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Conair Thermolator TW, User Manual

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Thermolator

®

TW Series

Water Temperature Control Units

TW, TW-1 and TW-2

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

U S E R   G U I D E

U G H 0 2 5 - 0 5 0 4

www.conairgroup.com

Summary of Contents for Thermolator TW

Page 1: ...eries Water Temperature Control Units TW TW 1 and TW 2 Corporate Office 724 584 5500 Instant Access 24 7 Parts and Service 800 458 1960 Parts and Service 814 437 6861 U S E R G U I D E UGH025 0504 www...

Page 2: ...ser Guide and all manuals engineering prints and parts lists together for documentation of your equipment Date Manual Number UGH025 0504 Serial Number s Model Number s DISCLAIMER Conair shall not be l...

Page 3: ...g the Installation TW Control 3 7 Testing the Installation TW 1 TW 2 Control 3 8 TW Control Initial Setup 3 9 TW Control Changing Temperature Units 3 10 TW 1 TW 2 Control Initial Setup 3 11 TW 1 TW 2...

Page 4: ...Few Words of Caution 6 2 Identifying the Cause of a Problem 6 3 TW Control Alarms 6 5 TW Control Mechanical Electrical Alarms 6 11 TW 1 TW 2 Control Shut Down Alarms 6 12 TW 1 TW 2 Control Warning Ala...

Page 5: ...1 1 UGH025 0504 Thermolator TW Series l Purpose of the User Guide 1 2 l How the Guide is Organized 1 2 l Your Responsibilities as a User 1 2 l ATTENTION Read this so no one gets hurt 1 3 INTRODUCTION...

Page 6: ...d 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...

Page 7: ...ve 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 oper...

Page 8: ...con sidered a hazardous substance and must be dealt with accordingly See the Material Safety Data Sheet which explains the potential haz ards how to avoid them and how to clean up and dispose of the m...

Page 9: ...e Thermolator TW Series 2 2 l Typical Applications 2 2 l How it Works Direct Injection DI Models 2 3 l How it Works Closed Circuit CC Models 2 4 l How it Works Isolated Circuit IC Models 2 5 l Specifi...

Page 10: ...ycol water process loop mixtures should use industrial grade ethylene glycol only The best model for your application depends on the process temperature you need to maintain and the quality of the coo...

Page 11: ...ss line for reheating or cooling 1 A B C If the process temperature is below the set point the heater elements inside the heater tank are energized E F 4 The pump moves water from the mixing tank to t...

Page 12: ...ured before and after the pump E F The temperature of the process fluid is measured as it flows into the cooling tank through the From Process line 2 B 3a If the temperature is above the setpoint valu...

Page 13: ...unit through the From Process line for reheating or cooling 1 A B C D If the process temperature is below the setpoint the heater elements inside the heater tank are energized E 4 The pump moves water...

Page 14: ...kW 208 230 460 575 C D A B C D Dimensions and performance characteristics vary according to the model voltage and components selected See the cabinet style reference chart to determine dimensional in...

Page 15: ...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...

Page 16: ...Add an audible or visual alarm to call attention to alarm conditions Motorized Cooling Valve Slow open close cycle time eliminates ther mal shock and water hammer from your process circuit Compressed...

Page 17: ...Controls 3 8 l TW Control Initial Setup 3 9 l TW Control Changing Temperature Units 3 10 l TW 1 TW 2 Control Initial Setup 3 11 l TW 1 TW 2 Control Changing Temperature Units 3 12 l TW 1 TW 2 Control...

Page 18: ...e 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...

Page 19: ...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 r A source of water for cooling City tower or chiller water m...

Page 20: ...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 w...

Page 21: ...let of the Thermolator 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...

Page 22: ...grounding mount If you have installed a discon nect device follow the manufacturer s wiring instructions 1 2 3 4 5 CONNECTING THE MAIN POWER SUPPLY 3 6 INSTALLATION WARNING Electrical shock hazard Th...

Page 23: ...pump is active for the final half of the sequence Indicator lights energize when the device is active u Normal operation begins The heater turns on if the actual temperature is below setpoint The coo...

Page 24: ...and the actual temperature Check the rotation of the pump Remove the top access panel and the pump motor drip cover Press the Run button until the pump starts Quickly press Pump Stop button verify th...

Page 25: ...tivi ty buttons being pushed The first screen is the process vari able This is a user selectable parameter and could be the to process from process or an average temperature The rest of the variables...

Page 26: ...figuration page UN is displayed Press Enter again to show C or F Toggle between the up down to select your desired units Press Enter to accept the units The Temperature units parameter allows selecti...

Page 27: ...able the Test Mode r Select the source point of tempera ture control To change the dip switch settings see the appropriate topic on the following pages 8 7 6 5 4 3 2 1 Dipswitch Configuration No OFF O...

Page 28: ...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 ele...

Page 29: ...st time passcode protec tion 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 C...

Page 30: ...t dip switch 3 to OFF Close the electrical enclosure and restore power to the unit A passcode now is required to change system parameters 7 8 8 7 6 5 4 3 2 1 9 10 11 Disabling Passcode Protection To d...

Page 31: ...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 rest...

Page 32: ...t 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 pow...

Page 33: ...narrower or wider acceptable temperature band for nor mal operation To change the temperature deviation settings Press the Setpoint Select button to select the deviation para meter you want to change...

Page 34: ...r 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 t...

Page 35: ...enclosure and restore power to the unit When Auto Start is enabled u The Auto Start indicator light flashes to indicate that the Thermolator can start at any time The Thermolator will start whenever...

Page 36: ...and 50 foot 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 mo...

Page 37: ...the TW 4 6 l Stopping the TW 4 7 l Starting the TW 1 TW 2 4 8 l Stopping the TW 1 TW 2 4 9 l Using the TW Manual Purge Option 4 10 l Using the TW 1 Manual Purge Option 4 11 l Using the TW 2 Purge Feat...

Page 38: ...on Decreases values and steps down through menus Display 3 digit screen shows Process temperature Alpha Alarms and Operation indicators Indicator light shows hot gas unloading Alarm Codes Informs user...

Page 39: ...ning the Thermolator The controller has three pre configured tuning parameter sets one of which should allow optimum temperature control Control Used to select parameters associated with control metho...

Page 40: ...y shows 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 c...

Page 41: ...lculated 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 Installation section 3 for instruct...

Page 42: ...hold START until the vent cycle begins If everything is working correctly u The Cooling indicator lights u The unit initiates a variable venting sequence The pump starts after the vent time 1 is over...

Page 43: ...hut down the unit to change water hookups Cool Unit to Less than 100 F Press Stop Start Shut off the cooling water supply and drain the unit of all fluid Use the two drain plugs on the back of the uni...

Page 44: ...t 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 Pres...

Page 45: ...e 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 do...

Page 46: ...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 Stop Start to stop the Thermolator Shut off the cooling water s...

Page 47: ...Thermolator u The RUN STOP LED turns red Shut off the cooling water supply to the unit Turn the manual purge switch to the ON position to start purging u The Purge Valve LED lights u The Vent and Cool...

Page 48: ...OP light turns red Shut off the cooling water supply to the unit Press to open the valve and start purging u The Purge Valve LED lights u The Vent and Cool outputs are activated u The STOP and RUN but...

Page 49: ...ortional band is 10 F NOTE Normal parame ter is the factory default setting Fast Responding System Select the fast setting FSt for small systems Less than 80 pounds of water 10 gallons and 1 000 pound...

Page 50: ...and the control displays the At ti error r 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 whi...

Page 51: ...sage 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...

Page 52: ...5 seconds The control will display 1 PaS to indicate a passcode is needed Press the Select s button until the correct passcode appears in the display Press again to enter the passcode If the passcode...

Page 53: ...st 5 7 l TW 1 TW 2 Control Output Test 5 8 l TW 1 TW 2 Control Disabling or Enabling Output Monitors 5 9 l TW 1 TW 2 Control Calibrating Temperature Sensors 5 10 l TW 1 TW 2 Control Logging Operating...

Page 54: ...he 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 r Check the process fluid le...

Page 55: ...u can also calibrate the supply and return thermo couples See Performing System Tests Section 5 WARNING Electrical shock and hot surface hazards Before attempting maintenance of any kind on the Thermo...

Page 56: ...ort 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...

Page 57: ...l displays tSt u The Test Mode LED lights Press any button to display the first test menu Test mode provides the following menus l Key Display Test l Input Test l Output Test l Calibration l Total Ope...

Page 58: ...l 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 indica...

Page 59: ...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 tested v1 v...

Page 60: ...st menu until 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...

Page 61: ...the actual display and the status of the selected output in the Select display Press the Setpoint s or t key to change the status Each press of the key changes the output status from ON to OFF or OFF...

Page 62: ...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 th...

Page 63: ...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 next t...

Page 64: ...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...

Page 65: ...characteristics of the pulse in Thermolator Direct Injection Model s Pulse Mode To access the Pulse Mode Setup Follow Steps 1 through 7 in Test mode until P Cy displays on the Actual screen This is t...

Page 66: ...5 minute increments TW DEVIATION ALARM BAND AND DELAY Parameter Alarm Delay Time Deviation Band Low Limit 1 0 second 1 F High Limit 1800 seconds 45 F Default Value 600 seconds 20 F Thermolator TW Ser...

Page 67: ...ized for the VT2 time To access the Vent Timer setups Press and hold the enter key till Uni is shown on screen Press the down key till VT1 is shown on screen Press the enter key to display the value 1...

Page 68: ...Thermolator TW Series UGH025 0504 5 16 MAINTENANCE...

Page 69: ...System Alarms 6 16 l Thermolator Will Not Power Up 6 17 l Replacing the TW Control 6 18 l Checking and Replacing Fuses 6 19 l Resetting Overloads 6 20 l Replacing Pump Overload 6 20 l Replacing the Mo...

Page 70: ...over 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 neve...

Page 71: ...or error messages to help determine the cause of the problem Find the alarm or error code in the diagnostics tables in this section of the User Guide Causes are listed in the order of most likely to...

Page 72: ...Thermolator control detects a problem the red Alarm light is activated and the RUN STOP light changes from green to flashing red IDENTIFYING THE CAUSE OF A PROBLEM FOR THE TW 1 TW 2 CONTROL WARNING Di...

Page 73: ...than the setpoint temper ature The actual temperature of the process fluid is more than 10 F lower than the setpoint temper ature Solution r Verify that the unit is run ning and that the pump is worki...

Page 74: ...cooling valve fail to close The temperature differ ence between the cooling water supply and the set point is too small A heater contactor failed to close The cooling valve under sized for the applica...

Page 75: ...r contactor failed to open The deviation tempera ture band is too narrow The Thermolator is under sized for the application Solution Disassemble the cooling valve and check for particles block ing the...

Page 76: ...ter flow is greater than the pump s capacity The motor overload is faulty or set incorrectly The pump is not working properly Solution Verify that the water supply is on and delivering water at a pres...

Page 77: ...between the supply and return The heater contactor failed Solution r Verify that the unit is running and that the pump is work ing r Check for closed or defective cooling or vent valves and plugged l...

Page 78: ...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 Motorized Cooling Valves Section 6 S...

Page 79: ...SSR 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 lockout the main power source Open...

Page 80: ...eating element or a heater contactor that failed in the open position See Replacing the Heater Contactor and Replacing Heater Elements Section 6 Check for a loose thermocou ple or loose wire connectio...

Page 81: ...pe or closed valve Check the cooling valve See Repairing Solenoid Valves or Motorized Cooling Valves Section 6 The temperature difference should be at least 25 F to achieve proper cooling Increase the...

Page 82: ...t See Repairing Solenoid Valves Section 6 With the unit powered down Check for loose connections Check resistance between the phases on the output side of the heater contactor Readings should be withi...

Page 83: ...f 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 r Check the network address The address may be set to any num...

Page 84: ...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 p...

Page 85: ...that the main power supply and any customer installed electrical discon nect or emergency stop devices are in the ON posi tion r Verify correct electrical con nections between the unit and the control...

Page 86: ...e Thermolator TW slides in and out of its casing for easy replacement Disconnect and lockout the main power Unscrew the nuts and then remove the control metal Disconnect connectors on back of controll...

Page 87: ...g used for this fuse location See Disabling or Enabling Output Monitors Section 5 1 2 3 4 1 2 3 4 5 6 7 8 CONFIGURATION DIP SWITCH OFF ON 4 3 2 1 4 3 2 1 UNLDR 1 VENT 2 SOL UNLDR 1 VENT 2 SOL UNLDR 2...

Page 88: ...at connect the overload module to the motor con tactor 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...

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

Page 90: ...es from the heater 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 old c...

Page 91: ...the leads Refer to the wiring diagrams that came with your unit Restart the Thermolator u If error message disappears replace the thermocouple u If error message does not disappear replace the moth e...

Page 92: ...93 80 27 1103 85 29 1115 90 32 1125 95 35 1136 100 38 1146 If you receive a sensor failure SF2 a possible cause may be the process temperature sensor failed Check with OHM meter and see if the resista...

Page 93: ...the top and side panels of the Thermolator Lift the top panel straight up then lift the side panels up Remove the cooling valve from the cooling water out line Disassemble the cooling valve See Repair...

Page 94: ...e Kit Coil Insulating Washer Spring Washer Housing with Nameplate Alternate Construction with Nameplate on Housing Indicates Parts Supplied in Solenoid Enclosure Kit Cover Yoke 7 8 Dia Hole for 1 2 Co...

Page 95: ...plate with the R side facing up On MS40 703 mod els the rotation switch must be in the R position Align the actuator with the mount ing plate then slide the anti rotation clip half way into the slot o...

Page 96: ...supply and allow the unit to cool to less than 100 F 38 C 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 t...

Page 97: ...eed 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 Lift the heating...

Page 98: ...Lift the pump assembly straight up to remove The pump can now be replaced or disas sembled for repair Extra long leads so the motor can be removed with disconnecting the wires Reverse the steps to rea...

Page 99: ...apped seat face Remount the adapter to the motor making 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 100: ...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 o...

Page 101: ...sket or O ring between the pump assembly and volute case Check for free rotation after assembly is completed 9 NOTE Before restarting close all drain openings using sealant on the threads and and refi...

Page 102: ...Thermolator TW Series UGH025 0504 6 34 TROUBLESHOOTING...

Page 103: ...model control type and serial numbers from the serial tag and parts list numbers for your particular equipment Service personnel will need this information to assist you r Make sure power is supplied...

Page 104: ...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 105: ...UGH025 0504 Thermolator TW Series APPENDIX B 1 PUMP CURVES...

Page 106: ......

Page 107: ...0 2 180 F 0 1 100 C 10 F FSt Fast Proportional Prop Band 0 2 180 F 0 1 100 C 15 F db Dead Band 0 10 F 0 5 6 C 0 5 F CCt Cooling Cycle Time 0 60 seconds 7 seconds Ci Cooling Integral Time Period 0 999...

Page 108: ......

Page 109: ...rmolator Poll retrieves it 0x21 0x20 Version 0x20 Retrieves 4 bytes of SPI version information 0x22 Setpoint Process Temperature 0x20 0x20 Sets and retrieves the process temperature setpoint 0x31 0x30...

Page 110: ...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 l If a bit is...

Page 111: ...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 l If a bit is not shown to be SET it is cleared l T...

Page 112: ...ater 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 l If a bit is not s...

Page 113: ...PD 1 UGH025 0504 Thermolator TW Series l TW 1 Circuit Board PD 2 l TW 2 Circuit Board PD 3 PARTS DIAGRAMS...

Page 114: ...TW 1 CIRCUIT BOARD UGH025 0504 PD 2...

Page 115: ...UGH025 0504 TW 2 CIRCUIT BOARD PD 3...

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