductor creates a high velocity flow at the eductor nozzle which then causes a
suction on the from process line.
Never turn the valve all the way to “negative” (counter clockwise), because all the flow will bypass the
process, and there will be no temperature control of the mold. When the unit is running in a negative
pressure mode, any leak that was in the system will now be drawing air in to the process piping.
The air and water mixture is separated in the separation tank located on the suction side of the pump. The
air is vented from the unit through the overflow connection on the back of the reservoir tank. If this vent
becomes plugged, the unit will not work properly.
1.4 TROUBLESHOOTING A VTR UNIT
A few things may cause the VTR unit to act erratically. If glycol is present in a heavy concentration
within the process water, it may foam and back up into the reservoir tank. This can cause the reservoir
tank to overflow, or the float switches to stick. This problem may be eliminated by using an anti-foaming
agent in the water, and periodically opening the (1”) pipe plugs on top of the tank to clean the switches
with a soft haired paint brush.
An inability to get desired cooling can be a problem with a VTR unit. If the cooling water out line
pressure is greater than the unit’s pump discharge pressure, there is no way for the unit to cool. A change
in the installation will be required in order to provide a reduced cooling water out line pressure.
If the reservoir tank continuously overflows there is a chance that either a float switch has stuck or the
cooling/make-up valve has stuck open from a piece of dirt.
Figure 1.
OPERATIONTHE TW-1 CONTROL
Actual values display
The green window displays the temperature
at the middle of the mold. This temperature
is calculated as an average of the temperatures of the supply water and return water.
The lights indicate whether the temperature
is in degrees Fahrenheit or Celsius.
Alarm
Press to acknowledge the alarm light
and silence the optional audible alarm.
The alarm light will flash until the
cause of the alarm condition is fixed.
Starting the Thermolator®.
Turn on main power to the Thermolator®.
◆ Setpoint and actual windows display for
three seconds, then display the most recently
entered setpoint temperature and the current
actual temperature.
◆ Indicator lights blink green, then red.
Turn on water supply to the unit.
If the water supply is on, go to Step 3.
Enter the temperature setpoint.
Press the Setpoint until the green light appears
next to Temperature. Press
▲ to increase the set-
point or
▼ to decrease.
Press .
◆ The RUN/STOP light turns green.
◆ The unit initiates a 60-second venting
sequence. Cooling and venting valves are
active for 60 seconds. The pump is active for
the final 30 seconds.
◆ Normal operation begins. The heater turns on
if the actual temperature is below setpoint.
The cooling valve remains active if the actual
temperature is above setpoint.
If the Alarm light turns on, press to silence an
audible alarm and go to the Troubleshooting section.
Stopping the Thermolator®.
Press .
◆ The RUN/STOP light turns red.
Setpoint display
The window displays the
setpoints entered for the
fluid temperature, the high
and low temperature deviation alarms, the SPI baud
rate and the SPI address.
1
2
3
Status lights
The lights indicate the operating
status of the listed components.
Except in Test Mode and Auto
Start, the lights indicate:
= Off or inactive
= On or active
= Alarm condition
Test Mode is used for initial programming. When test mode is
enabled, normal operation is
disabled.
= Test Mode off
= Test Mode on; unit dis-
Setpoint Select button
Press repeatedly until a green
light appears next to the parameter you want to program or
view.
NOTE: Default settings for the deviation setpoints are:
High = setpoint + 10˚ F
Low = setpoint - 10˚ F
A warning alarm occurs (indicator
light turns red) whenever the actual
temperature is outside this setpoint
range. Recommend setting: ± 2-10˚.
Setpoint adjustment
buttons
Press ▲ or ▼ to enter temperature and SPI parameters. Press
▲ to increase a value. Press ▼
to decrease a value.
TIP: Press and hold the button for
faster scrolling speed.
Run/Stop
Press the RUN button to
start normal operation.
Press STOP to stop the
temperature control unit.
= Running
= Stopped
= Alarm (flashing)
4
Run
Stop
1
Actual temperature of water supplied to the mold is
higher than the setpoint deviation limit allows.
1. High deviation temperature is set too low. Increase.
2. Water has stopped flowing between supply outlet and
return inlet. Check for plugged pipe or failed cooling
valve.
3. The heater contact failed. Replace the contactor.
4. The heater and lines may be too
large for this application.
Actual temperature of water supplied to
the mold is higher than the programmed
190˚ F safety limit.
1. Water has stopped flowing between supply outlet and
return inlet. Check for closed valve or plugged line.
2. The heater contactor failed. Replace contactor.
Actual temperature of water supplied to
the mold is below the programmed 20˚ F
safety limit.
1. The cooling valve is stuck open. Clean valve.
2. The heater has failed. Check for a bad heating element,
or a heater contact that failed in the open position.
The incoming power is out of phase. A
leg may have failed or is disconnected.
1. The pump is rotating in the wrong direction. Reverse any
two leads on the power connection.
2. Check fuses or circuits at the main power supply.
The return line temperature probe failed.
Check for loose connections, or replace.
The supply line temperature probe failed.
Check for loose connections, or replace.
The pump fuse failed.
Replace the fuse on the motherboard.
NOTE: See the Thermolator User Guide for additional alarm messages regarding fuses and controller errors.
TROUBLESHOOTING
Shut down alarms
The Thermolator has shut down automatically to prevent
damage to equipment or personnel. To resume normal
operation, press , fix the problem, then press .
The pump overload has tripped. Contact is open.
1. Verify that the correct voltage is supplied to the motor.
2. Water flow may be more than the pump can handle.
Check current draw against motor rating. Decrease flow
as needed.
The supply water level is low.
1.Verify that the water supply is turned on.
NOTE: The low water pressure alarm does not require manual
reset. It will reset automatically when the water level is sufficient.
The actual temperature of water supplied to the mold
exceeds the 190˚ F temperature safety switch limit.
1. The unit is not running. Start the Thermolator.
2. Water has stopped flowing between supply outlet and
return inlet. Check for closed valve or plugged line.
3. The heater contactor failed. Replace contactor.
If there is a problem, the Thermolator®activates the red Alarm light
and changes the RUN/STOP light from green to flashing red.
Press to silence the optional audible alarm.
Check the indicator lights and messages
to help determine the cause of the problem.
Warning alarms
The Thermolator continues operating, but this problem
could lead to a shutdown condition if not corrected.
Actual temperature of water supplied to the mold is
lower than the setpoint deviation limit allows.
1. Low deviation temperature is set too low. Increase.
2. The heater failed. Check for a bad heating element or a
heater contact that failed in the open position.
3. The cooling valve is stuck open. Clean valve as needed.
Stop Run
WARNING: Before servicing the Thermolator
®
Allow the unit to cool to below 100˚ F. Disconnect and lockout
the main power source. Disconnect water and air supply lines.
!
1
2
Low Deviation
High Deviation
SPI Communication
FUS
002
PbS
Err
Pbr
Err
Hi
SAF
Lo
SAF
PHS
Err
Pump
Pump
High Temp. Safety
Low Water Pressure
QCH005/1197 © 1997
Positive/Negative Water
Temperature Controller
with TW-1 Microprocessor
Quick Card
Thermolator
®
vacuTrac
The Conair Group, Inc.
One Conair Drive
Pittsburgh, PA 15202
Phone: (412) 312-6000
Fax: (412) 312-6001
Basic
Operation
Troubleshooting
Instant Access Parts
& Service:
(800) 458-1960
(814) 437-6861
www.conairnet.com
OPERATIONTHE TW-2 CONTROL
Actual values display
The green window displays the temperature
at the middle of the mold. This temperature
is calculated as an average of the temperatures of the supply water and return water.
The lights indicate whether the temperature
is in degrees Fahrenheit or Celsius.
Alarm
Press to acknowledge the
alarm light and silence the
optional audible alarm.
The alarm light will flash
until the cause of the
alarm condition is fixed.
Starting the Thermolator®.
Turn on main power to the Thermolator®.
◆ Setpoint and actual windows display for
three seconds, then display the most recently
entered setpoint temperature and the current
actual temperature.
◆ Indicator lights blink green, then red.
Turn on water supply to the unit.
If the water supply is on, go to Step 3.
Enter the temperature setpoint.
Press the Setpoint until the green light appears
next to Temperature. Press
▲ to increase the set-
point or
▼ to decrease.
Press .
◆ The RUN/STOP light turns green.
◆ The unit initiates a 60-second venting
sequence. Cooling and venting valves are
active for 60 seconds. The pump is active for
the final 30 seconds.
◆ Normal operation begins. The heater turns on
if the actual temperature is below setpoint.
The cooling valve remains active if the actual
temperature is above setpoint.
If the Alarm light turns on, press to silence an
audible alarm and go to the Troubleshooting section.
Stopping the Thermolator®.
Press .
◆ The RUN/STOP light turns red.
Setpoint display
The window displays the
setpoints entered for the
fluid temperature, the high
and low temperature deviation alarms, the SPI baud
rate and the SPI address.
1
2
3
Status lights
The lights indicate the operating
status of the listed components.
Except in Test Mode and Auto
Start, the lights indicate:
= Off or inactive
= On or active
= Alarm condition
Test Mode is used for initial programming. When test mode is
enabled, normal operation is
disabled.
= Test Mode off
= Test Mode on; unit disabled
Auto Start allows you to start
and stop the Thermolator
®
from
a remote switching or timing
device, such as the processing
machine control. This feature
can only be enabled by configuring a dip switch on the control
motherboard.
= Disabled; Auto Start not
available
=
(flashing) Enabled; unit can
start at any time
= On and under control of
Setpoint Select button
Press repeatedly until a green
light appears next to the parameter you want to program or view.
NOTE: Default settings for the deviation setpoints are:
High = setpoint + 10˚ F
Low = setpoint - 10˚ F
A warning alarm occurs (indicator
light turns red) whenever the actual
temperature is outside this setpoint
range. Recommend setting: ± 2-10˚.
Setpoint adjustment
buttons
Press ▲ or ▼ to enter temperature and SPI parameters. Press
▲ to increase a value. Press ▼
to decrease a value.
TIP: Press and hold the button for
faster scrolling speed.
Run/Stop
Press the RUN button to
start normal operation.
Press STOP to stop the
temperature control unit.
= Running
= Stopped
= Alarm (flashing)
4
Display Select button
Press repeatedly until a green light
appears next to the parameter you want
to program or view in the Actual values
window. See the User Guide for programming information.
Run
Purge On/Off
The purge option is not available
on positive/negative pressure
water temperature controllers.
Stop
1
Actual temperature of water supplied to the mold is
higher than the setpoint deviation limit allows.
1. High deviation temperature is set too low. Increase.
2. Water has stopped flowing between supply outlet and
return inlet. Check for plugged pipe or failed cooling
valve.
3. The heater contact failed. Replace the contactor.
4. The heater and lines may be too
large for this application.
Actual temperature of water supplied to
the mold is higher than the programmed
190˚ F safety limit.
1. Water has stopped flowing between supply outlet and
return inlet. Check for closed valve or plugged line.
2. The heater contactor failed. Replace contactor.
Actual temperature of water supplied to
the mold is below the programmed 20˚ F
safety limit.
1. The cooling valve is stuck open. Clean valve.
2. The heater has failed. Check for a bad heating element,
or a heater contact that failed in the open position.
The incoming power is out of phase. A
leg may have failed or is disconnected.
1. The pump is rotating in the wrong direction. Reverse any
two leads on the power connection.
2. Check fuses or circuits at the main power supply.
The return line temperature probe failed.
Check for loose connections, or replace.
The supply line temperature probe failed.
Check for loose connections, or replace.
The pump fuse failed.
Replace the fuse on the motherboard.
NOTE: See the Thermolator User Guide for additional alarm messages regarding fuses and controller errors.
TROUBLESHOOTING
Shut down alarms
The Thermolator has shut down automatically to prevent
damage to equipment or personnel. To resume normal
operation, press , fix the problem, then press .
The pump overload has tripped. Contact is open.
1. Verify that the correct voltage is supplied to the motor.
2. Water flow may be more than the pump can handle.
Check current draw against motor rating. Decrease flow
as needed.
The supply water level is low.
1.Verify that the water supply is turned on.
NOTE: The low water pressure alarm does not require manual
reset. It will reset automatically when the water level is sufficient.
The actual temperature of water supplied to the mold
exceeds the 190˚ F temperature safety switch limit.
1. The unit is not running. Start the Thermolator.
2. Water has stopped flowing between supply outlet and
return inlet. Check for closed valve or plugged line.
3. The heater contactor failed. Replace contactor.
If there is a problem, the Thermolator®activates the red Alarm light
and changes the RUN/STOP light from green to flashing red.
Press to silence the optional audible alarm.
Check the indicator lights and messages
to help determine the cause of the problem.
Warning alarms
The Thermolator continues operating, but this problem
could lead to a shutdown condition if not corrected.
Actual temperature of water supplied to the mold is
lower than the setpoint deviation limit allows.
1. Low deviation temperature is set too low. Increase.
2. The heater failed. Check for a bad heating element or a
heater contact that failed in the open position.
3. The cooling valve is stuck open. Clean valve as needed.
Stop Run
WARNING: Before servicing the Thermolator
®
Allow the unit to cool to below 100˚ F. Disconnect and lockout
the main power source. Disconnect water and air supply lines.
!
1
2
Low Deviation
High Deviation
SPI Communication
FUS
002
PbS
Err
Pbr
Err
Hi
SAF
Lo
SAF
PHS
Err
Pump
Pump
High Temp. Safety
Low Water Pressure
QCH006/1197 © 1997
Positive/Negative Water
Temperature Controller
with TW-2 Microprocessor
Quick Card
Thermolator
®
vacuTrac
The Conair Group, Inc.
One Conair Drive
Pittsburgh, PA 15202
Phone: (412) 312-6000
Fax: (412) 312-6001
Basic
Operation
Troubleshooting
Instant Access Parts
& Service:
(800) 458-1960
(814) 437-6861
www.conairnet.com
Thermolator
®
TW-1 and TW-2
Instant Access
Parts and Service
(800) 458-1960
(814) 437-6861
www.conairnet.com
The Conair Group, Inc.
One Conair Drive
Pittsburgh, PA 15202
Phone: (412) 312-6000
Fax: (412)-312-6320
Water Temperature Control Units
UGH015/0100
Installation
Operation
Maintenance
Troubleshooting
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: UGH015/0100
Serial number(s):
Model number(s):
DISCLAIMER: The Conair Group, Inc., 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.
Please record your
equipment’s model and
serial number(s) and
the date you received it
in the spaces provided.
Copyright 1999
All rights reserved
THE CONAIR GROUP, INC.
UGH015/0100 Thermolator TW-1 and TW-2
TABLE OF
CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . .1-1
Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . .1-2
How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . .1-2
Your responsibility as a user . . . . . . . . . . . . . . . . . . . . . . .1-2
ATTENTION: Read this so no one gets hurt . . . . . . . . . . .1-3
D
ESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1
What is the Thermolator TW Series? . . . . . . . . . . . . . . . . .2-2
Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
How it works: Direct Injection . . . . . . . . . . . . . . . . . . . . . .2-3
How it works: Closed Circuit . . . . . . . . . . . . . . . . . . . . . . .2-4
How it works: Isolated Circuit . . . . . . . . . . . . . . . . . . . . . .2-5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Features and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
INSTALLATION . . . . . . . . . . . . . . . . . . . .3-1
Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Connecting the water supply . . . . . . . . . . . . . . . . . . . . . . .3-4
Optional purge valve hookups . . . . . . . . . . . . . . . . . . . . . .3-5
Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . .3-6
Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Initial setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Changing temperature units . . . . . . . . . . . . . . . . . . . . . . . .3-9
Enabling and disabling passcode protection . . . . . . . . . . .3-10
Selecting the temperature control point
(TW-2) . . . . . . . . . .3-12
Entering setpoint deviation parameters . . . . . . . . . . . . . . .3-14
Activating SPI communication . . . . . . . . . . . . . . . . . . . . .3-15
Enabling the Auto Start feature
(TW-2) . . . . . . . . . . . . . . . .3-16
OPERATION . . . . . . . . . . . . . . . . . . . . . .4-1
TW-1 control features . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
TW-2 control features . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Positioning the control panel . . . . . . . . . . . . . . . . . . . . . . .4-4
Starting the Thermolator . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Entering passcodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Stopping the Thermolator . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Using the manual purge option . . . . . . . . . . . . . . . . . . . . .4-8
Using the TW-2 purge feature . . . . . . . . . . . . . . . . . . . . . .4-9
Performing an Auto Tune . . . . . . . . . . . . . . . . . . . . . . . . .4-10
MAINTENANCE . . . . . . . . . . . . . . . . . . . .5-1
Preventative maintenance schedule . . . . . . . . . . . . . . . . . . .5-2
To access the Thermolator enclosure . . . . . . . . . . . . . . . . .5-3
Checking fluid level in the reservoir
(IC) . . . . . . . . . . . . . . .5-4
i
Thermolator TW-1 and TW-2 UGH015/0100
TABLE OF
CONTENTS
MAINTENANCE . . . . . . . . . . . . . . .(continued)
Performing System Tests . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
The Key/Display Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Input Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Disabling and Enabling Outputs . . . . . . . . . . . . . . . . . . . . .5-9
Calibrating Temperature Sensors . . . . . . . . . . . . . . . . . . .5-10
Logging Operating Hours . . . . . . . . . . . . . . . . . . . . . . . .5-11
T
ROUBLESHOOTING . . . . . . . . . . . . . . . .6-1
Before Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
A Few Words of Caution . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
How to Identify the Cause of a Problem . . . . . . . . . . . . . . .6-3
DIAGNOSTICS
Shut Down Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Warning Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
System Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
Thermolator Will Not Power Up . . . . . . . . . . . . . . . . . . .6-12
REP
AIR
Checking and Replacing Fuses . . . . . . . . . . . . . . . . . . . . .6-13
Resetting and Replacing Overloads . . . . . . . . . . . . . . . . .6-14
Replacing the Motherboard . . . . . . . . . . . . . . . . . . . . . . .6-15
Replacing the Heater Contactor . . . . . . . . . . . . . . . . . . . .6-16
Checking and Replacing Thermocouples . . . . . . . . . . . . .6-17
Repairing Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . .6-18
Replacing Heater Elements . . . . . . . . . . . . . . . . . . . . . . .6-20
Removing the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
Disassembling and assembling 3/4 to 2 HP Pumps . . . . . .6-23
Disassembling and assembling 3 to 7.5 HP Pumps . . . . . .6-24
APPENDIX
Customer Service Information . . . . . . . . . . . . . . . . . . . . . .A-1
Warranty/Guarantee Information . . . . . . . . . . . . . . . . . . . .A-2
Plumbing Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Thermolator SPI commands . . . . . . . . . . . . . . . . . . . . . . .D-1
PARTS/DIAGRAMS
Spare Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PD-1
TW-1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PD-5
TW-1 Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .PD-6
TW-2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PD-7
TW-2 Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .PD-8
ii
1-1
UGH015/0100 Thermolator TW-1 and TW-2
●●
Purpose of the User Guide . . . .1-2
●●
How the guide is organized . . . .1-2
●●
Your responsibilities as a user .1-2
●●
ATTENTION: Read this so
no one gets hurt . . . . . . . . . . .1-3
INTRODUCTION
Thermolator TW-1 and TW-2 UGH015/0100
1-2 INTRODUCTION
This User Guide describes the Conair Thermolator®TW-1 and
TW-2 water temperature control units and explains step-bystep how to install, operate, maintain and repair this equipment.
Before installing this product, please take a few moments to
read the User Guide and review the diagrams and safety information in the instruction packet. You also should review manuals covering associated equipment in your system. This
review won’t take long, and it could save you valuable installation and operating time later.
Symbols have been used to help organize the User Guide and
call your attention to important information regarding safe
installation and operation.
Symbols within triangles warn of conditions that could
be hazardous to users or could damage equipment.
Read and take precautions before proceeding.
Numbers within shaded squares indicate tasks or steps
to be performed by the user.
A diamond indicates the equipment’s response to an
action performed by the user.
An open box marks items in a checklist.
A shaded circle marks items in a list.
You must be familiar with all safety procedures concerning
installation, operation and maintenance of this equipment.
Responsible safety procedures include:
● Thorough review 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 requirements, intended uses and
warning labels.
● Thorough review of instruction manuals for associated
equipment.
● Step-by-step adherence to instructions outlined in this
User Guide.
P
URPOSE OF
T
HE USER
GUIDE
HOW THE
G
UIDE IS
ORGANIZED
1
◆
❒
●
YOUR
RESPONSIBILITY
ASAUSER
UGH015/0100 Thermolator TW-1 and TW-2
INTRODUCTION 1-3
We design equipment with the user’s safety in mind. You can
avoid the potential hazards identified on this machine by
following the procedures outlined below and elsewhere in the
User Guide.
ATTENTION:
READ THIS SO NO
ONE GETS HURT
CAUTION: Hot surfaces
Surface temperatures inside the Thermolator
can exceed 250° F (121° C). Always allow the
unit to cool to below 100° F (38° C) before
opening, servicing or disassembling the unit.
WARNING: Electrical shock hazard
This equipment is powered by three-phase
main voltage, as specified on the machine serial tag and data plate.
Always disconnect and lock out the incoming
main power source before opening the electrical enclosure or performing non-standard operating procedures, such as troubleshooting or
maintenance. Only qualified personnel should
perform procedures that require access to the
electrical enclosure while power is on.
WARNING: Improper installation,
operation or servicing may result in
equipment damage or personal injury.
This equipment should be installed, adjusted,
and serviced by qualified technical personnel
who are familiar with the construction, operation and potential hazards of this type of equipment.
All wiring, disconnects and fuses should be
installed by qualified electrical technicians in
accordance with electrical codes in your region.
Always maintain a safe ground. A properly
sized conductive ground wire from the incoming
power supply must be connected to the chassis
ground terminal inside the electrical enclosure.
Improper grounding can result in personal
injury and erratic machine operation.
Do not operate the equipment at power levels
other than what is specified on the the equipment serial tag and data plate.
WARNING: Hazardous substance
The electrical contactors in the
Thermolator have mercury contactors.
Mercury is considered a hazardous substance and must be dealt with accordingly. Material Safety Data Sheet (#7439-
97) has been included in the instruction
packet. This sheet explains the potential
hazards, how to avoid them and how to
clean up and dispose of the mercury if it
spills.
ATTENTION:
R
EAD THIS SO NO
ONE GETS HURT
Thermolator TW-1 and TW-2 UGH015/0100
1-4 INTRODUCTION
2-1
UGH015/0100 Thermolator TW-1 and TW-2
●●
What is the Thermolator
TW Series?
. . . . . . . . . . . . . . .2-2
●●
Typical applications . . . . . . . . . .2-2
●●
How it works:
Direct Injection (DI) models . . .2-3
●●
How it works:
Closed Circuit (CC) models . . .2-4
●●
How it works:
Isolated Circuit (IC) models . . .2-5
●●
Specifications . . . . . . . . . . . . . .2-6
●●
Features and options . . . . . . . . .2-8
DESCRIPTION
The Thermolator TW models circulate water at a temperature
higher than the available water supply, to add or remove heat
as needed to maintain a uniform temperature setpoint in the
process. The TW-2 offers an enhanced control, with additional
diagnostic features and autostart capabilities.
Both the TW-1 and TW-2 models are available in single or
multiple-zone configurations, using direct injection or closed
circuit process heating and cooling. Multiple-zone models can
control up to three temperatures at different locations in the
process. Two- and three-zone models have common cooling
water manifolds and electrical connections.
The best model for your application depends on the process
temperature you need to maintain and the quality of the cooling water supply.
Direct injection (DI) models control the temperature by
discharging heated process water and adding cooling water
directly from the water supply. DI models are designed for:
● Process temperatures up to 250°F (121°C).
● Use with chiller water or properly treated and filtered tower
or city water.
Closed circuit (CC) models add cooling water to the process
loop only during the initial filling or when make-up water is
needed. CC models are recommended for:
● Process temperatures 180°F (82°C) to 250°F (121°C).
● Use with contaminated cooling water, or with properly
treated and filtered tower or city water..
Isolated circuit (IC) models separate the cooling water from
the process fluid, which is held in a reservoir. IC models are
recommended for:
● Process temperatures up to 180°F (82°C).
● Use with contaminated cooling water or a process fluid
mixture of water and glycol.
WHAT IS THE THERMOLATOR ?
Thermolator TW-1 and TW-2 UGH015/0100
2-2 DESCRIPTION
T
YPICAL
A
PPLICATIONS
IMPORTANT: Do not use
deionized water or glycol
mixtures containing additives
in a Thermolator. Softened
water or glycol mixtures with
additives, such as automotive fluids, can damage the
Thermolator. Glycol/water
process loop mixtures should
use industrial-grade ethylene
glycol only.
Direct injection models maintain the process temperature
by electrically heating and injecting cool water supplied to
the Thermolator by a chiller, tower or other water source.
HOW IT WORKS:
D
IRECT INJECTION
UGH015/0100 Thermolator TW-1 and TW-2
DESCRIPTION 2-3
A
B
The temperature of the process fluid is measured
as it leaves the unit’s heater tank. The fluid then
flows through the “To Process” line to the mold
or process. The fluid returns to the unit through the
“From Process” line for reheating or cooling.
1
A
B
C
D
If the process
temperature is
below the setpoint, the heater
elements inside
the heater tank
are energized.
E
F
4
The pump moves water from the mixing
tank to the heater tank. Pressure is
measured before and after the pump .
NOTE: Some higher kW models have an
additiona heater in the mixing tank
E
F
The temperature of the process
fluid is measured as it flows into
the mixing tank through the
“From Process” line .
2
B
If the average temperature is
above the setpoint value, the cooling valve opens. Cool water enters
the bottom of the mixing tank via
the “Cooling In” line . Warm
water flows out of the top of the
tank via the “Cooling Out” line .
C
D
3b
3a
Cooling Water Out
From Process
Cooling Water In
To Process
Purge Valve
(optional)
Check
Valve
Thermocouple
Thermocouple
Check
Valve
Cooling
Valve
Mixing
Tank
Heater
Supply
Pressure
Relief
Valve
Gauge
Direct Injection
Check valves included only with
optional mold purge.
Return
Pressure
Gauge
Pump
HOW IT WORKS:
C
LOSED CIRCUIT
Thermolator TW-1 and TW-2 UGH015/0100
2-4 DESCRIPTION
A
B
The temperature of the process
fluid is measured as it leaves
the unit’s heater tank. The fluid
then flows through the “To
Process” line to the mold or
process. The fluid returns to the
unit through the “From Process”
line for reheating or cooling.
1
A
B
C
D
3b
If the process temperature
is below the setpoint, the
heater elements inside the
heater tank are energized.
E
F
4
The pump moves water from the
mixing tank to the heater tank.
Pressure is measured before
and after the pump .
E
F
The temperature of
the process fluid is
measured as it flows
into the cooling tank
through the “From
Process” line .
2
B
3a
If the temperature is above
the setpoint value, the cooling
valve opens. Cool water
enters the cooling piping
and circulates through a tube
heat exchanger to cool the
process fluid. The cooling
valve allows warm fluid to
escape through the process
vent line via the “Cooling Out”
line and cooling make-up
water to enter through the
“Cooling In” line .
C
D
Closed Circuit models maintain the process temperature by
heating and cooling fluid for 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.
C
Cooling Water In
Cooling Water Out
Check
Valve
Process Vent/Fill Line
Process Vent Line
Cooling
Valve
Return Thermocouple
From Process
Vent
Valve
Cooling Heat
Exchanger
Heater
Relief
Valve
Supply
Pressure
Gauge
Compressed
Air Connection
Supply Thermocouple
To Process
Check
Valve
Mold Purge
Solenoid Valves
(optional)
Closed Circuit
Check valves included only with
optional mold purge.
Return
Pressure
Gauge
Pump
HOW IT WORKS:
I
SOLATED CIRCUIT
UGH015/0100 Thermolator TW-1 and TW-2
DESCRIPTION 2-5
Isolated Circuit models maintain the process temperature
by heating and cooling fluid for the process circuit. The
process fluid, which is stored in a reservoir, is isolated from
cooling water supplied by a chiller, tower or other source
A
B
The temperature of the
process fluid is measured
as it leaves the unit’s heater
tank. The fluid then flows
through the “To Process”
line to the mold or
process. The fluid returns to
the unit through the “From
Process” line for reheating or cooling.
1
A
B
C
D
If the process temperature
is below the setpoint, the
heater elements inside the
heater tank are energized.
E
4
The pump moves water
from the mixing tank to
the heater tank. Pressure
is measured after the
pump .
E
The temperature of
the process fluid is
measured as it flows
into the cooling tank
through the “From
Process” line .
2
B
If the temperature is
above the setpoint
value, the cooling valve
opens. Cool water
enters the cooling piping
and circulates through a
tube heat exchanger to
cool the process fluid.
C
G
The vent line allows warm
process fluid to expand to the
reservoir . The reservoir
supplies process fluid through
a make-up line as needed.
G
3b
3a
Cooling Water In
Cooling Water Out
Return Thermocouple
From Process
Cooling
Valve
Vent Line
Manual Fill
and Vent Port
3 Gal. Reservoir
Low Level
Switch
Level
Sight Glass
Cooling Heat
Exchanger
Make-Up Line
Supply Thermocouple
To Process
Heater
Relief
Valve
Supply
Pressure
Gauge
Pump
Isolated Circuit
NOTE: There is a 180˚ F operating temperature
limit on isolated circuit units.
SPECIFICATIONS
Thermolator TW-1 and TW-2 UGH015/0100
2-6 DESCRIPTION
CABINET STYLE REFERENCE
Heater Voltage Selection Single Zone 2 Zone 3 Zone
Direct Injection (DI)
9, 12, 18 or 24 kW 208, 230, 460, 575 A B C
36 kW 208 or 230 D E N/A
36 kW 460 or 575 A B C
48 kW 208, 230, 460, 575 D E N/A
Closed Circuit (CC)
9 or 12 kW 208, 230, 460, 575 A B C
18 or 24 kW 208, 230, 460, 575 D E N/A
Isolated Circuit (IC)
9, 12, 18 or 24 kW 208, 230, 460, 575 D E N/A
A
B
C
D
E
Dimensions and performance characteristics vary according to
the model, voltage and components selected. See the cabinet
style reference chart to determine dimensional information for
your specific model. Additional technical information can be
found in the Appendix of this User Guide.
Height
Width
Single Zone
Width
2- Zone
Width
3-Zone
Depth
Width
Single Zone
Width
2- Zone
Height
Depth
NOTE: 2-zone and 3-zone
models have common wiring
and plumbing.
WATER CONNECTIONS
All models
NPT inches (female)
From process 1.25
Cooling water in/out 0.75
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