Advantage Sentra SK Series Instruction Manual Download Page 9

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Temperature Control Units : Sentra with VE Series Instrument

Page: 9

Advantage Engineering, Inc.

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-0729 Fax: 317-881-1277

Service Department Fax: 317-885-8683

www.AdvantageEngineering.com

Observe all safety precautions during installation, startup and service of this equipment

due to the presence of high voltage. Only qualified personnel should install, startup and

service this equipment.

When working on this equipment, observe precautions in literature and on tags, stickers

and labels located on the equipment. Wear work gloves and safety glasses.

Before installing and operating the unit, be aware of and follow any local laws and codes

that apply to the installation.

Samples of Warning Labels applied to typical temperature control units.

Alerts users to the danger of high voltage.

Alerts the user to possible explosive danger.

Alerts the user to a hot surface danger due to high operating temperatures.

1.4 WATER TREATMENT

The fluid used in your temperature control unit will greatly effect its short and long-

term operation. Lack of as well as improper water treatment can damage the

temperature control unit by causing scale build-up, excessive corrosion and/or bacterial

contamination. It is the equipment owner’s responsibility to prevent damage caused by

poor water quality. The services of a water treatment professional is recommended.

CAUTION

WARNING

J5318-BF

Summary of Contents for Sentra SK Series

Page 1: ...ERATION MAINTENANCE ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood IN 46142 317 887 0729 fax 317 881 1277 Service Department fax 317 885 8683 www AdvantageEngineering com sales AdvantageEngineering com Model Serial Number Models with VE Series Instrument ...

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Page 3: ...ENT COVERING INSTALLATION OPERATION MAINTENANCE ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood IN 46142 317 887 0729 fax 317 881 1277 Service Department fax 317 885 8683 www AdvantageEngineering com E mail sales AdvantageEngineering com ...

Page 4: ...peration 22 3 3 Instrument Quick Start 26 3 4 Shut Down Disconnect 29 4 0 TROUBLESHOOTING 31 4 1 Unit Will Not Start Display is not Illuminated 32 4 2 Unit Will Not Start Display Illuminated 32 4 3 Unit Stops 32 4 4 Unit Overheats 33 4 5 Unit Underheats 34 4 6 Pressure Relief Valve Leaks 34 5 0 MAINTENANCE 37 5 1 Pump Seal Replacement 38 5 2 Heating Cylinder Replacement 41 5 3 Cooling Valve Servic...

Page 5: ...ood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com 8 0 APPENDIX 61 8 1 Model And Suffix Coding 62 8 2 Interpretation of Process Pressure Gauges 63 8 3 Mold Purge Operation 64 8 4 AS5 Pump Parts List 1 2 HP to 1 HP 66 8 5 AS5 Pump Parts List 1 1 2 HP to 3 HP 67 ...

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Page 7: ...Advantage Engineering Inc 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com 1 0 GENERAL 1 1 Receiving Instructions 1 2 Introduction 1 3 Safety 1 4 Water Treatment 1 5 Components ...

Page 8: ...r installation can lead to equipment damage and poor performance Failure to follow the installation operation and maintenance instructions may result in damage to the unit that is not covered under the limited warranty This manual is for standard products The information contained in this manual is intended to be general in nature The information is typical only and may not represent the actual un...

Page 9: ...lling and operating the unit be aware of and follow any local laws and codes that apply to the installation G Samples of Warning Labels applied to typical temperature control units 1 Alerts users to the danger of high voltage 2 Alerts the user to possible explosive danger 3 Alerts the user to a hot surface danger due to high operating temperatures 1 4 WATER TREATMENT A The fluid used in your tempe...

Page 10: ...n algae bacteria or slime The manufacturer recommends filtering the process water to prevent solids from plugging critical parts C It is recommended that the services of a qualified water treatment specialist be engaged to determine what water treatment is required D Advantage assumes no responsibility for equipment failures which result from untreated or improperly treated water D Do not use deio...

Page 11: ...t Fax 317 885 8683 www AdvantageEngineering com Models with 10 16 kW heaters and 3 4 3 HP pumps typical Models with 24 34 kW heaters and 5 7 5 HP pumps typical Pump Thermoformed Cover Panel Vented Stainless Steel Cabinet Pump Motor Caster Cooling Cylinder Heating Cylinder Temperature Sensor Electrical Panel Inside stainless steel cabinet Cooling Valve Heater Instrument Pressure Gauges ...

Page 12: ...d Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Warning Label Summarizes the safety precautions when unit is in use Process Connection Label Details process connections hook up Unit Data Tag Details unit Serial Number voltage and other important unit information ...

Page 13: ...ng Inc 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com 2 0 INSTALLATION 2 1 General 2 2 To and From Process Connections 2 3 Water Supply Connection 2 4 Drain Connection 2 5 Electrical Connection ...

Page 14: ...ture of 300 F or less and a maximum pressure of 150 PSI The unit is most efficient when full size plumbing is run from the unit connections to and from the process If necessary reduce the plumbing size at your process not at the unit B Be certain all process piping materials have the equivalent or larger diameter of the particular process connection 2 2 TO AND FROM PROCESS CONNECTIONS A Connect th...

Page 15: ... temperature D Static water supply pressure can be determined at the unit s location by reading the unit s 0 160 PSI pressure gauges when the unit s pump motor is OFF E If water supply pressure as read on the unit s pressure gauges exceeds 75 PSI a pressure reducing valve must be installed in the water supply line refer to section 7 3 of this manual for installation information The factory recomme...

Page 16: ... For most applications the drain line should not be valved However for installations with a pressurized drain system it may be necessary to install a valve in the drain line In such cases the installed valve must be fully opened after installation and the valve handle removed to prevent operating the unit with a closed drain valve The valve handle can be reattached to the valve body when it is nec...

Page 17: ...Verify that available voltage supply is the same as the unit s voltage requirements WARNING DO NOT connect the unit to a voltage supply source not equal to the unit s voltage requirements as specified on the unit s data plate Use of incorrect voltage will void the unit s warranty and cause a significant hazard that may result in damage to the unit or serious personal injury 2 Appropriate conduit a...

Page 18: ...iable conductor 2 Make certain the power conductor disconnecting means and fusing are properly sized according to the unit s power supply requirements 3 Make certain all electrical connections are tightly affixed Any loose wiring connections must be tighten before engaging the power supply 4 Make certain no moisture or standing water is present inside the electrical cabinet WARNING Check that all ...

Page 19: ...East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Power Entry Low Water Pressure Switch Control Transformer Pump Motor Con troller Terminal Strip Heater Con tactor Transformer Fuse Blocks Typical Electrical Panel ...

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Page 21: ...tage Engineering Inc 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com 3 0 OPERATIONS 3 1 General 3 2 Machine Start Up and Operation 3 3 Instrument Operation 3 4 Shut Down Disconnect ...

Page 22: ...e water supply source by opening the water supply valve customer installed at the unit s location If a valve is not installed engage the water supply source at the plant s water supply central control point 2 Once the water supply source is open the unit will fill automatically Allow a few moments for the unit to completely fill The operator can determine the unit is properly filled when the To Pr...

Page 23: ...ch Once the correct voltage is supplied to the unit the Power light on the display will illuminate b Remove the thermoformed cover panel and open the hinged electrical cabinet panel cover Note that the electrical power is engaged at this point and caution must be observed while the electrical supply is engaged and the cabinet panel is open c Locate the electric motor and identify the motor shaft i...

Page 24: ... Adjustments 1 The operator must determine and set proper water flow rate for the most efficient and trouble free operation a Water flow rate through the process is determined by the pressure losses in the process loop Generally higher flow rates result in turbulent flow achieving maximum temperature control and lower maintenance b If the flow rate exceeds the motor HP capacity the electric motor ...

Page 25: ... outlined here a Open electrical cabinet panel door The panel cover is hinged and held open by a support cable Note that the electrical power is engaged at this point and caution must be observed while the cabinet panel is open b Identify the motor starter block This block consists of the motor starter contactor and the overload relay c Place an amp meter on a single power lead coming from the ove...

Page 26: ...mp rating of the motor The process flow is now correctly adjusted The valve should remain in this position during operation 6 LOW PROCESS FLOW The minimum recommended process flow rate is 10 GPM Process restrictions may limit the flow to less than 10 GPM We recommend the addition of bypass lines to raise the flow rate to 10 GPM The best place to add bypass lines are on the extra ports on the moldi...

Page 27: ...rument will not start and will illuminate no FLO in the temperature display window 4 Conditions that will prevent the unit from starting process temperature control operations are a Water supply pressure inadequate pressure switch is open The unit is prevented from operating without adequate water supply pressure by an electrical panel mounted pressure switch Sufficient water supply pressure must ...

Page 28: ... control operation 4 To display the setpoint temperature briefly touch the Up Arrow or Down Arrow push buttons To change the setpoint hold the Up Arrow or Down Arrow push buttons until the preferred setpoint temperature is indicated in the Temperature window Setpoint temperatures can be adjusted anytime C INSTRUMENT CONTROLS 1 UNIT ON OFF SWITCH This rocker switch engages disengages electrical sup...

Page 29: ...r to the drain Opening the valve also allows cooling water flow from the water supply source to enter the circulating system and mix with the heated process water to reduce process temperature 3 4 SHUT DOWN DISCONNECT A UNIT SHUT DOWN 1 Decrease the setpoint temperature lower than 85 F and allow the unit to cool to the temperature A pump seal cooling feature can be selected from the features menu ...

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Page 31: ...reenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com 4 0 TROUBLESHOOTING 4 1 Unit will not start Display is not Illuminated 4 2 Unit will not start Display Illuminated 4 3 Unit Stops 4 4 Unit Overheats 4 5 Unit Underheats 4 6 Pressure Relief Valve Leaks ...

Page 32: ...nue An excessive flow condition must be isolated and corrected immediately 3 High temperature limit switch open The unit is prevented from operations at temperatures exceeding 256 F by a high temperature limit switch This switch is installed in the To Process temperature sensor If this switch is open due to a high temperature condition the unit cannot be started and must cool down before the high ...

Page 33: ... stop and a safety fault to be displayed 2 PVTTM valve defective The instrument opens and closes the PVTTM cooling valve as prescribed by the current process load If the valve becomes clogged with process water debris or scaled with mineral deposits its operation is hindered or fully prevented and adequate process water discharge to drain is prevented The operator must service the PVTTM valve and ...

Page 34: ...defective The instrument is designed and manufactured exclusively by Advantage The instrument is life tested and found to be field reliable However in the case where the instrument is determined to be defective the operator must remove the assembly according to instructions outlined in this manual and return the assembly to the factory The instrument is not a field serviceable component 4 6 PRESSU...

Page 35: ...is causing the valve not to close properly If this is the case flushing the valve for a moment will cleanse the seat and allow it to work properly If flushing the valve does not remedy the leaking the valve must be replaced E Extreme internal system pressure If the internal pressure in the Sentra unit is elevated the pressure relief valve will leak as a safety measure to dissipate excessive pressu...

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Page 37: ... 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com 5 0 SERVICE MAINTENANCE 5 1 Pump Seal Replacement 5 2 Heater Replacement 5 3 Cooling Valve Service 5 4 Voltage Change 5 5 Sensor Probe Service 5 6 Pressure Switch Service 5 7 Electronic Instrument Repair Policy Procedure 5 8 Celsius Temperature Display ...

Page 38: ...r light on the display is off 3 Remove the lift off access panel and set aside 4 Remove the thermoformed panel It is attached to the stainless steel cabinet by 4 small screws figure 5 1B 5 Drain machine by removing the pump casing drain plug 6 Remove the three motor wire leads from the motor wiring terminals The operator should map the wire terminal locations to ensure correct rewiring The power c...

Page 39: ...r shaft and lubricate with a mild soap solution Note Oil must never be used as a lubricant as it will damage the rubber parts of the seal assembly 13 Install new stationary seal member in pump casing cavity figure 5 1H Be certain the stationary seal member is fully squared and seated in cavity 14 Slide the rotating member onto the lubricated pump shaft figure 5 1I Be certain not to damage or tear ...

Page 40: ...Engineering com 20 Replace the thermoformed front panel and the lift off cover D When this procedure is complete the operator may restart the unit In many cases a new pump seal will experience a small amount of leakage for a short time This is normal After a few moments the new seal will take seat and the leak will stop Stationary member Figure 5 1H Rotating member Figure 5 1I Aligning impeller an...

Page 41: ... s pressure gauges read 0 2 Disengage main power supply Verify the Power light on the display is off 3 Remove the lift off access panel and set aside 4 Drain machine The machine can be drained by removing the pump casing drain plug 5 Remove heater s junction box cover to locate wiring connections The operator should note the wiring connections to ensure correct reinstallation figure 5 2B 6 Disconn...

Page 42: ...1 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com 11 Replace the 4 heater mounting bolts Alternate to the opposite bolt while tightening 12 Reconnect the power cable to the heater terminals Be certain to tighten the power cord junction box connector Replace the junction box cover and the lift off cover panel E When complete restart the unit ...

Page 43: ...e mechanism C To service the solenoid valve follow the procedure below 1 Disengage process operations according to the procedure outlined in section 3 4 Be certain process fluid pressure is relieved coolant pressure gauge reads 0 and water system flow is shut off 2 Disengage main power supply The operator must follow all lockout tagout procedures 3 Remove or open any access cover panel and set asi...

Page 44: ... Engineering Inc 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Coil and solenoid base sub assembly Body Gasket Valve body Core assembly Core spring Diaphragm spring Diaphragm assembly ...

Page 45: ...unit data tag with tag stating new voltage and amp rating D The qualified technician should follow this procedure to complete a field voltage changeover 1 Disengage operations and verify all system pressure is relieved and the unit s pressure gauges read 0 2 Disengage main power supply Follow proper lock out procedures The operator must verify the Power light on the display is off 3 Remove the lif...

Page 46: ...chematics for 240 and 480 volt pump motors Transformer Figure 5 5E Figure 5 5C Wiring schematics for 240 and 480 volt heaters Revised 4 11 Motor Starter and Overload Block Figure 5 5F 8 Replace the motor starter and overload block Adjust the overload block settings for the current draw at the new voltage figure 5 4F 9 Once a voltage change is complete be certain the unit is properly connected to t...

Page 47: ...ch can be cleared by pressing the Start push button If not continue with replacement 2 REPLACEMENT Replacement of the sensor probe involves ceasing process operations as outlined in section 3 4 of this manual and removing the defective sensor probe All factory supplied replacement probes are complete with the service connection Unit with G Series instruments use one sensor probe The high temperatu...

Page 48: ...nit operations according to section 3 4 in this manual Be certain proper lock out procedures are followed Also be certain system pressure is eliminated and the unit s pressure gauges read 0 pressure 2 Drain unit by removing the pump casing drain plug 3 A capillary runs from the cooling cylinder to the pressure switch Remove the capillary connection 4 The brass elbow mounted on the pressure switch ...

Page 49: ...u will need to pay for it C OUT OF WARRANTY SERVICE INCIDENT 1 Call the factory for diagnostic assistance 2 If a control instrument is determined to be at fault there are 3 options a Purchase a new instrument as a replacement b Send your instrument back for repair freight prepaid For a nominal fee your instrument will be repaired and returned c Purchase a new instrument and repair the old one as a...

Page 50: ...in power supply Verify the Power light on the display is off Follow standard lock out procedures 3 Remove the thermoformed front panel and set aside The panel is attached to the stainless steel cabinet by 4 small screws 4 Open the hinged electrical cabinet panel cover The panel is opened by removing four small screws 5 Locate the instrument A jumper bar controls the Temperature display The jumper ...

Page 51: ...es Instrument Page 51 Advantage Engineering Inc 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com 6 0 COMPONENTS 6 1 Mechanical System 6 2 Electrical System ...

Page 52: ...lectrical motor The electric motor is a dual voltage 3 phase ODP motor The motor serves to turn the pump impeller creating process flow 4 Impeller The impeller is custom designed for the unit and creates the higher flow gpm from standard HP ratings 5 Pump Seal The pump seal prevents water leakage from the pump adapter The seal is made up of three items The stationary member seated in the seal cavi...

Page 53: ...ginates at the heat pump discharge cylinder From process pressure originates at the cooling cylinder The gauges accurately display system pressures from 0 to 160 PSI figure 6 1G H CASTERS The unit is mounted on 4 swivel ball bearing casters The casters allow the unit to be portable and easily move from location to location I STAINLESS STEEL CABINETRY The stainless steel cabinetry prevents unsightl...

Page 54: ...tate contactor rather than the standard mechanical contactor E PRESSURE SWITCH The electric panel mounted pressure switch will close when sufficient pressure is supplied to the unit 20 psi A closed pressure switch will consent the control circuit to the instrument controller to allow process operations F SENSOR PROBES The unit uses 1 sensor probe The sensor and the high temperature limit safety sw...

Page 55: ...age Engineering Inc 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com 7 0 RELATED DRAWINGS 7 1 Physical 7 2 Circuit Schematic 7 3 Regulator Bypass 7 4 Dual Zone Dolly 7 5 Stacking Rack ...

Page 56: ... East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com 7 1 PHYSICAL To Process Drain Water Supply From Process Pressure Gauges Right Side View Left Side View Left Side View Rear View Instrument 12 1 2 26 5 8 19 1 2 ...

Page 57: ...ntageEngineering com A DRAIN CONNECTION TO PROCESS SENSOR HI TEMP SAFETY TO PROCESS PRESSURE GAUGE TO PROCESS CONNECTION HEATER DISCHARGE TANK PUMP PUMP SEAL FLUSH DRAIN FROM PROCESS PRESSURE GAUGE PRESSURE RELIEF VALVE FROM PROCESS CONNECTION WATER SUPPLY CONNECTION SUCTION TANK PVT COOLING VALVE Provided for display purposes only Refer to electrical drawing supplied with unit for details 7 2 CIR...

Page 58: ... Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com 7 3 REGULATOR BYPASS INSTALLATION WATER SUPPLY PRESSURE REGULATOR VALVE TYPE WATTS U5B 1 2 25 75psi RANGE BYPASS VALVE TYPE WATTS BP 30 1 2 45 100psi RANGE DRAIN FROM PROCESS TO PROCESS ...

Page 59: ... WATER SUPPLY CONNECTION TO SENTRA 2 WATER SUPPLY MANIFOLD CONNECTION DRAIN MANIFOLD CONNECTION WATER SUPPLY CONNECTION DRAIN CONNECTION DRAIN CONNECTION FROM PROCESS CONNECTION SENTRA 2 SENTRA 1 TO PROCESS CONNECTION Molders often need to run different temperatures on each mold half to produce the best quality part Advantage can provide a dual zone dolly that holds two standard single zone temper...

Page 60: ... Sentra with VE Series Instrument Page 60 Advantage Engineering Inc 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com 7 5 STACKING RACK ...

Page 61: ...oad Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com 8 0 APPENDIX 8 1 Model and Suffix Coding 8 2 Interpretation of Process Pressure Gauges 8 3 Mold Purge Operation 8 4 AS5 Pump Parts List 1 2 hp to 1 hp 8 5 AS5 Pump Parts List 1 5 hp to 3 hp ...

Page 62: ...power 75 75 GPM 2 Horsepower 80 80 GPM 3 Horsepower 90 90 GPM 5 Horsepower 100 100 GPM 7 1 2 Horsepower Control Instrument T T series instrument G G series instrument VE VE series instrument The data tag on your Sentra Temperature Control Unit provides general information about the unit Compare the information below with your data tag for more information about your unit Some data tags may have ot...

Page 63: ...ss gauges is the pump generated circulating pressure which is also equal to the pressure drop across the process C PUMP ROTATION INDICATION If the pump is running and both gauges are close to same value it is likely that the pump is rotating backward or the pump is generating such a high flow that an overload condition will result D PUMP MOTOR OVERLOAD CONDITION If the P is low with the pump rotat...

Page 64: ...alve 3 Connect a regulated air supply to mold purge compressed air connection Note Air supply should be regulated approximately 10 PSI above drain line pressure 4 Mold Purge is activated by selecting the mold purge item from the Utilities menu Mold purge is started immediately If the pump is running the follow message will be displayed If the pump is not running the mold purge will start 5 Press t...

Page 65: ...tion DRAIN CONNECTION FROM PROCESS CONNECTION AVT VALVE Closed to prevent purge of unit WATER SUPPLY CONNECTION Valve must be closed during mold purge operation LINE TO DRAIN CHECK VALVE Prevents compressed air from purging unit TO PROCESS CONNECTION CHECK VALVE Prevents water bleed to air line during normal run cycle SOLENOID VALVE Opens to purge water to drain SOLENOID VALVE Opens to allow compr...

Page 66: ...EPT 6491000 Shaft seal EPT Ceramic 4949 AE5 AS5 6207000 MOTOR PUMP ASSEMBLY AS5 3 4HP ODP 230 460 414 Adapter iron C2 4551 AS5 771599 Pump case iron D2 1839 AS5 3444400 Tank gasket 2 3 8 A 9159 AS5 3444401 Tank gasket 4 1 2 A2 8748 AS5 4310602 Impeller B2 5264 4 5 AS5 4757862 Motor AE5 AS5 A5W 3 4HP S 2772R 5486522 Nut S 4989 AS5 5622271 O ring Case S 5091 AS5 6490000 Shaft seal 101 173 5 8 EPT 64...

Page 67: ... AE5 AS5 6207000 MOTOR PUMP ASSEMBLY AS5 3 4HP ODP 230 460 414 Adapter iron C2 4551 AS5 771599 Pump case iron D2 1839 AS5 3444400 Tank gasket 2 3 8 A 9159 AS5 3444401 Tank gasket 4 1 2 A2 8748 AS5 4310602 Impeller B2 5264 4 5 AS5 4757862 Motor AE5 AS5 A5W 3 4HP S 2772R 5486522 Nut S 4989 AS5 5622271 O ring Case S 5091 AS5 6490000 Shaft seal 101 173 5 8 EPT 6491000 Shaft seal EPT Ceramic 4949 AE5 A...

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Page 69: ...END 2017 ADVANTAGE ENGINEERING INC RE 01272017 ...

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