Conair Thermolater vacuTrac, VTR1-DI, VTR2-DI User Manual

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Page 1

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

Page 2

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 equi pment 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, 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.

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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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.

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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

Air Vent Line

Air/Water Separation Tank

Pressure Relief Valve

Heater Tank (9 or 12 kW)

Pump

Note: Maximum Set Point is 180°F

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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.

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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.

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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

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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.

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Figure 1.

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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.

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)

Run

Stop

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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

SAF

PHS

Err

Pump

High Temp. Safety

Low Water Pressure

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

Page 12

Page 13

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.

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.

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)

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

Page 14

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

SAF

PHS

Err

Pump

High Temp. Safety

Low Water Pressure

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

Page 15

Page 16

Page 17

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

Page 18

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.

THE CONAIR GROUP, INC.

Page 19

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

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

Page 20

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

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

Page 21

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

Page 22

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.

URPOSE OF

HE USER

GUIDE

HOW THE G

UIDE IS

ORGANIZED

◆

❒

●

YOUR RESPONSIBILITY ASAUSER

Page 23

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.

Page 24

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:

EAD THIS SO NO

ONE GETS HURT

Thermolator TW-1 and TW-2 UGH015/0100

1-4 INTRODUCTION

Page 25

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

Page 26

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

YPICAL

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.

Page 27

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

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

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

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

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

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

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

Cooling Water Out

From Process

Cooling Water In

To Process

Purge Valve (optional)

Check Valve

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

Page 28

HOW IT WORKS: C

LOSED CIRCUIT

Thermolator TW-1 and TW-2 UGH015/0100

2-4 DESCRIPTION

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

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

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

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

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.

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

Page 29

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

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

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

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

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

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

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.

Page 30

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

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

Page 31

SPECIFICATIONS

UGH015/0100 Thermolator TW-1 and TW-2

DESCRIPTION 2-7

TW1 TW2

Zones

(1, 2 or 3)

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

PERFORMANCE CHARACTERISTICS -

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

Models TW1 -DI or TW2 -DI TW1 -CC or TW2 -CC TW1 -IC or TW2 -IC

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

Maximum Setpoint Temperature °F {°C} 250 {121} 250 {121} 180 {82} Minimum Operating Temperature °F {°C} Approximately 20° {11°} above the cooling water inlet temperature* Standard Cooling Valve Size inches {mm} 1/4 {6.35} 3/4 {19.05} 3/4 {19.05} Available pump sizes 0.75, 1, 2, 3, 5 or 7.5 Hp {0.56, 0.75, 1.49, 2.24, 3.73 or 5.59 kW} Available heater sizes 9, 12, 18, 24, 36 or 48 kW 9, 12, 18 or 24 kW

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

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

TOTAL FULL LOAD AMPS PER ZONE All voltages are 3 phase, 60 Hz. Heater 9 kW 12 kW 18 kW 24 kW 36 kW 48 kW

Voltage

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

Pump

0.75 HP {0.56 kW} 28.9 26.2 13.1 10.5 37.3 33.8 16.9 13.5 54.0 48.8 24.4 19.5 70.7 64.0 32 25.6 1 HP {0.75 kW} 29.4 26.6 13.3 10.6 37.8 34.2 17.1 13.7 54.4 49.2 24.6 19.7 71.2 64.4 32.2 25.8 2 HP {1.49 kW} 31.8 28.8 14.4 11.5 40.2 36.4 18.2 14.6 56.8 51.4 25.7 20.6 73.6 66.6 33.3 26.6 3 HP {2.24 kW} 34.7 31.4 15.7 12.6 43.1 39.0 19.5 15.6 59.7 54.0 27.0 21.6 76.5 69.2 34.6 27.7 5 HP {3.73 kW} 38.5 34.8 17.4 13.9 46.9 42.4 21.2 17.0 63.4 57.4 28.7 23 80.2 72.6 36.3 29.0

7.5 HP {5.59 kW} 45.7 41.4 20.7 16.6 54.1 49.0 24.5 19.6 70.7 64.0 32.0 25.6 87.5 79.2 39.6 31.7

SHIPPING WEIGHT RANGES lbs {kg} Weights vary depending on cabinet size and cooling type (DI, CC or IC).

Single Zone 2 Zone 3 Zone

Pump Min Max Min Max Min Max

0.75 HP {0.56 kW} 240 {109} 300 {136} 480 {218} 600 {272} 720 {327} 840 {381} 1 HP {0.75 kW} 240 {109} 300 {136} 480 {218} 600 {272} 720 {327} 840 {381} 2 HP {1.49 kW} 250 {113} 310 {141} 500 {226} 620 {282} 750 {336} 870 {396} 3 HP {2.24 kW} 260 {118} 320 {145} 520 {236} 640 {290} 780 {354} 900 {408} 5 HP {3.73 kW} 270 {122} 330 {150} 540 {244} 660 {300} 810 {366} 930 {423}

7.5 HP {5.59 kW} 280 {127} 340 {154} 560 {254} 680 {308} 840 {381} 960 {435}

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

Height 28.0 {710} 28.0 {710} 28.0 {710} 43.0 {1090} 43.0 {1090} Depth 22.5 {570} 22.5 {570} 22.5 {570} 31.5 {800} 31.5 {800} Width 13.75 {350} 27.5 {700} 41.25 {1050} 14.0 {355} 28.0 {710}

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

104.0 94.0 47.0 37.6 137.0 124.0 62.1 49.7

104.3 94.4 47.2 37.8 137.7 124.6 62.3 49.6

106.7 96.6 48.3 38.6 140 126.8 63.4 50.7

109.6 99.2 49.6 39.7 143 129.4 64.7 51.8

113.4 102.6 51.3 41.0 146.7 132.8 66.4 53.1

120.7 109.2 54.6 43.7 154 139.4 69.7 55.8

MODEL DESIGNATIONS

TOTAL FULL LOAD AMPS PER ZONE All voltages are 3 phase, 60 Hz. Heater 0 heaters

Voltage

208V 230V 460V 575V

Pump

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

7.5 HP {5.59 kW} 20.7 18.8 9.9 7.6

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

Page 32

High efficiency pumps

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

Pump seal flush line

continuously cleans the pump seal for extended life.

Incoloy heaters

minimize chemical and high temperature damage

Built-in sediment trap

settles contaminants away from the pump seals.

Motor drip cover

protects motor windings from moisture damage.

Two-piece cast construction

Alarm packages

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

Motorized Cooling Valve

Eliminates thermal shock from your process circuit by modulating the cooling water.

Compressed Air Mold Purge

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

Stacking Rack

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

OPTIONS

Thermolator TW-1 and TW-2 UGH015/0100

2-8 DESCRIPTION

FEATURES AND OPTIONS

Page 33

3-1

UGH015/0100 Thermolator TW-1 and TW-2

●●

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

●●

Activ

ating SPI

comm

unication . . . . . . . . . . . .3-15

●●

Installing the Auto Start

feature . . . . . . . . . . . . . . . . . .3-16

INSTALLATION

Page 34

UNPACKING THE BOXES

Thermolator TW-1 and TW-2 UGH015/0100

3-2 INSTALLATION

Carefully remove the Thermolator and compo-

nents from their shipping containers, and set upright.

Remove all packing material, protective paper,

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

Carefully inspect all components to make sure no

damage occurred during shipping, and that you have all the necessary hardware. If damage is found, notify the freight company immediately.

Take a moment to record serial numbers and

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

You are now ready to begin installation.

Complete the preparation steps on the next page.

Remote control cord

(TW-2 only)

Thermolator

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

Motorized cooling valve

(optional)

Compressed air mold purge

(optional)

Page 35

UGH015/0100 Thermolator TW-1 and TW-2

INSTALLATION 3-3

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

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

Make sure the installation area provides:

❒❒

A three-phase power source supplying the correct

current for your Thermolator model. Check the serial tag

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

❒❒

A clean, well-ventilated environment.

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

❒❒

Minimum clearance for safe operation and

maintenance. The diagram at right shows

minimum clearance for operation. You also need enough clearance in the rear for water hookups. For maintenance, you should move the Thermolator to provide at least 36 inches on any side of the Thermolator.

❒❒

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 85 psi.

Install plumbing for process and cooling lines.

You will need two 1

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

PREPARING FOR INSTALLATION

Process machine

Thermolator

Alternate locations

12 inches

(305 mm)

12 inches

(305 mm)

20 inches (508 mm)

Page 36

Motorized Cooling Valve

If you have the optional motorized cooling valve, connect the cooling water supply to the female

inch NPT fitting on the valve. except as noted, all other connections should be made as described above.

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

Remove the shipping pipe plug from the female

connections on the back of the Thermolator.

Install pipe to the rear of the Thermolator.

Use male 1

-inch NPT piping for process connections

and male

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

Coat the pipe threads with thread sealant.

Follow the sealant manufacturer’s directions.

Connect the male pipe to the appropriate female connection on the back of the unit

. Start by hand until the threads engage, then use a pipe wrench to tighten the connection only enough to prevent leaks.

Do not over-tighten!

CONNECTING PROCESS AND WATER SUPPLY LINES

Thermolator TW-1 and TW-2 UGH015/0100

3-4 INSTALLATION

Tools for installation:

❒ Pipe wrench large enough

for a 2-inch pipe

❒ Premium quality Teflon

thread sealant

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

From

process

From

process

Cooling water out

Cooling water in

Cooling water out

Cooling water in

DIRECT INJECTION

CLOSED CIRCUIT

ISOLATED CIRCUIT

From

process

Page 37

A purge valve is available as an option on Direct Injection and Closed Circuit units only. This valve quickly evacuates fluid from the process circuit, allowing faster disconnection of the temperature controller from molds and hoses. An optional manual purge button controls this valve on TW-1 models. TW-2 models have a purge button on the control panel.

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

Remove the shipping pipe plug from the female

connections on the back of the Thermolator.

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

This valve is

required when a purge valve is used.

Install pipe to the rear of the Thermolator.

Use male 1

-inch NPT piping for process connections

and male

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

Coat the pipe threads with thread sealant.

Follow the sealant manufacturer’s directions.

Connect the male pipe to the appropriate female connection on the back of the unit

. Connect cooling water lines as indicated on the previous page. Connect process lines as indicated below. Start by hand until the threads engage, then use a pipe wrench to tighten the connection only enough to prevent leaks. Do

not over-tighten!

Connect the purge valve to the compressed air supply.

The air pressure

should not exceed 100 psi.

UGH015/0100 Thermolator TW-1 and TW-2

PTIONAL

PURGE VALVE HOOKUPS

INSTALLATION 3-5

From

process

Compressed air

fitting

Page 38

Thermolator TW-1 and TW-2 UGH015/0100

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

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

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

Open the unit’s electrical enclosure.

Insert the main power wire

through the knockout

hole in the right side of the enclosure.

Secure the power wire with a rubber compression fitting or strain relief.

Connect the power wires to the terminals.

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

Connect the ground wire

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

CONNECTING T

HE MAIN

POWER

SUPPLY

3-6 INSTALLATION

WARNING: Electrical shock hazard

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

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

IMPORTANT! Before initiating power to the unit:

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

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

❒ Verify that resistance to ground on

each phase is at least 1 meg ohm.

Page 39

UGH015/0100 Thermolator TW-1 and TW-2

INSTALLATION 3-7

Turn on the cooling water supply and check for leaks.

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

Apply power to the unit.

◆ Indicator lights on the control panel blink green, then

red, to test operation of the LEDs.

◆ Setpoint and actual windows will display for

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

Check the rotation of the pump. Remove the top

access panel and the pump motor drip cover. Verify that the pump rotation matches the direction indicated on the rotation sticker on top of the pump.

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

Replace the drip cover and top access panel.

Press the RUN key to start the unit.

If everything is working correctly:

◆ 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. Indicator lights will energize when the device is active.

◆ Normal operation begins. The heater turns on if the

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

The test is over. Proceed to initial setup if the unit operated normally; refer to the

ROUBLESHOOTING

section if it did not.

TESTING THE INSTALLATION

WARNING: Only qualified personnel should perform this procedure.

Parts of this test require 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.

Page 40

Thermolator TW-1 and TW-2 UGH015/0100

3-8 INSTALLATION

INITIAL

SETUP

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

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

ETTINGSETPOINTDEVIATIONPARAMETERS

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

❒ Select the units of measure for tem-

perature displays.

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

ture control.

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

Dipswitch Configuration

No. OFF ON

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

†

Controller type selection Controller type selection

†

Controller type selection Controller type selection

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

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

WARNING: Electric shock hazard

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

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

876

54321

Page 41

UGH015/0100 Thermolator TW-1 and TW-2

CHANGING TEMPERATURE UNITS

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

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

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

Disconnect and lock out main power to the

Thermolator.

Open the electrical enclosure.

Change Dip Switch 1 to:

OFF for °F ON for °C

Close the electrical enclosure and restore main

power to begin operating.

2 3

NSTALLATION 3-9

WARNING: Electric shock hazard

NOTE: All dip switch illustrations in this manual show switches 7 and 8 set to ON. If you have an Isolated Circuit model, these switches should be set to OFF.

54321

876

54321

Page 42

Thermolator TW-1 and TW-2 UGH015/0100

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

● The Process Setpoint

● High Deviation Alarm Setpoint

● Low Deviation Alarm Setpoint

● Baud Rate selection for serial communications

● Address selection for serial communications

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

Disconnect and lock out main power to the unit.

Open the electrical enclosure.

Set dip switch 3 to ON and switches 5 and 6 to OFF.

Close the electrical enclosure and restore power to the unit.

Press any button when the control displays “Pas rSt”

(Passcode Reset). The control will display the last passcode used.

Select a new passcode using the ▲▲and

▼▼

setpoint adjustment buttons.

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

ENABLING AND DISABLING PASSCODE PROTECTION

3-10 INSTALLATION

WARNING: Electric shock hazard

1 2

NOTE: All dip switch illustra-

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

Continued on next page

876543

Page 43

UGH015/0100 Thermolator TW-1 and TW-2

Press the RUN button to save the passcode.

◆◆

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

remove power to the unit.

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

Turn off power to the unit. Disconnect and lock out

the main power supply.

Open the electrical enclosure.

Set dip switch 3 to OFF.

Close the electrical enclosure and restore power to the unit.

A passcode now is required to change system parameters.

INSTALLATION 3-11

ENABLING AND DISABLING PASSCODE PROTECTION

Disabling Passcode Protection

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

Follow Steps 1 through 5

in the previous section on enabling passcode protection.

Hold down the

▼▼

setpoint adjustment button

to select “OFF” as the new passcode.

Follow steps 7 through 11 in the previous section.

876543

Page 44

Thermolator TW-1 and TW-2 UGH015/0100

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

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

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

Disconnect and lockout power to the unit.

Open the electrical enclosure.

Set dip switches 3 and 6 to the OFF position.

Set dip switch 5 to the ON position.

Close the electrical enclosure and restore power to the unit.

Press any button when the control displays “Cnt Pt”.

The controller will display “Sel CnP” and flashes the LED for the current control point.

Select a new control point using the Display button.

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

3-12 INSTALLATION

1 2

WARNING: Electric shock hazard

SELECTING THE TEMPERATURE CONTROL POINT

(TW-2 ONLY

)

NOTE: All dip switch illustra-

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

Continued on next page

876543

Page 45

UGH015/0100 Thermolator TW-1 and TW-2

SELECTING THE TEMPERATURE CONTROL POINT

(TW-2 ONLY

)

INSTALLATION 3-13

Press the RUN button to save the control point.

◆◆

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

remove power to the unit.

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

Turn off power to the unit. Disconnect and lock out

the main power supply.

Open the electrical enclosure.

Set dip switch 5 to OFF.

Close the electrical enclosure and restore power to the unit.

The Thermolator will now control the process temperature based on actual temperatures recorded at the new control point source.

876

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Page 46

Thermolator TW-1 and TW-2 UGH015/0100

3-14 INSTALLATION

You can establish a normal operating range around the process temperature setpoint using the high and low deviation parameters. If the process temperature exceeds the high deviation limit, or falls below the low deviation limit for longer than 15 minutes, the Thermolator will alert you to the unacceptable temperature variation with an alarm light.

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

The factory default setting is the process temperature setpoint ± 25° F (4° C). This parameter is adjustable to establish a narrower or wider acceptable temperature range for normal operation. The Low Deviation cannot be set to fall below the factory-set Low Safety temperature. The High Deviation cannot be set to exceed the factory-set High Safety temperature.

To change the temperature deviation settings:

Press the Setpoint Select button to select the deviation parameter you want to change.

Use the ▲ and ▼ setpoint buttons to enter the deviation temperature.

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

NTERING

ETPOINT

DEVIATION P

ARAMETERS

FACTORY DEFAULT SETTINGS Model DI and CC IC

Process Setpoint 100° F (38° C) 100° F (38° C) High Safety 260° F (127° C) 190° F (88° C) Low Safety 22° F (-6° C) 22° F (-6° C)

NOTE:

If you enabled passcode protection, you must enter the passcode to change this parameter. Too enter the passcode:

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

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

Page 47

UGH015/0100 Thermolator TW-1 and TW-2

INSTALLATION 3-15

TW-1 and TW-2 Thermolators provide SPI compatible support for RS-485 serial communications with a host machine. You can use SPI communication to change or monitor the:

● Process temperature setpoint

● High and low temperature deviation alarms

● Process status (run and alarm conditions)

● Machine 1 status

● Machine 2 status

● Actual temperature to process

● Actual temperature from process

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

Connect the host machine to the unit.

Plug the male DB9 connector into the serial communications port on the Thermolator.

Apply power to the Thermolator.

Enter the passcode, if necessary.

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

Enter the node address.

Press the Setpoint Select button to choose Address. Then press the setpoint ▲ or ▼ arrow until the address you want appears in the setpoint display. The address may be set to any number from 32 to 254 (a hexadecimal integer between 20 and FE), as long as that number has not been assigned to another machine connected to the same network.

Set the baud rate to 12, 24, 48 or 96.

The Thermolator must be set to send and receive data at the same baud rate as the host machine. Press the setpoint ▲ or ▼ arrow until the baud rate you want appears in the setpoint display window. 12 = 1200 bps 48 = 4800 bps 24 = 2400 bps 96 = 9600 bps

The green SPI status light on the control panel should flash when the unit is communicating. The LED will turn red, indicating an alarm, if SPI communication is not properly set up.

2 3

ACTIVATING SPI C

OMMUNICATION

NOTE:

To disable SPI, use

the setpoint

▲

or ▼arrow to

select Address. Press the

▼

arrow until OFF is displayed in the sepoint window.

See the A

PPENDIX

for additional

SPI programming information.

Page 48

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

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

Disconnect and lockout power to the unit.

Open the electrical enclosure.

Punch a small hole in the left side of the electrical enclosure.

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

Insert the two power leads from the device

through the conduit into the electrical enclosure.

Connect the 110VAC device contact wires to the Auto Start terminals.

Make sure terminals are

screwed tight.

Thermolator TW-1 and TW-2 UGH015/0100

INSTALLING THE AUTO START FEATURE

(TW-2 ONLY

)

3-16 INSTALLATION

1 2 3

WARNING: Electric shock hazard

IMPORTANT:

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

Device contacts

Continued on next page

65432

LLS/WPS

AC IN 4

AC IN + 3

AC OUT 2

AC OUT + 1

AUTOSTART

HPS/LPS

AUTOSTART

HPS/LPS

432

OPS

FS TAT

Page 49

Set dip switch 4 to the ON position.

Close the electrical enclosure and restore power to the unit.

When Auto Start is enabled:

◆ The Auto Start indicator light flashes to indicate that the

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

◆ The Auto Start indicator light is on whenever the

Thermolator is under the control of the remote device.

To disable Auto Start:

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

INSTALLING THE AUTO START FEATURE

(TW-2 ONLY

)

UGH015/0100 Thermolator TW-1 and TW-2

INSTALLATION 3-17

NOTE:

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

876

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Page 50

Page 51

4-1

UGH015/0100 Thermolator TW-1 and TW-2

●●

TW-1 control . . . . . . . . . . . . . . . .4-2

●●

TW-2 control . . . . . . . . . . . . . . . .4-3

●●

Mounting the TW-2 control

in a remote location . . . . . . . .4-4

●●

Entering a passcode . . . . . . . . .4-5

●●

Starting the Thermolator . . . . . .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

OPERATION

Page 52

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

TW-1 C

ONTROL

Thermolator TW-1 and TW-2 UGH015/0100

4-2 OPERATION

Setpoint adjustment buttons

Press ▲ or ▼ to enter the process temperature setpoint, SPI parameters and passcodes.

Press ▲ to increase a value. Press ▼ to decrease a value.

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

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

Actual values display

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

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

NSTALLATION

section for instructions on how

to change the temperature units.

Setpoint display

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

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

Run/Stop

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

= Running (green)

= Stopped (red)

= Alarm (red, flashing)

Status lights

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

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

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

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

unit disabled

Alarm

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

Setpoint Select button

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

NOTE: Default settings for the deviation setpoints are: High = setpoint + 25° F Low = setpoint - 25° F A warning alarm occurs (indicator light red) whenever the actual temperature is outside this setpoint range for more than 15 minutes. Recommended setting: ± 2-10° F.

Page 53

TW-2 CONTROL

UGH015/0100 Thermolator TW-1 and TW-2

OPERATION 4-3

Purge Valve

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

= Off or inactive

= On or active

Display Select button

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

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

Status lights

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

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

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

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

unit disabled

Auto Start allows you to start

and stop the TW-2 from a

remote switching or timing device, such as the processing machine control. This feature can only ben enabled by configuring a dip switch on the control motherboard.

= Disabled; Auto Start

not available

= Enabled

(flashing green)

;

unit can start any time

= On and under control of

the remote device

Actual values display

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

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

NSTALLATION

section for instructions on how

to change the temperature units.

Setpoint display

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

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

Run/Stop

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

= Running (green)

= Stopped (red)

= Alarm (red, flashing)

Setpoint adjustment buttons

Press ▲ or ▼ to enter the process temperature setpoint, SPI parameters and passcodes.

Press ▲ to increase a value. Press ▼ to decrease a value.

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

Alarm

Setpoint Select button

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

Page 54

Thermolator TW-1 and TW-2 UGH015/0100

4-4 OPERATION

MOUNTING THE TW-2 C

ONTROL

IN A

REMOTE

LOCATION

CAUTION: Improper use of the swiveling

control panel can damage the unit.

● Do not use the control panel handles or

control cables to move the Thermolator. The handles are designed only for orientation of the control panel.

● Do not mount the detached TW-2 control

panel to a hot surface.

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

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

To detach the TW-2 control panel:

Grasp the black control panel handles and pull upward.

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

Page 55

UGH015/0100 Thermolator TW-1 and TW-2

OPERATION 4-5

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

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

Press and hold the Setpoint Select button for 5 seconds.

The control will display 1 PaS to indi-

cate a passcode is needed.

Press the Select ▲ button until the correct passcode appears in the display.

Press again to enter the passcode.

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

Press Setpoint to select the parameter you want to change.

You will have access to the system parameters until:

● The power is cycled off and on.

● The RUN or STOP button is pressed.

● No key has been pressed for 30 seconds.

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

ENTERING A P

ASSCODE

Page 56

Thermolator TW-1 and TW-2 UGH015/0100

4-6 OPERATION

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

NSTALLATION

section.

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

Turn on the water supply to the Thermolator.

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

Turn on main power to the Thermolator.

The control initiates a brief self test.

◆ Indicator lights blink green, then red.

◆ Setpoint and actual windows will display for

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

Enter the passcode, if necessary.

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

Enter the temperature setpoint.

Press the Setpoint Select button until the green light appears next to Temperature. Press

▲ to

increase or

▼ to decrease the

temperature setting.

Press to start normal operation.

◆ 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 when the

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

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

ROUBLESHOOTING

section.

STARTING THE THERMOLATOR

Run

IMPORTANT:

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

“Performing an Auto Tune.”

Page 57

UGH015/0100 Thermolator TW-1 and TW-2

OPERATION 4-7

STOPPING THE THERMOLATOR

You must shut down the Thermolator whenever you:

● Change the water hookups.

● Shut down the process machine.

● Purge the process circuit of the water or fluid.

● Run the unit’s diagnostic tests.

● Perform routine or preventative maintenance.

● See an alarm condition that requires troubleshooting.

● Relocate, ship or store the unit.

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

To shut down the unit to change water hookups:

Press and drain the unit of all water or fluid.

Drain the unit using the two drain plugs on the back of the unit.

Once the unit is cool, remove the water hookups.

To shut down the unit for relocation or storage:

Press and drain the unit of all fluid.

Drain the unit using the two drain plugs.

Disconnect the power supply and all water feeds.

Position the control panel to rest flush with the unit.

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

WARNING: Electrical shock and

hot surface hazards

Before attempting maintenance of any kind on the Thermolator, you must stop the unit; disconnect and lockout the main power supply; and allow the unit to cool to less than 100° F (38° C).

Stop

Drain plug

Stop

2 3

Page 58

Thermolator TW-1 and TW-2 UGH015/0100

4-8 OPERATION

TW-1 and TW-2 direct injection and closed circuit models can be ordered with an optional purge valve, which clears the process lines of fluid using compressed air. The valve is operated by a manual purge switch on the side of the unit.

IMPORTANT:

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

Press to shut down the Thermolator.

◆ The RUN/STOP LED turns red.

Turn off the cooling water supply to the unit.

Press and hold the manual purge switch to start purging.

◆ The Purge Valve LED lights.

◆ The Vent and Cool outputs are activated.

◆ The STOP and RUN buttons are deactivated during the

purge or when the cool delay off timer is active.

The time required to clear the process lines of fluid will vary according to the length of the process piping and the size of the tooling.

Release the purge switch to stop purging.

USING THE MANUAL PURGE OPTION

Stop

2 3

NOTE:

The purge operation will terminate immediately if the unit detects a blown fuse in the Vent or Cool output. The unit will alarm and shut down.

See the T

ROUBLESHOOTING

section for instructions on how

to clear the alarm and fix the problem.

Page 59

UGH015/0100 Thermolator TW-1 and TW-2

OPERATION 4-9

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

IMPORTANT:

Press to shut down the Thermolator.

◆ The RUN/STOP light turns red.

Turn off the cooling water supply to the unit.

Press to open the valve and start purging.

◆ The Purge Valve LED lights.

◆ The Vent and Cool outputs are activated.

◆ The STOP and RUN buttons are deactivated during the

purge or when the cool delay off timer is active.

The time required to clear the process lines of fluid will vary according to the length of the process piping and the size of the tooling.

Press to close the valve and stop purging.

◆ The Vent and Cool solenoids remain energized for 5

seconds after the purge is terminated.

SING THE TW-2

URGE FEATURE

Stop

2 3

NOTE:

The purge operation will terminate immediately if the unit detects a blown fuse in the Vent or Cool output. The unit will alarm and shut down.

See the T

ROUBLESHOOTING

section for instructions on how to

clear the alarm and fix the problem.

CAUTION: Gases Under Pressure

Do not disconnect the mold lines until you varify pressure in the cooling water return line is low. Compressed gases can blast liquid at high pressure at the operator, possibly causing serious injury. Check the pressure gauge before disconnecting lines.

Page 60

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

To ensure a successful Auto Tune, verify that:

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

enabled or disabled via dip switch 2 on the motherboard.

❒ The process value is stable. A fluctuating process value

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

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

ambient temperature. This allows the software to obtain

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

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

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

Press to shut down the Thermolator.

Disconnect and lock out main power to the unit.

Enable Auto Tune.

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

Restore power to the unit.

PERFORMING AN AUTO TUNE

Thermolator TW-1 and TW-2 UGH015/0100

4-10 OPERATION

WARNING: Electric shock hazard

1 2

Stop

Continued on next page

876

54321

Page 61

Press and (the Setpoint Select button) simultaneously to begin the Auto Tune.

The Actual display will flash “At” and the current process temperature to indicate that an Auto Tune is underway.

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

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

PERFORMING AN AUTO TUNE

UGH015/0100 Thermolator TW-1 and TW-2

OPERATION 4-11

Run

ERROR MESSAGE ERROR DESCRIPTION

Insufficient setpoint/process deviation.

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

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

Invalid PID constants were generated.

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

dEv

bad

Page 62

Page 63

5-1

UGH015/0100 Thermolator TW-1 and TW-2

●●

Maintenance schedule . . . . . . . .5-2

●●

Accessing the Thermolator

enclosure . . . . . . . . . . . . . . . . .5-3

●●

Checking fluid level in the

reservoir

(IC models)

. . . . . . . . . .5-4

●●

Performing system tests . . . . . .5-5

●●

Key/Display Test . . . . . . . . . . . . .5-6

●●

Input Test . . . . . . . . . . . . . . . . . .5-7

●●

Output Test . . . . . . . . . . . . . . . . .5-8

●●

Disabling or enabling

output monitors . . . . . . . . . . .5-9

●●

Calibrating temperature

sensors . . . . . . . . . . . . . . . . . .5-10

●●

Logging operating hours . . . . .5-12

MAINTENANCE

Page 64

Thermolator TW-1 and TW-2 UGH015/0100

5-2 MAINTENANCE

PREVENTATIVE MAINTENANCE SCHEDULE

Thermolator TW-1 and TW-2 water temperature controllers are essentially maintenance-free. However, to maintain the best performance, we recommend the following maintenance schedule.

●●

Whenever process variables change

❒❒

Perform an Auto Tune.

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

ERFORMING AN

UTOTUNE

in the

PERATION

section.

●●

Daily

❒❒

Check for leaks in cooling and process lines.

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

❒❒

Keep the unit and the area around it clean.

Check for and remove lint, dust or other obstructions on the unit, especially around air intake areas. Keep the floor around the unit dry.

❒❒

Check the process fluid level (IC models).

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

an adequate amount of process fluid. Refill as needed.

●●

Monthly, or as often as needed.

❒❒

Inspect the fluid reservoir (IC models only).

For at least the first three months of operation, check the level switches in the process fluid reservoir for debris or deposits that could interfere with proper operation. Flush and clean the reservoir, if necessary.

●●

Quarterly (every 3 months)

❒❒

Inspect power cords, wires and electrical connections.

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

Page 65

PREVENTATIVE MAINTENANCE SCHEDULE

UGH015/0100 Thermolator TW-1 and TW-2

MAINTENANCE 5-3

●●

Annually (every 12 months)

❒❒

Test and calibrate the unit’s control systems.

The Thermolator’s Test Mode checks the operation

of displays, control buttons, inputs and outputs. You

can also calibrate the supply and return thermocouples.

See

ERFORMINGSYSTEM

ESTS

in this section.

WARNING: Electrical shock and

hot surface hazards

Before attempting maintenance of any kind on the Thermolator, you must stop the unit; disconnect and lockout the main power supply; and allow the unit to cool to less than 100° F (38° C)

To access the Thermolator enclosure:

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

ACCESSING THE T

HERMOLATOR

ENCLOSURE

Page 66

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

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

To fill the reservoir:

Disconnect and lockout power, and remove the top panel of the Thermolator.

Locate the reservoir near the top of the unit.

Locate the fill port at the top of the reservoir.

Refill the reservoir. Monitor the level using the sight

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

Replace the top panel of the Thermolator.

CHECKING THE FLUID LEVEL IN

THE

RESERVOIR

(IC MODELS ONLY

)

Thermolator TW-1 and TW-2 UGH015/0100

5-4 MAINTENANCE

2 3

IMPORTANT: Do not use deionized water or gly-

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

Sight glass

Page 67

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

System tests and calibration should be performed annually.

To enable Test Mode:

Press to shut down the Thermolator.

Disconnect and lock out main power to the unit, then open the electrical enclosure.

Set dip switches 3 and 5 to OFF.

Set dip switch 6 to ON.

Close the electrical enclosure and restore power to the unit.

◆ The control displays “tSt.”

◆ The Test Mode LED lights.

Press any button to display the first test menu.

Test mode provides the following menus:

● Key/Display Test

● Input Test

● Output Test

● Calibration

● Total Operating Hours

● Output Monitor Enable/Disable

After performing each test, hold the Setpoint for 3 seconds to index to the next test menu.

The procedure for each test is described on the following pages.

ERFORMING

YSTEM TESTS

UGH015/0100 Thermolator TW-1 and TW-2

MAINTENANCE 5-5

Stop

4 5

IMPORTANT: All normal

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

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

54321

876

Page 68

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

Enable Test Mode.

Press any key.

If necessary, index to the Key/Display menu.

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

Press any key to clear all displays.

Repeatedly press any key to test displays.

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

Exit the test and enter the next test.

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

KEY/DISPLAY TEST

Thermolator TW-1 and TW-2 UGH015/0100

5-6 MAINTENANCE

2 3

4 5

Page 69

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

Connect all inputs to the system.

Press any key to display the first test menus.

Select the Input Test menu.

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

Repeatedly press and release any key to test.

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

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

Exit the test and enter the next test.

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

INPUT TEST

UGH015/0100 Thermolator TW-1 and TW-2

MAINTENANCE 5-7

2 3

Page 70

OUTPUT TEST

Thermolator TW-1 and TW-2 UGH015/0100

5-8 MAINTENANCE

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

Connect all outputs to the system.

Enable Test Mode.

Press any key to display the first test menus.

Select the Output Test menu.

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

Repeatedly press and release any key to test.

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

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

Exit the test and enter the next test.

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

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

2 3 4

Page 71

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

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

Enable Test Mode.

Press any key to display the first test menus.

Select the OM Enable/Disable menu.

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

Press the Setpoint ▲▲or ▼▼key to change the status.

Each press of the key changes the output status

from ON to OFF or OFF to ON.

Press the Setpoint to select the next output.

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

Save changes and exit the output menu.

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

DISABLING OR ENABLING OUTPUT MONITORS

UGH015/0100 Thermolator TW-1 and TW-2

MAINTENANCE 5-9

1 2

OUTPUT MONITOR SELECTION GUIDE

MODEL TYPE DI CC IC (TCC)

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

Page 72

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

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

Enable Test Mode.

See

ERFORMINGSYSTEM

ESTS

Press any button to display the first test menu.

Select the Calibration Mode menu.

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

Release the Setpoint key.

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

Using the thermocouple calibrator, apply the appropriate temperature to the control input.

CALIBRATING TEMPERATURE SENSORS

Thermolator TW-1 and TW-2 UGH015/0100

5-10 MAINTENANCE

Special Tools Needed:

❒ type K thermocouple

calibrator

SETPOINT ACTUAL

CALIBRATION DISPLAY DISPLAY

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

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

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

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

Continued on next page

Page 73

Press the up ▲▲key to begin calibrating.

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

Wait until the control displays “don” or “bad.”

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

Press Select to start the next calibration.

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

Exit Calibration Mode.

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

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

CALIBRATING TEMPERATURE SENSORS

UGH015/0100 Thermolator TW-1 and TW-2

MAINTENANCE 5-11

NOTE: The original calibration value stored in

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

TO DISABLE TEST MODE, complete steps 2

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

Page 74

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

Enable Test Mode.

Press any key to display the first test menus.

Index through test menus to the operating log.

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

Exit the Operating Hours Log.

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

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

LOGGING OPERATING HOURS

Thermolator TW-1 and TW-2 UGH015/0100

5-12 MAINTENANCE

1 2

TO DISABLE TEST MODE, complete steps 2

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

Page 75

6-1

UGH015/0100 Thermolator TW-1 and TW-2

●●

Before beginning . . . . . . . . . . . .6-2

●●

A few words of caution . . . . . . .6-2

●●

w to identify the cause

of a pr

oblem . . . . . . . . . . . . . . .6-3

IAGNOSTICS

●●

Shut down alarms . . . . . . . . . . .6-4

●●

Warning alarms . . . . . . . . . . . . .6-8

●●

System alarms . . . . . . . . . . . . .6-11

●●

Thermolator will not power up .6-12

EPAIR

●●

Checking and replacing fuses .6-13

●●

Resetting overloads . . . . . . . . .6-14

●●

Replacing the pump overload .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 assemb

ling

3/4 - 2 HP pumps

. . . . . . . . . .6-23

●●

Disassembling and assemb

ling

3 - 7.5 HP pumps

. . . . . . . . . .6-24

TROUBLESHOOTING

Page 76

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

Before you begin troubleshooting:

❏ Find the wiring, plumbing and other diagrams

that were shipped with your equipment.

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

❏ Verify that you have manuals for other equip-

ment in the process line.

Solving problems may require troubleshooting malfunctions or incorrect operating procedures on other pieces of equipment.

❏ If an alarm is present, note any indicator lights

and messages shown on the control panel.

These indicators will help you discover the cause of the problem more quickly.

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

Thermolator TW-1 and TW-2 UGH015/0100

6-2 TROUBLESHOOTING

EFORE

EGINNING

A FEW WORDS

AUTION

WARNING: Hot surfaces and liquids

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

WARNING: This machines should be

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

DANGER: Voltage hazard.

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

Page 77

UGH015/0100 Thermolator TW-1 and TW-2

TROUBLESHOOTING 6-3

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

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

A problem can trigger three types of alarms:

●●

Shut Down Alarms: The Thermolator detected a problem

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

●●

Warning Alarms: The Thermolator continues to operate,

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

●●

System Errors: The system error codes indicate a non-

recoverable problem with the microprocessor control.

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

When an Alarm condition occurs:

Press to silence any optional audible alarm.

◆ The RUN/STOP light changes from flashing red to

steady red.

Note any indicator lights or error messages to

help determine the cause of the problem.

Find the alarm or error code in the diagnostics tables

in the TROUBLESHOOTING section of this manual.

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

Press to resume normal operation after the problem is corrected.

HOW TO IDENTIFY

THE

CAUSE OF A

ROBLEM

Stop

WARNING:

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

Run

Page 78

Thermolator TW-1 and TW-2 UGH015/0100

6-4 TROUBLESHOOTING

SHUT DOWN ALARMS

Alarm

The cooling water pressure is less than 25 psi.

Note: The unit will

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

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

WARNING:

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

Possible cause

Is the water supply pressure at least 25 psi?

Did the pressure switch fail?

Did the cooling valve fail?

Is the correct voltage supplied to the pump motor?

Is the required water flow greater than the pump’s capacity?

Is the motor overload faulty or set incorrectly?

Is the pump working properly?

Solution

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

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

Check the cooling valve. See

Repairing Solenoid Valves or

the Motorized Cooling Valve instructions.

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

❒

Review pump sizing for the application.

❒

Decrease the water flow from the process.

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

Resetting and Replacing Overloads.

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

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

◆ The Alarm LED lights and the STOP/RUN LED flashes red.

◆ The Thermolator automatically shuts down.

◆ The control displays a red LED or alarm code indicating the

source of the problem.

Low Water Pressure

Pump

Page 79

UGH015/0100 Thermolator TW-1 and TW-2

TROUBLESHOOTING 6-5

Alarm

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

WARNING:

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

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

WARNING:

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

Possible cause

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

Is the optional electromechanical safety switch improperly set or defective?

Has the heater contactor failed?

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

Has the heater contactor failed?

Solution

❒ Verify that the unit is run-

ning and that the pump is working.

❒ Check for closed or defec-

tive cooling or vent valves and plugged lines. See

Repairing Solenoid Valves.

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

See Checking and Replacing

Switches.

Replace the contactor if defective. See Replacing

the Heater Contactor.

❒ Verify that the unit is run-

ning and that the pump is working.

❒ Check for closed or defec-

tive cooling or vent valves and plugged lines. See

Repairing Solenoid Valves.

Replace the contactor if defective. See Replacing

the Heater Contactor.

High Temp. Safety

HUT DOWN

ALARMS

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

◆ The Alarm LED lights and the STOP/RUN LED flashes red.

◆ The Thermolator automatically shuts down.

◆ The control displays a red LED or alarm code indicating the

source of the problem.

SAF

Page 80

Thermolator TW-1 and TW-2 UGH015/0100

6-6 TROUBLESHOOTING

Alarm

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

The thermocouple in the process return line failed.

The thermocouple in the process supply line failed.

Possible cause

Is the cooling valve stuck open?

Has the heater failed?

Is the thermocouple loose?

Has the thermocouple failed?

Is the thermocouple loose?

Has the thermocouple failed?

Solution

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

Repairing Solenoid Valves.

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

See Replacing the Heater

Contactor and Replacing Heater Elements.

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

Check the thermocouple and replace if necessary. See

Checking and Replacing Thermocouples.

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

Check the thermocouple and replace if necessary. See

Checking and Replacing Thermocouples.

SAF

Err

Pbr

SHUT DOWN ALARMS

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

◆ The Alarm LED lights and the STOP/RUN LED flashes red.

◆ The Thermolator automatically shuts down.

◆ The control displays a red LED or alarm code indicating the

source of the problem.

Err

PbS

Page 81

UGH015/0100 Thermolator TW-1 and TW-2

TROUBLESHOOTING 6-7

SHUT DOWN ALARMS

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

◆ The Alarm LED lights and the STOP/RUN LED flashes red.

◆ The Thermolator automatically shuts down.

◆ The control displays a red LED or alarm code indicating the

source of the problem..

Alarm

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

NOTE: This alarm

is available only on

TW-2 models.

Pump fuse.

Heater fuse.

Cooling valve fuse.

Vent valve fuse.

Purge valve fuse.

Possible cause

Is the pump rotating in the wrong direction?

Has one of the main supply wire leads become disconnected?

Has the indicated device blown a fuse?

Is the correct device being used for this fuse location?

Has the motherboard output channel at the designated fuse failed?

Solution

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

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

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

See Checking and Replacing

Fuses.

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

See Performing System Tests

and Disabling or Enabling

Output Monitors in the

AINTENANCE

section.

Replace the motherboard. See

Checking and Replacing the Motherboard.

Err

PHS

002

FUS

003

FUS

004

FUS

005

FUS

006

FUS

Page 82

Thermolator TW-1 and TW-2 UGH015/0100

6-8 TROUBLESHOOTING

WARNING A

LARMS

Alarm

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

WARNING:

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

Possible cause

Is the cooling valve stuck open or leaking water?

Did a heater element fail?

Did a heater contactor fail?

Is the low deviation temperature set too low?

Is the Thermolator correctly sized for the application?

Solution

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

Solenoid Valves.

With the unit powered down:

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

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

Elements.

With power on and the Heater LED lit: Check the

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

Contactor.

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

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

Low Deviation

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

◆ The Alarm LED lights.

◆ The Thermolator continues operating.

◆ The control displays a red LED or alarm code indicating the

source of the problem.

Page 83

UGH015/0100 Thermolator TW-1 and TW-2

TROUBLESHOOTING 6-9

WARNING ALARMS

Alarm

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

WARNING:

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

Possible cause

Has water stopped flowing between supply outlet and return inlet?

Did the cooling valve fail?

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

Did a heater contactor fail?

Is the cooling valve the wrong size?

Is the high deviation temperature set too low?

Solution

Check for a plugged pipe or closed valve.

Check the cooling valve. See

Repairing Solenoid Valves or

the Motorized Cooling Valve instructions.

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

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

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

Contactor.

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

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

High Deviation

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

◆ The Alarm LED lights.

◆ The Thermolator continues operating.

◆ The control displays a red LED or alarm code indicating the

source of the problem.

Page 84

WARNING ALARMS

Thermolator TW-1 and TW-2 UGH015/0100

6-10 TROUBLESHOOTING

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

◆ The Alarm LED lights.

◆ The Thermolator continues operating.

◆ The control displays a red LED or alarm code indicating the

source of the problem.

Alarm

The SPI communication link has failed.

Possible cause

Is the unit connected to a host machine?

Are the network address and baud rate correct?

Is something wrong with the cable?

Solution

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

❒ Check the network address.

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

❒ Make sure the baud rate

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

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

SPI Communication

Page 85

SYSTEM ALARMS

UGH015/0100 Thermolator TW-1 and TW-2

TROUBLESHOOTING 6-11

Alarm

RAM hardware failure.

ROM, checksum failure.

COP failures.

Illegal Opcode.

through

Software cannot write to CPU nonvolatile memory.

Cause

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

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

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

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

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

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

Solution

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

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

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

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

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

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

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

◆ The Alarm LED lights and the STOP/RUN LED flashes red.

◆ The Thermolator shuts down or will not start.

◆ The control displays an error code indicating the source of

the problem.

001

ERR

003

ERR

002

ERR

004

ERR

006

ERR

005

ERR

015

ERR

014

ERR

016

ERR

Page 86

Thermolator TW-1 and TW-2 UGH015/0100

6-12 TROUBLESHOOTING

THERMOLATOR WILL NOT POWER UP

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

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

Symptom

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

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

Possible cause

Is power reaching the Thermolator?

Has the unit blown a fuse?

Is the correct voltage reaching the Thermolator?

Is the unit in Test Mode?

Solution

❒ Verify that the main power

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

❒ Verify correct electrical con-

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

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

ing and Replacing Fuses.

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

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

System Tests in the

AINTENANCE

section.

Page 87

UGH015/0100 Thermolator TW-1 and TW-2

TROUBLESHOOTING 6-13

CHECKING AND REPLACING FUSES

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.

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

To replace a blown fuse:

Disconnect and lockout the main power.

Open the electrical enclosure door.

Turn the screw

on the front panel counterclockwise to open.

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

board and are labeled and identified on the orange shield.

Close the electrical enclosure and restart the unit.

If fuses continue to fail:

❒ Verify that the unit is receiving the correct voltage.

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

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

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

❒ Check all wiring referencing the fusing location for

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

Monitors in the

AINTENANCE

section.

1 2

Fuse 1

Control power

Fuse 5

Vent valve

Fuse 4

Cooling valve

Fuse 2

Pump

Fuse 3

Heater

Fuse 6

Purge valve

WARNING:

Shock Hazard

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

432

AUTOSTART

HPS/LPS

OPS

FSTAT

HPS/LPS

1 23456

(-2) CONTROL

OPER PNL CABLE

FSTAT

UNLDR 1/ VENT 2 SOL +

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

LLS/PURGE 3SOL LLS/PURGE 3SOL +

TCPL'S

SUP RET

65432

LLS/WPS

AC IN 4

AUTOSTART

AC IN + 3

AC OUT 2

AC OUT + 1

OFF

CONFIGURATION

DIP SWITCH

+ 120 Ohm

+ TR

GND

+ TR

120 Ohm

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

3 PHASE INPUT

PUMP OL PUMP OL

PMP AUX

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

PUMPDOWN PUMPDOWN

HEAT/COMP

HEAT/COMP HTS/COMP OL HTS/COMP OL

ALARM

PURGE 4SOL

PURGE 4 SOL +

PUMP PUMP

110V

4 3 2 1

6 5 4 3 2 1

4 3 2 1

3 2 1

4 3 2 1

Page 88

Disconnect and lockout the main power.

Open the electrical enclosure door.

Turn the screw

on the front panel counterclockwise to open.

Locate the pump overload module attached

to the pump motor starter.

Disconnect the three power leads from the over-

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

Disconnect auxiliary wiring on the overload module.

Remove the overload module.

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

Reverse these steps to install the new overload module.

Set the module reset mode to M for manual.

Set the proper FLA trip point.

Do not exceed the FLA for the pump motor.

Thermolator TW-1 and TW-2 UGH015/0100

6-14 TROUBLESHOOTING

RESETTING OVERLOADS

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

Disconnect and lockout the main power.

Open the electrical enclosure door.

Turn the

screw on the front panel counterclockwise to open.

Check the overload.

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

Motor contactor

Motor overload

REPLACING THE PUMP OVERLOAD

1 2

Page 89

UGH015/0100 Thermolator TW-1 and TW-2

TROUBLESHOOTING 6-15

REPLACING THE MOTHERBOARD

IMPORTANT:

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

Disconnect and lockout the main power supply.

Open the electrical enclosure door.

Turn the screw

on the front panel counterclockwise to open.

Mark or label each wire connected to the motherboard.

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

Disconnect the wires from the motherboard by pulling the terminal blocks up.

Loosen the screws holding the orange shield.

Remove the motherboard and shield

from the

electrical enclosure as a unit.

Remove the motherboard from the shield

and replace with the new motherboard.

Reattach the shield and new motherboard

in the electrical enclosure. Tighten the screws.

Reconnect the terminal blocks and wires to the new board.

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

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

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

Program output monitors on the new board.

See Disabling or Enabling Output Monitors in the

AINTENANCE

section.

432

65432

AC IN 4

AC IN + 3

AC OUT 2

AC OUT + 1

LLS/WPS

OPS

FSTAT

HPS/LPS

AUTOSTART

OFF

1 23456

CONFIGURATION

DIP SWITCH

+ 120 Ohm

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

+ TR

AC IN 4

AC IN + 3

GND

AC OUT 2

AC OUT + 1

(-2) CONTROL

OPER PNL CABLE

+ TR

120 Ohm

65432

OPS

LLS/WPS

OPS

HPS/LPS

AUTOSTART

OFF

CONFIGURATION

DIP SWITCH

1 23456

(-2) CONTROL

+ 120 Ohm

+ TR

OPER PNL CABLE

GND

+ TR

120 Ohm

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

3 PHASE INPUT

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

1FS/ COMP AUX 1FS/ COMP AUX

PUMPDOWN PUMPDOWN

HEAT/COMP

HEAT/COMP HTS/COMP OL HTS/COMP OL

ALARM

LLS/PURGE 3SOL LLS/PURGE 3SOL +

PURGE 4SOL PURGE 4 SOL +

TCPL'S

SUP RET

432

FSTAT

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

PUMP

PUMP PUMP OL PUMP OL

PMP AUX PMP AUX

C NC NO

110V

3 PHASE INPUT

1FS/ COMP AUX 1FS/ COMP AUX

PUMPDOWN PUMPDOWN

HEAT/COMP

HEAT/COMP HTS/COMP OL HTS/COMP OL

ALARM

LLS/PURGE 3SOL LLS/PURGE 3SOL +

PURGE 4SOL

PURGE 4 SOL +

TCPL'S

SUP RET

4 3 2 1

6 5 4 3 2 1

4 3 2 1

6 5 4 3 2 1

4 3 2 1

PUMP OL PUMP OL

PMP AUX PMP AUX

4 3 2 1

PUMP PUMP

110V

C NC NO

3 2 1

6 5 4 3 2 1

4 3 2 1

6 5 4 3 2 1

4 3 2 1

Page 90

Thermolators use mercury displacement heater contactors. The heater contactors should be replaced if:

● You have checked the amp draw on each of the three-phase

legs and discovered a voltage imbalance greater than 10%.

● You have checked the continuity and found that ohms at

the coil equal zero.

To replace the heater contactor:

Disconnect and lockout the main power.

Open the electrical enclosure door.

Turn the

screw on the front panel counterclockwise to open.

Disconnect the wires from the heater contactor contactor.

Make sure you label the wires to ensure you

can connect them correctly to the new contactor.

Remove the contactor

by removing the screws that hold it in place.

Discard the old contactor using the proper disposal procedure.

See Material Safety Data Sheet #7439-97 in the

PPENDIX

Reverse this procedure to install the new contactor.

Make sure the wires

are connected correctly

Thermolator TW-1 and TW-2 UGH015/0100

6-16 TROUBLESHOOTING

1 2

WARNING: Hazardous Substance

Thermolators use mercury displacement contactors. Mercury is considered a hazardous substance and must be dealt with accordingly. See Material

Safety Data Sheet #7439-97-6 for information on

the how to avoid the potential hazards and how to clean up and dispose of mercury if it spills.

IMPORTANT:

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

WARNING:

Electrical Shock Hazard

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

REPLACING THE HEATER CONTACTOR

Heater contactor

Page 91

UGH015/0100 Thermolator TW-1 and TW-2

TROUBLESHOOTING 6-17

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

To check a thermocouple after a probe error:

Disconnect and lockout the main power.

Open the electrical enclosure door.

Turn the screw

on the front panel counterclockwise to open.

Unplug the appropriate thermocouple from the motherboard and install a jumper on the leads.

Refer to the wiring diagrams that came with your unit.

Restart the Thermolator.

◆ If error message disappears, replace the thermocouple.

◆ If error message does not disappear, replace the mother-

board. See Replacing the Motherboard.

To replace a thermocouple:

Disconnect and lockout the main power.

Shut off the cooling water infeed and drain the unit.

Drain all water using the drain plugs located the

bottom of the unit.

Remove the unit’s top panel and open the electrical enclosure

Remove the thermocouple.

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

Install the new thermocouple.

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

CHECKING THERMOCOUPLES

1 2

REPLACING THERMOCOUPLES

Thermocouple

Nut

WARNING: Hot surfaces

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

Page 92

Thermolator TW-1 and TW-2 UGH015/0100

6-18 TROUBLESHOOTING

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

Shut off the cooling water infeed.

Drain the unit of all water

through the draing plugs in the rear of the unit.

Remove the cooling water out feed.

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

Disconnect and lockout main power.

Remove the top and side panels of the Thermolator.

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

Remove the solenoid valve from the cooling water out line.

Disassemble the solenoid valve.

(See exploded views on next page.)

Inspect and clean or repair the valve body assembly.

Remove foreign particles and replace dam-

aged parts as necessary.

REPAIRING SOLENOID VALVES

Drain plugs

Cooling water in

WARNING:

Electrical shock and

hot surface hazards

Before attempting maintenance of any kind on the Thermolator, you must stop the unit; disconnect and lockout the main power supply; and allow the unit to cool to 100° F (38° C)

DIRECT INJECTION

CLOSED CIRCUIT

ISOLATED CIRCUIT

Cooling water out

Cooling water in

Page 93

UGH015/0100 Thermolator TW-1 and TW-2

TROUBLESHOOTING 6-19

Reassemble the valve and other components.

Reassemble in reverse order. Seal all pipe fittings

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

EPAIRING

OLENOID

VALVES

Nameplate

Cover*

Yo k e *

Housing*

7/8" Dia. Hole

for 1/2" Conduit

Solenoid Base Sub-Assembly

0.9375-26 UNS-2A Thread

Core (AC)

Tapped Hole in Core

0.250-28 UNF-2B

0.38 Minimum Full Thread

Retaining Clip*

Retaining Cap*

Sleeve*

Grounding Wire

(Not present on all constructions)

Insulating Washer

Sleeve*

Spring Washer

Housing* with Nameplate*

*Indicates Parts Supplied

in Solenoid Enclosure Kit

Alternate Construction with Nameplate on Housing

Coil

Insulating Washer

*Indicates Parts Supplied

in Solenoid Enclosure Kit

Cover*

Yo k e *

7/8" Dia. Hole

for 1/2" Conduit

Solenoid Base Sub-Assembly

0.9375-26 UNS-2A Thread

Core (AC)

Tapped Hole in Core

0.250-28 UNF-2B

0.38 Minimum Full Thread

Retaining Clip*

Sleeve*

Grounding Wire

(Not present on all constructions)

Sleeve*

Coil

Page 94

Thermolator TW-1 and TW-2 UGH015/0100

6-20 TROUBLESHOOTING

Disconnect and lockout the main power.

Remove the top panel of the Thermolator.

Remove the heater cap.

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

Remove the heater wiring harness.

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

The wiring layout will be one of the following:

Then unscrew the locking screws on the wiring harness and remove the wires.

Shut off the cooling water infeed.

Drain the Thermolator using the drain plugs located at the rear of the unit.

Remove the four bolts that hold the heater element in place.

Use a 15/16-inch socket with 1/2-inch

drive.

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)

REPLACING HEATER ELEMENTS

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.

HEATER TERMINAL CONNECTIONS

Heater cap

Continued on next page

Parallel Delta

230/3/60

2T2

GND

2T1

2T3

Series Delta

460/3/60

2T2

2T1

2T3

Page 95

UGH015/0100 Thermolator TW-1 and TW-2

TROUBLESHOOTING 6-21

Lift the heating element out of the heater tube.

Lift the element straight up.

Replace the heater gasket if it is worn or cracked.

Use a high termpertaure Teflon paste to ensure a good seal.

Reverse these steps to install the new heater element and reassemble the unit.

REPLACING HEATER ELEMENTS

Heater cap

Heater element

Heater gasket

Page 96

Disconnect and lockout the main power.

Shut off the cooling water in feed.

Drain the unit of all fluid.

Remove the drain plugs at the rear of the unit

Remove the top and side panels of the Thermolator.

Remove the seal flush line.

Use a 1/2-inch open-end wrench to remove the vent line from the connection on the pump adapter.

Remove the pump assembly bolts.

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

Lift the pump assembly straight up to remove.

The pump can now be replaced or disassembled for repair.

Reverse the steps to reassemble the unit.

NOTE:

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

Thermolator TW-1 and TW-2 UGH015/0100

6-22 TROUBLESHOOTING

REMOVING

THE

PUMP

Drain plugs

Cooling water in

DIRECT INJECTION

CLOSED CIRCUIT

ISOLATED CIRCUIT

Cooling water out

Cooling water in

WARNING:

Electrical shock and

hot surface hazards

Before attempting maintenance of any kind on the Thermolator, you must stop the unit; disconnect and lockout the main power supply; and allow the unit to cool to less than 100° F (38° C)

Pump seal flush line

Pump

assembly

bolts

Page 97

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

Remove the impeller nut. Insert a screwdriver in one

of the impeller waterway passages and back off the impeller nut.

Remove the impeller. Insert a screwdriver in the slot

of the motor shaft. Unscrew the impeller while holding the shaft against the rotation.

Remove the seal, gasket case, adapter and flinger.

See the exploded view for detail.

Clean the gasket and flange faces, seal seat cavity and shaft.

The shaft shoulder that fits against the

impeller must be clean.

Replace the flinger. Lubricate the seal seat cavity of

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

Remount the adapter to the motor. Make sure the

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

Replace the remaining seal components. Apply a

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

Reassemble the remaining components, holding

the shaft against rotation as previously described. Remove any burrs caused by the screwdriver on the impeller.

Reattach the pump to the volute case. Make sure

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

DISASSEMBLING

AND

ASSEMBLING

/4- 2 HP PUMPS

UGH015/0100 Thermolator TW-1 and TW-2

TROUBLESHOOTING 6-23

Pump motor

Flinger*

Pump adapter

Gasket, case*

Seal*

Impeller

D washer*

Impeller nut*

*Indicates Parts Supplied

in the Seal Repair Kit

NOTE:

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

Page 98

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

Remove the impeller retaining assembly. Insert a

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

Remove the impeller. Be careful not to lose the key,

spring and seal retainer. If the impeller is difficult to remove, you may need to use a bearing puller.

Remove the seal, adapter, shaft and flinger. See

the exploded view for detail.

Clean the gasket and flange faces, seal seat cavity, shaft sleeve and motor shaft.

Replace the shaft

sleeve if it is damaged or worn.

Replace the flinger. Lubricate the seal seat cavity of

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

Remount the adapter to the motor. Make sure the

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

Replace the remaining seal components. Apply a

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

Place the key in the key seat and slide the impeller on the shaft.

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

Thermolator TW-1 and TW-2 UGH015/0100

6-24 TROUBLESHOOTING

Pump motor

Flinger*

Pump adapter

Gasket, case*

Seal*

Impeller

O-ring, shaft*

Impeller retainer*

*Indicates Parts Supplied

in Repair Kit

Shaft* sleeve

Seal retainer*

Key*

Wear ring

DISASSEMBLING

AND

ASSEMBLING

3 - 7.5 HP PUMPS

Continued on next page

Page 99

UGH015/0100 Thermolator TW-1 and TW-2

TROUBLESHOOTING 6-25

Reattach the pump to the volute case.

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

NOTE:

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

DISASSEMBLING

AND

ASSEMBLING

3 - 7.5 HP PUMPS

Page 100

Conair Thermolater vacuTrac, VTR1-DI, VTR2-DI User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

DESCRIPTION

WHAT IS THE THERMOLATOR ?

SPECIFICATIONS

FEATURES AND OPTIONS

INSTALLATION

UNPACKING THE BOXES

PREPARING FOR INSTALLATION

CONNECTING PROCESS AND WATER SUPPLY LINES

TESTING THE INSTALLATION

CHANGING TEMPERATURE UNITS

ENABLING AND DISABLING PASSCODE PROTECTION

OPERATION

TW-2 CONTROL

STARTING THE THERMOLATOR

STOPPING THE THERMOLATOR

USING THE MANUAL PURGE OPTION

PERFORMING AN AUTO TUNE

MAINTENANCE

PREVENTATIVE MAINTENANCE SCHEDULE

KEY/DISPLAY TEST

INPUT TEST

OUTPUT TEST

CALIBRATING TEMPERATURE SENSORS

LOGGING OPERATING HOURS

TROUBLESHOOTING

SHUT DOWN ALARMS

Low Water Pressure

Pump

High Temp. Safety

Low Deviation

High Deviation

SPI Communication

THERMOLATOR WILL NOT POWER UP

CHECKING AND REPLACING FUSES

RESETTING OVERLOADS

REPLACING THE PUMP OVERLOAD

REPLACING THE MOTHERBOARD

REPLACING THE HEATER CONTACTOR

CHECKING THERMOCOUPLES

REPLACING THERMOCOUPLES

REPAIRING SOLENOID VALVES

REPLACING HEATER ELEMENTS