Mokon Duratherm Instruction Manual Download Page 54

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Section 8 – Condensed Parts List

8.1

All Models:

Part No.

Description

006257

40 Amp Heater Contactor 110V Coil

006298

50 Amp Heater Contactor 110V Coil

006256

24 Amp Motor Contactor 110V Coil

006373

0.2 – 1.0 Amp Overload

006366

1.0 – 5.0 Amp Overload

006367

3.2 – 16 Amp Overload

006368

5.4 – 27 Amp Overload

006396

5.0 Amp Mini Motor Contactor

006400

0.9 – 1.3 Amp Overload

006401

1.1 – 1.6 Amp Overload

006402

1.4 – 2.0 Amp Overload

006403

1.8 – 2.5 Amp Overload

006404

2.3 – 3.2 Amp Overload

006405

3.5 – 4.8 Amp Overload

008005

0 – 160 PSI Pressure Gauge, Suction, and Discharge

022038

Start/Stop Button

022185

Purge Button

022187

Low Pressure Safety Switch

025183

Adjustable Relief Valve

040002

Thermocouple

Note: Motor starter contactor is dependent on model/date purchase

8.2

Duratherm Models:

DA, DB, DC, DD, DE, DF, DG, DH, DK, DL, DM, DN, DO, DP, DQ, DR, DT, DU, DV, DW, DX,
DY, DZ: (Refer to model code on serial tag then Section 9 for kW capacity and voltage)

011026

9 KW Heater Element 460V

011020

18 KW Heater Element 460V

011021

24 KW Heater Element 460V

011023

9 KW Heater Element 230V

011024

18 KW Heater Element 230V

011025

24 KW Heater Element 230V

011036

9 KW Heater Element 208V

011042

18 KW Heater Element 208V

011055

24 KW Heater Element 208V

011029

9 KW Heater Element 575V

011030

18 KW Heater Element 575V

011031

24 KW Heater Element 575V

011053

9 KW Heater Element 380V

011034

18 KW Heater Element 380V

011056

24 KW Heater Element 380V

019036

Heater Canister Gasket

023070

High Temperature Switch (Adjustable)

023090

High Temperature Switch (260°F Preset – Not Adjustable)

023096

High Temperature Switch (310°F Preset – Not Adjustable)

NOTE: For units built after 05/04/05

Summary of Contents for Duratherm

Page 1: ...000C 02 17 INSTRUCTION MANUAL Circulating Water Temperature Control System Models Covered Duratherm Hydrotherm II Minitherm 2150 Elmwood Avenue Buffalo NY 14207 P 716 876 9951 F 716 874 8048 www mokon...

Page 2: ...5 Section 3 Operation 6 3 1 Initial Starting Procedure 6 3 2 Process Flow Adjustment 6 3 3 Changing Temperature Settings 7 3 4 Shut Down Procedure 7 3 5 Restarting Procedure 7 Section 4 Maintenance a...

Page 3: ...Tuning 35 5 3 Troubleshooting 37 5 4 Alarm Indicators 37 To Acknowledge an Alarm 37 5 6 Restarting the Automatic Air Purge Timer After Start Up 39 5 7 Manual Air Purge Operation After Start Up 39 5 8...

Page 4: ...ensed Parts List 49 8 1 All Models 49 8 2 Duratherm Models 49 8 3 Minitherm Models 50 8 4 Hydrotherm II Models 50 Section 9 Model Codes 51 9 1 Duratherm Model Codes 52 9 2 Minitherm Model Codes 53 9 3...

Page 5: ...ss Electrical wiring completed and disconnect sized and installed per code and compliance Motor rotation verified motor s bumped Verify any remote control wiring is complete Mechanical Inspection Mech...

Page 6: ...SURFACE MAY BE HOT HIGH TEMPERATURE When it is seen on the following pages of this manual care should be taken to avoid possible burns All maintenance and service must be performed with the system com...

Page 7: ...aution Equipment supplied with a safety door disconnect is design rated for a short circuit current rating SCCR of 5 000 amperes RMS if protected with a class RK5 fuse and equipment supplied with a po...

Page 8: ...not tip After removing from pallet the system should only be placed on a level surface 2 2 Location Mokon systems should be located in an area that provides adequate space for pedestrian and vehicle t...

Page 9: ...cal information and schematic drawing number 2 4 Electrical Connections Warning The Mokon temperature control system as with all high voltage electrical equipment should be connected according to all...

Page 10: ...e control system for the reasons outlined above The pressure regulator if included on system as an option is set at the factory for suitable operation of the Mokon temperature control For systems with...

Page 11: ...either lengthen or shorten this timed cycle Please refer to Sections 5 5 and 5 6 for additional information on the automatic air purge feature Set the controller to the desired temperature The system...

Page 12: ...r amps as displayed on the amp meter until the actual motor amps equal the listed full load amp rating of the motor The process flow is correctly adjusted The valve should remain in this position duri...

Page 13: ...h a procedure Electrical Danger High Temperature Surface May Be Hot High Voltage Hot Surface 4 1 Preventative Maintenance Mokon temperature control systems are designed for a long trouble free service...

Page 14: ...m warranty will be void Monthly Checks Corrective Procedures Check that the high temperature switch TS has a set of N O and N C contacts and it is properly wired Replace the switch if necessary Check...

Page 15: ...ing Check for plumbing leaks Repair solder joints Replace necessary parts if leaks persist Visually check all threaded fittings for signs of leakage Tighten with proper tooling Replace necessary parts...

Page 16: ...is energizing Replace solenoid valve if necessary Check the controller calibration by setting the controller for three random setpoints within the operating range of the system Observe that the proces...

Page 17: ...t heater wiring Verify customer supply voltage is balanced and fluctuations are within 15 of nominal Replace elements if necessary Check that the Warning High Voltage Caution and lamicoid labeling are...

Page 18: ...NPT 018266 1 CASE 1 25 X 1 NPT 018268 1 CASE 1 5 x 1 25 NPT 018267 2 1 IMPELLER 4 88 STAINLESS 018275 1 IMPELLER 5 25 STAINLESS 018276 1 IMPELLER 6 3 STAINLESS 018277 1 IMPELLER 6 3 STAINLESS 018342 4...

Page 19: ...INLESS 018275 1 IMPELLER 4 0 STAINLESS 018498 1 IMPELLER 5 75 STAINLESS 018497 1 IMPELLER 6 3 STAINLESS 018277 1 IMPELLER 6 3 STAINLESS 018342 4 1 MOTOR 56J CONSULT FACTORY 11 1 COVER STAINLESS 018269...

Page 20: ...fficient antifreeze Seal Replacement Disassembly Turn off power Close suction and discharge valves if equipped Drain pump Remove bolts holding base to foundation Remove casing bolts Remove motor and r...

Page 21: ...y procedure then thread impeller on shaft until it is tight against the shaft shoulder The impeller will compress the seal spring to the proper length assuring correct pressure on lapped faces Replace...

Page 22: ...00 ODP Contact Factory 1 MOTOR 10 0 HP 3 60 208 230 460 3500 ODP Contact Factory 11 1 COVER 018312 14 1 SHAFT SLEEVE 018313 26 1 IMPELLER RETAINER 018314 32 1 KEY 018315 38 1 SHAFT O RING 018316 40 1...

Page 23: ...n operation or add sufficient antifreeze Seal Replacement Disassembly Turn off power Close suction and discharge valves if equipped Drain pump Remove bolts holding down pump to mounting plate Remove p...

Page 24: ...inst the lapped face of the stationary seat Do not chip or scratch faces during installation Take extra care to make sure the lapped faces are clean Install the seal spring on the seal head and retain...

Page 25: ...1 S S 034009 4 1 SHAFT DRIVE SLEEVE S S 034006 5 1 DRIVE CLAMP ASSEMBLY 034020 6 1 MOTOR 56 C FRAME Contact Factory 7 1 HOUSING 1 X 3 4 034021 HOUSING 034027 8 2 PIPE PLUG GUAGE PORT 017043 9 1 HEX J...

Page 26: ...a subject to freezing temperatures the pump must be drained when not in operation or add sufficient antifreeze Seal Replacement Disassembly Turn off the electric power and the water supply to the syst...

Page 27: ...h soapy water Lubricate the seal seat gasket with soapy water Use a wood dowel of sufficient diameter to press the seal seat squarely into cavity on pump frame HAND PRESSURE ONLY Note Polished metal s...

Page 28: ...s DB DC DF DG DT DL under Section 4 2 Pump Maintenance for seal replacement Impeller Clearance Adjustment Impeller face and back clearances are not critical The impeller must be adjusted axially so th...

Page 29: ...460 3500 ODP Consult Factory MOTOR 7 5 HP 3 60 208 230 460 3500 ODP Consult Factory MOTOR 10 HP 3 60 208 230 460 3500 ODP Consult Factory 14 1 SHAFT SLEEVE 018324 25 1 WEAR RING 50 018325 WEAR RING 52...

Page 30: ...ned when not in operation or add sufficient antifreeze Seal Replacement Disassembly Turn off power Close suction and discharge valves if equipped Drain pump Remove bolts holding base to foundation Rem...

Page 31: ...kit to the stub shaft and the rubber bellows of the rotary seal Slide the seal head on the stub press the rubber drive band on the rotary head until the lapped face the head seats firmly against the l...

Page 32: ...4 5 1 SEAL ASSEMBLY SILCONE CARBIDE SEE NOTE BELOW 034113 6 1 IMPELLER SHIM SET 034112 7 1 IMPELLER 034111 8 1 013 O RING VITON 034110 9 1 7 16 20 ACORN NUT 034109 10 1 243 O RING 034108 11 1 CASING 0...

Page 33: ...antifreeze Seal Replacement Disassembly Should the mechanical seal which consists of seal seat Ref 5a and seal head Ref 5b require replacement proceed as follows and refer to Figure 1 Important Always...

Page 34: ...crewing the impeller nut into place Reassemble the pump A short run in period may be necessary to provide completely leak proof seal operation Shim Adjustment When installing a replacement impeller Re...

Page 35: ...eed cleaning or replacement o To Clean Remove the adjust stem spring and piston Clean any debris from the seat and the piston then reassemble the pressure relief valve o To Replace Remove the pressure...

Page 36: ...31 4 6 Heater Assembly Models DA DB DC DD DE DF DG DH DJ DK DL DM DN DO DP DQ DR DT DU DV DW DX DY DZ ACCESS PLATE BUNDLE WIRES INSDE S S DIVERTER...

Page 37: ...elements of the new heater bundle as follows see figure to the right o Locate the N stamped on the lead end of the heater bundle o Set the heater bundle upright on the lead end with the N facing righ...

Page 38: ...lowing chart to select between wiring method A and B to wire MOKON replacement heaters dual element hair pin type Refer to the MOKON system electrical schematic for complete heater wiring illustration...

Page 39: ...st Navigation To step through list levels press and hold the Page button until level 1 is obtained Press the up button or the down button to change levels To step through parameters within a particula...

Page 40: ...setting the value of the parameters listed in the table below The PID controller consists of the following parameters Button or Indicator Name Explanation OP1 Output 1 When lit it indicates that heati...

Page 41: ...rom the amplitude and period of the oscillation it calculates the tuning parameter values If the process cannot tolerate full heating or cooling being applied then the levels can be restricted by sett...

Page 42: ...error and contact your supplier E Lin Invalid input type This refers to custom linearization which may not have been applied corrector or may have been corrupted Go to the INPUT list in configuration...

Page 43: ...Auto Air Purge OP4 and Run will illuminate on the controller The system should automatically be purged of air at the end of the five 5 minute timer If pressure gauges are still erratic or air appears...

Page 44: ...acon RUN Off OP4 Off 5 7 Manual Air Purge Operation After Start Up There is a manual purge button that can be used after the Automatic Air Purge time has expired This is a momentary push button 5 8 Re...

Page 45: ...pring washer and slip ring Grasp stem nut with fingers or pliers and lift module from body Replace module and reassemble valve Readjust pressure setting Adjustment To adjust the pressure setting loose...

Page 46: ...upply Tank Remove the fill port plug for the supply tank located on top of the system Note Do not add air into the tank until step 7 Fill supply tank to the top of the sight glass with fluid With cont...

Page 47: ...ts minimum setting of 0 15 inches of water A green pilot light will illuminate once the relay has timed out indicating it is safe to operate the unit The magnehelic gauge has a scale of 0 to 5 inches...

Page 48: ...n the mold or in the process the built in push pull system permits stable temperature control without interrupting production Through the use of the vacuum adjusting valve the push pull system makes i...

Page 49: ...he vacuum adjust valve in the full vacuum position as this position allows no flow to the process Process control could be lost Note If a tool mold has a leak the to from process lines should be adjus...

Page 50: ...clockwise to increase time and counter clockwise to decrease time To determine the proper setting Heat the machine up to operating temperature Once you reach operating temperature turn the set point d...

Page 51: ...actory Safety shut down Consult factory Open winding in pump motor Check motor windings with an OHM meter if open reading replace motor Refer to possible causes and corrective measures for Problem 1 D...

Page 52: ...cal connections Tighten connection or replace broken wires Thermocouple or RTD Inspect replace component Controller calibration See Controller Section 5 Variance in temperature readings Plugged flow p...

Page 53: ...RTD Inspect replace component Controller calibration See Controller Section 5 Noisy pump System at end of long feeder line Install another source line Entrapped air Press purge button Cooling solenoid...

Page 54: ...is dependent on model date purchase 8 2 Duratherm Models DA DB DC DD DE DF DG DH DK DL DM DN DO DP DQ DR DT DU DV DW DX DY DZ Refer to model code on serial tag then Section 9 for kW capacity and volta...

Page 55: ...Hydrotherm II Models Models HN HR HW HX HY HZ Refer to model code on serial tag then Section 9 for kW capacity and voltage 011043 2 25 KW Copper Immersion Heater 230V and 460V 011088 3 KW Copper Imme...

Page 56: ...51 Section 9 Model Codes See Following Pages...

Page 57: ...Closed Circuit D HTP 7 5 HP 100 GPM 300 o F Max 8 Obsolete A HTP 10 HP 120 GPM 300 o F Max 9 Obsolete G Dual Zone HTP 1 1 2 HP 25 GPM 300 o F Max 0 Eurotherm 1 16 DIN Open Circuit J Dual Zone HTP 2 HP...

Page 58: ...olts 3 Phase 60 Hertz J Obsolete 8 Not used 3 Eurotherm 1 4 or 1 8 DIN Open Circuit 9 Special Voltage see option code 4 Eurotherm 1 4 or 1 8 DIN Closed Circuit 10 400 Volts 3 phase 50 Hertz 5 Eurother...

Page 59: ...cuit 5 575 Volts 3 Phase 60 Hertz D Special Closed Circuit 6 415 Volts 3 Phase 50 Hertz H Obsolete 7 208 Volts 3 Phase 60 Hertz J Obsolete 8 Not Used 3 Eurotherm 1 4 or 1 8 DIN Open Circuit 9 Special...

Page 60: ...for a period of 3 years from the date of shipment limited to the original customer Microprocessor Controllers with Special Features are covered for three 3 years Solid State controllers are covered f...

Page 61: ...and fitness for a particular purpose Mokon shall in no event be liable for any consequential damages or for any breach of warranty in an amount exceeding the original price of the unit Mokon s product...

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