Conair Thermolater vacuTrac User Manual Download Page 20

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Thermolator TW-1 and TW-2

UGH015/0100

ABLE OF

ONTENTS

AINTENANCE

. . . . . . . . . . . . . . .

(continued)

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

REPAIR

PPENDIX

Customer Service Information . . . . . . . . . . . . . . . . . . . . . .A-1
Warranty/Guarantee Information  . . . . . . . . . . . . . . . . . . . .A-2
Plumbing Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Technical Information  . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Thermolator SPI commands  . . . . . . . . . . . . . . . . . . . . . . .D-1

ARTS

IAGRAMS

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

Summary of Contents for Thermolater vacuTrac

Page 1: ...stant Access 24 7 Parts and Service 800 458 1960 Parts and Service 814 437 6861 USERGUIDE UGH003 0102 Thermolater vacuTrac Positive Negative Pressure Water Temperature Controller with TW 1 or TW 2 Mic...

Page 2: ...lists together for documentation of your equipment Date Manual Number UGH003 0102 Serial Number s Model Number s DISCLAIMER Conair shall not be liable for errors contained in this User Guide or for i...

Page 3: ...FT OFF ACCESS PANELS Convenient tool free access to internal components The cabinet lifts away for easy maintenance and servicing STATE OF THE ART CONTROLS Easy to use microprocessor controls provide...

Page 4: ...m static pressure Cooling water outlet Cooling water inlet From Process From Process Pressure Gauge Cooling In and Make Up Manual Three Way Ball Valve To Process Pressure Gauge To Process Cooling Out...

Page 5: ...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 O...

Page 6: ...ht 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...

Page 7: ...nect the COOLING WATER IN MAKE UP and COOLING WATER OUT piping to the Thermolator using NPT pipe Viewed from the rear the COOLING IN MAKE UP hookup is in the lower left hand side through the back pane...

Page 8: ...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 negati...

Page 9: ...Figure 1...

Page 10: ...oling 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 Pres...

Page 11: ...e 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 al...

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Page 13: ...the high and low temperature devia tion alarms the SPI baud rate and the SPI address 1 2 3 Status lights The lights indicate the operating status of the listed components Except in Test Mode and Auto...

Page 14: ...e 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 al...

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Page 17: ...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 Insta...

Page 18: ...er 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 dam ages in connection with th...

Page 19: ...e 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 cont...

Page 20: ...ower Up 6 12 REPAIR 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 1...

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: ...ons 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 i...

Page 23: ...ch 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 ser...

Page 24: ...tance and must be dealt with accord ingly 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...

Page 25: ...t 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 Specificat...

Page 26: ...e 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...

Page 27: ...t s heater tank The fluid then flows through the To Process line to the mold or process The fluid returns to the unit through the From Process line for reheating or cooling 1 A B C D If the process te...

Page 28: ...emperature is below the setpoint the heater elements inside the heater tank are energized E F 4 The pump moves water from the mixing tank to the heater tank Pressure is measured before and after the p...

Page 29: ...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...

Page 30: ...9 12 18 or 24 kW 208 230 460 575 D E N A A B C D E Dimensions and performance characteristics vary according to the model voltage and components selected See the cabinet style reference chart to deter...

Page 31: ...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 2...

Page 32: ...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...

Page 33: ...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 contr...

Page 34: ...at 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 Use...

Page 35: ...0 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 nee...

Page 36: ...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 appropri...

Page 37: ...ator This valve is required when a purge valve is used Install pipe to the rear of the Thermolator Use male 11 4 inch NPT piping for process connections and male 3 4 inch NPT piping for water connecti...

Page 38: ...copper grounding mount If you have installed a disconnect device follow the manufacturer s wiring instructions 1 2 3 4 5 CONNECTING THE MAIN POWER SUPPLY 3 6 INSTALLATION WARNING Electrical shock haza...

Page 39: ...ectrical 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 s...

Page 40: ...its 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...

Page 41: ...lator 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 8 7 6 5 4 3 2 1 1 2 3 8 7 6 5 4 3 2 1 4 INSTALLAT...

Page 42: ...d restore power to the unit Press any button when the control dis plays Pas rSt Passcode Reset The control will display the last passcode used Select a new passcode using the and setpoint adjustment b...

Page 43: ...h 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 7 8 8 7 6 5 4 3 2 1 9 10 11 ENABLING AND DISABLING PASS...

Page 44: ...ny button when the control displays Cnt Pt The controller will display Sel CnP and flashes the LED for the current con trol point Select a new control point using the Display button Stop pressing the...

Page 45: ...t 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...

Page 46: ...mperature 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 tempera...

Page 47: ...1 PaS use the setpoint adjustment but tons 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...

Page 48: ...gh 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...

Page 49: ...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 OF...

Page 50: ......

Page 51: ...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...

Page 52: ...ows the setpoints entered for fluid temper ature 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...

Page 53: ...e is calculated as an average of the tempera tures of the supply water and return water The lights indicate whether the temperature is in degrees Fahrenheit or Celsius See the INSTALLATION section for...

Page 54: ...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 ca...

Page 55: ...aS 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...

Page 56: ...etpoint 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 Temperatur...

Page 57: ...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 un...

Page 58: ...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 lig...

Page 59: ...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...

Page 60: ...in ambient temperature This allows the software to obtain good approximations of process parameters which are crit ical for performing an accurate tune If this requirement is not met then a good tune...

Page 61: ...ESCRIPTION Insufficient setpoint process deviation If the absolute value of setpoint process value is less than 25 F The Auto Tune can not be started until the temperature difference is at least 25 F...

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Page 63: ...e 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...

Page 64: ...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 flu...

Page 65: ...the supply and return thermocouples See PERFORMING SYSTEM TESTS in this section WARNING Electrical shock and hot surface hazards Before attempting maintenance of any kind on the Thermolator you must s...

Page 66: ...t 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 corr...

Page 67: ...trol 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 Ho...

Page 68: ...nu 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...

Page 69: ...ndex 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 indi cate the number of the input being test...

Page 70: ...ntil the controller displays oUt Repeatedly press and release any key to test With each key press and release the left display will indi cate the number of the output being tested oS1 OM1 oS2 OM2 etc...

Page 71: ...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 O...

Page 72: ...dex 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 calibr...

Page 73: ...he end of a calibration tells the controller to perform the next calibra tion Exit Calibration Mode Press and hold the Select key for 3 seconds to exit the Calibration Mode You can now proceed to the...

Page 74: ...dicates Log The Setpoint display indicates the total number of operat ing 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...

Page 75: ...t power up 6 12 REPAIR 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 repla...

Page 76: ...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...

Page 77: ...icroprocessor 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...

Page 78: ...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...

Page 79: ...ed Has water stopped flow ing 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 Chec...

Page 80: ...enoid 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 thermocou ple or...

Page 81: ...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 discon nect and lock...

Page 82: ...red 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 Rea...

Page 83: ...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 th...

Page 84: ...ud rate correct Is something wrong with the cable Solution If the Thermolator is not con nected to a host device set the SPI address to OFF using the Setpoint adjustment buttons on the control panel C...

Page 85: ...e 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 socke...

Page 86: ...the main power supply and any customer installed electrical discon nect or emergency stop devices are in the ON posi tion Verify correct electrical con nections between the unit and the control and b...

Page 87: ...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 th...

Page 88: ...he 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...

Page 89: ...et off for IC models Program output monitors on the new board See Disabling or Enabling Output Monitors in the MAINTENANCE section 1 2 3 4 5 6 1 2 3 4 5 6 7 8 CONFIGURATION DIP SWITCH OFF ON 4 3 2 1 4...

Page 90: ...in the APPENDIX Reverse this procedure to install the new con tactor Make sure the wires are connected correctly Thermolator TW 1 and TW 2 UGH015 0100 6 16 TROUBLESHOOTING 1 2 3 4 5 WARNING Hazardous...

Page 91: ...ocouple 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...

Page 92: ...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 cool ing water out line Disassemble the solenoid...

Page 93: ...n Core 0 250 28 UNF 2B 0 38 Minimum Full Thread or Retaining Clip Retaining Cap Sleeve Grounding Wire Not present on all constructions Insulating Washer Sleeve Spring Washer Housing with Nameplate Ind...

Page 94: ...the drain plugs located at the rear of the unit Remove the four bolts that hold the heater ele ment in place Use a 15 16 inch socket with 1 2 inch drive 1 2 3 4 5 6 WARNING Electrical shock and hot s...

Page 95: ...ter 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 elemen...

Page 96: ...e 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...

Page 97: ...seat of the seal Replace the remaining seal components Apply a soapy water solution to the motor shaft and the rubber bel lows of the rotating seal Be sure the rotating seal face stays in the holding...

Page 98: ...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 m...

Page 99: ...am aged 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...

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Page 101: ...cting the Customer Service Department Standard rates include an on site hourly rate with a one day minimum plus expenses Before You Call If you do have a problem please complete the following checklis...

Page 102: ...the following options Inspect the equipment and perform alterations or adjustments to satisfy performance claims Charges for such inspections and corrections will be waived unless failure to meet warr...

Page 103: ...heck Valve Return Pressure Gauge Supply Pressure Gauge PLUMBING DIAGRAMS Return Thermocouple Heater Supply Thermocouple To Process From Process Cooling Water In Cooling Water Out Vent Valve Cooling Va...

Page 104: ...From Process Cooling Water In Cooling Water Out Vent Line Cooling Valve Relief Valve Cooling Heat Exchanger Pump Isolated Circuit NOTE There is a 180 F operating temperature limit on isolated circuit...

Page 105: ...Gallons Minute Liters Minute 55 78 180 49 69 160 43 61 140 37 52 120 30 43 100 24 35 80 18 26 40 12 17 30 6 9 20 0 0 10 38 20 76 30 114 40 152 50 190 60 228 70 266 80 304 90 342 100 380 110 418 120 4...

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Page 107: ...emperature controllers Device ID hex 20 Commands Select Poll Echo 0x20 0x20 Select stores 4 bytes of information at the Thermolator Poll retrieves it 0x21 0x20 Setpoint Process Temperature 0x20 0x20 S...

Page 108: ...fines the Processing bit as being cleared if the unit is not processing otherwise it is SET Elsewhere on the chart If a bit is not shown to be SET it is cleared The System Alarm bit is SET if an alarm...

Page 109: ...ase error SET SET SET NOTES The SPI I O list defines the Processing bit as being cleared if the unit is not processing otherwise it is SET Elsewhere on the chart If a bit is not shown to be SET it is...

Page 110: ...SET SET Low water level SET SET Test Mode Phase error NOTES The SPI I O list defines the Processing bit as being cleared if the unit is not processing otherwise it is SET Elsewhere on the chart If a...

Page 111: ...in or on your clothing Do not breathe mercury dust Keep mercury in a tightly closed container Use with adequate ventilation Wash thoroughly after handling Effects of overexposure Mercury causes skin d...

Page 112: ...ental regulations 7 Storage and Handling Precautions Mercury should be stored in a secure poison area inside a tightly closed container 8 Exposure Control and Protective Equipment Ventilation Use gene...

Page 113: ...PD 1 UGH015 0100 Thermolator TW 1 and TW 2 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 PARTS DIAGRAMS...

Page 114: ...n 09000751 HP through 2 HP nickle resistant seal 11C 12C 09000752 3 HP through 7 nickle resistant seal 50C 09000358 HP through 2 HP silicon carbide seal 12CS 09000359 3 HP through 7 HP silicon carbide...

Page 115: ...4554 inch solenoid overhaul kit 5 0 CV COOLING SOLENOID VALVES Part No Description 09001551 inch solenoid valve 0 72 CV 09000457 3 8 inch solenoid valve 1 5 CV 09002969 inch solenoid valve 4 0 CV 0900...

Page 116: ...mp overload for HP 208V and 1 HP 208 230V 20003912 Pump overload for 3 HP 460V 20003913 Pump overload for 2 HP 208 230V and 5 HP 460V 20003914 Pump overload for 3 HP 208 230V and 7 HP 460V 09000346 Pu...

Page 117: ...UGH015 0100 TW 1 230 460V WIRING DIAGRAM PD 5...

Page 118: ...1 2 3 4 1 CONTROL OPER PNL CABLE 120 Ohm TR TR GND GND TR TR 120 Ohm 4 3 2 1 F R O M X F R M R F I L L I C T C C P U R G E D I C C W P S F R O M X F R M R F I L L I C T C C P U R G E D I C C W P S 2...

Page 119: ...UGH015 0100 TW 2 230 460V WIRING DIAGRAM PD 7 2...

Page 120: ...2 1 Y R R Y 1 2 3 4 5 6 7 8 1 2 3 4 2 CONTROL OPER PNL CABLE 120 Ohm TR TR GND GND TR TR 120 Ohm 4 3 2 1 F R O M X F R M R F I L L D I N W P S A U T O S T A R T A U T O S T A R T F R O M X F R M R F...

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