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Temptek G-500 Series, Instruction Manual

Introducing the Temptek G-500 Series—a breakthrough in cutting-edge technology. Enhance your user experience with our high-performance industrial equipment. Find comprehensive instructions in the free downloadable Instruction Manual available exclusively on manualshive.com. Unlock the full potential of your product with this essential manual, designed to simplify your operations.

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Summary of Contents for G-500 Series

Page 1: ...AINTENANCE Model Serial Number TEMPTEK INC 525 East Stop 18 Road Greenwood IN 46142 317 887 6352 fax 317 881 1277 Service Department fax 317 885 8683 www Temptek com E mail sales Temptek com Temperature Controller Oil Unit For Models with the G500 Series Control Instrument ...

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Page 3: ...strument COVERING INSTALLATION OPERATION MAINTENANCE TEMPTEK INC 525 East Stop 18 Road Greenwood IN 46143 Phone 317 887 6352 Fax 317 881 1277 Service Department fax 317 885 8683 www Temptek com E mail sales Temptek com Temperature Controller Oil Unit ...

Page 4: ...trument Basic Navigation 25 3 5 Instrument Operating Screens 26 3 6 Instrument Fault Screens 27 3 7 Instrument Main Menu 28 3 8 Instrument Setpoints Menu 28 3 9 Instrument Utilities Menu 29 3 10 Instrument Network Menu 30 3 11 Instrument Options Menu 32 3 12 Instrument Machine Menu 32 3 13 Shut Down Disconnect 33 4 0 TROUBLESHOOTING 35 4 1 Unit will not start Display is not Illuminated 36 4 2 Unit...

Page 5: ...m 6 0 COMPONENTS 49 6 1 Mechanical system 50 6 2 Electrical system 50 7 0 RELATED DRAWINGS 53 7 1 Physical 12 kW Heaters 1 3 HP Pumps 54 7 2 Physical 16 24 kW Heaters 1 3 HP Pumps 55 7 3 Physical 36 48 kW Heaters 5 7 5 HP Pumps 56 7 4 Circuit Schematic with Cooling Circuit 57 8 0 APPENDIX 59 8 1 Model And Suffix Coding 60 8 2 Water Cooled Process Pumps 61 8 3 Mold Purge Operation 62 ...

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Page 7: ...ies with G500 Series Instrument Page 7 TEMPTEK INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Email service Temptek com 1 0 GENERAL 1 1 Receiving Instructions 1 2 Introduction 1 3 Safety 1 4 Components ...

Page 8: ...pment 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 unit purchased C When calling for...

Page 9: ...vice this equipment E 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 F Before installing 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 dan...

Page 10: ...6352 Fax 317 881 1277 Email service Temptek com 1 4 COMPONENTS WARNING Improper fluid quality will void unit warranty From Process Valve and Connection Process Pump Fluid Drain Valve Water Drain Connection Water Supply Connection To Process Valve and Connection Sight Glass Heat Cylinder Expansion Tank Typical unit with lift off cabinetry ...

Page 11: ...d Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Email service Temptek com From Process Valve and Connection Process Pump Fluid Drain Valve Water Drain Connection Water Supply Connection To Process Valve and Connection Sight Glass Heat Cylinder Expansion Tank Typical unit with clam shell cabinetry ...

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Page 13: ...t Page 13 TEMPTEK INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Email service Temptek 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: ...ice avoid tight twists or curls and excessive lengths 2 3 WATER SUPPLY CONNECTION A Connect the unit s Water Supply port to the plant s city water well water tower water or chilled water supply B If unit is a Heating Only Unit the water supply must be a minimum of 1 2 GPM at a maximum temperature of 100 F for efficient component cooling If the unit is a Heating and Cooling Unit including a heat ex...

Page 15: ...controlled by the solenoid valve 2 A 1 2 ball valve is placed in the heat exchanger water supply line after the solenoid valve The ball valve should be open during operations from 100 F to 200 F During operations with temperatures over 200 F this valve should be closed In such cases the necessary cooling water is proportioned to the heat exchanger through the small capillary line which some water ...

Page 16: ...e a significant hazard that may result in serious personal injury and or unit damage 2 For standard units with 12 kW heaters and up to 3 horsepower pumps a four conductor cable 10 foot in length is provided for connection to an operator supplied fused disconnect 3 For units with 16 kW to 48 kW heaters the owner must provide a four conductor power cable and the fused disconnect 4 The owner supplied...

Page 17: ...ply entry terminal block C Control Circuit Wiring 1 The unit s supplied control circuit is 110 volt 1 phase 60 cycle The control circuit is supplied by the factory installed transformer A control circuit fuse is provided D General 1 Make certain all ground connections to the unit are properly affixed A proper connection to earth ground is required A conduit ground is not a reliable conductor 2 Mak...

Page 18: ... Typical Electrical Panel shown as reference of a RK 1230H model Refer to the electrical drawing available for specific model A B C D E F G H I A High temperature limit Factory set to 515 F B High temperature limit instrument relay C Power entry terminal block D Motor starter and overload block E Transformer fuses F Control transformer G Heater contactors H Water supply pressure switch I Power Cor...

Page 19: ... 1 General 3 2 Machine Start Up and Operation 3 3 Instrument Operation Quick Start 3 4 Instrument Basic Navigation 3 5 Instrument Operating Screens 3 6 Instrument Fault Screens 3 7 Instrument Main Menu 3 8 Instrument Setpoints Menu 3 9 Instrument Utilities Menu 3 10 Instrument Network Menu 3 11 Instrument Features Menu 3 12 Instrument Options Menu 3 13 Instrument Machine Menu 3 14 Shut Down Discon...

Page 20: ...disconnection from the system 3 2 MACHINE START UP AND OPERATION A System Fill 1 Use only approve high temperature heat transfer fluids in this unit such as Paratherm NF or an equivalent fluid www paratherm com Never use water in this unit List of Approved Heat Transfer Fluids Paratherm OR https www paratherm com heat transfer fluids paratherm or heat transfer fluid Paratherm NF https www parather...

Page 21: ...illuminate b 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 inside the electric motor housing The motor shaft can be seen through the vent slots in the motor housing or by removing the shaf...

Page 22: ...op Generally higher flow rates result in turbulent flow achieving maximum temperature control and lower maintenance b If the flow rate exceeds the motor horsepower capacity the electric motor will draw excessive amps This is a result of the process loop s ability to flow fluid at a greater rate than can be provided by the pump This will eventually result in tripping the motor overload relay overlo...

Page 23: ...art the unit f The amp meter will display the motor amps Compare the actual motor amps as displayed on the amp meter to the full load amp rating as listed on the motor name plate g If the amp draw is excessive higher than the listed name plate amp rating a throttling valve must be installed in the from process line The throttling valve can be a gate valve or a ball valve h With the throttling valv...

Page 24: ...s unit features an LCD screen Use the five soft touch buttons to navigate the available screens and select parameters 3 A System Safety Fault may prevent startup Probe water supply pressure pump overload or high temperature limit may display once power is applied and must be corrected prior to operation 4 Adjust the setpoint to the desired value by pressing the Increment or Decrement buttons Power...

Page 25: ...rough a series of screens or save a value 5 The Back button when pressed will go backwards through a series of screens B Prompts on Selection Screens Selection screens display a menu of selectable items 1 The Up button will scroll up through the menu items The screen indicators will scroll along with the pressing of the button 2 The Down button will scroll down through the menu items The screen in...

Page 26: ...screen E Screen Indicators 1 Small indication triangles are used as on screen pointers 2 The horizontal indicators point to the current selection By pressing the Go button the screen advances to that selection 3 The vertical indicator shows that some menu items are not currently shown on the screen By pressing the Down button the menu will scroll down to display the menu items not currently visibl...

Page 27: ...l not start or run if the motor overload is tripped During operations this error is triggered by excessive flow causing the pump to draw more amps then it is rated for A throttling valve should be placed in the from process line to control flow 2 High Temp If process temperature exceed 515 F the high temperature limit switch opens and the unit shuts down High temperature conditions are generally c...

Page 28: ...u item the values for the Process Setpoint Hi Deviation Low Deviation can be set or changed B Process Setpoint Use the Up or Down buttons to change the process setpoint 1 The Setpoint range is from 100 F to 500 F Please note the unit can not reduce process temperature below the provided water supply temperature 2 Once acknowledged the unit will control to the new setpoint temperature Press the Bac...

Page 29: ...emperature cools to 195 F 1 The factory default is 10 The range for the Lo Deviation is from 0 F 50 F 2 Once acknowledged press the Back button repeatedly to return to the Setpoints screen or press the home button to return to the Home screen 3 9 INSTRUMENT UTILITIES MENU A Items in the Utilities menu include the operations for the Software Version Display Test and Display Sensors B Software Versi...

Page 30: ... Sensors Not active on this unit 3 10 INSTRUMENT NETWORK MENU A Items in the Network menu include Protocol Address and Baud Rate B Protocol This is the data format for communication between the unit and the host computer Available values are SPI CCP Modbus RTU CAMAC Network Baud Rate Address Protocol Back Pick Go Setpoints Utilites Network Features Machine Back Pick Go Main Menu Setpoints Utilites...

Page 31: ...3 Press the Select button to save the selection and confirm success D Address This is the number assigned to the unit in a network 1 Press the Select button to select Address 2 Use the Up and Down arrow keys to select the address for this unit The factory default is 1 The selection range is from 1 10 3 Press the Select button to save the address and confirm success 3 11 INSTRUMENT OPTIONS MENU A O...

Page 32: ...be changed above a certain temperature The Maximum Setpoint can never exceed 500 F in the unit 1 Use the Up or Down arrow keys to select the Max Setpoint and then press the Select button to save and confirm success 2 The value range for the Max Setpoint is 100 F to 500 F The factory default is 500 F C Units This screen controls how the temperature is displayed The options are English Options Remot...

Page 33: ...t exchanger for cooling 1 Use the Up or Down arrow keys to select the Heat Only Mode and then press the Select button to save and confirm success 2 The factory default value is Disabled 3 14 SHUT DOWN DISCONNECT A UNIT SHUT DOWN 1 Decrease the setpoint temperature lower than 100 F and allow the unit to cool to the temperature 2 Press the stop button 3 Relieve residual static pressure before discon...

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Page 35: ...op 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Email service Temptek 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 Water Pressure Relief Valve Leaks ...

Page 36: ...ult System Safety screen The electric motor is protected from overload conditions by a set of thermal overload relays These relays will open trip If the overload relay is open it must be reset before operation can continue An excessive flow condition must be isolated and corrected immediately 3 High temperature limit switch open The display shows a Fault System Safety screen The unit is prevented ...

Page 37: ...upply and water drain to achieve full cooling capacity is 20 PSI The minimum water supply pressure is 20 PSI 2 Cooling valve defective On units with the cooling heat exchanger the instrument opens and closes the 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 ...

Page 38: ...oling valve should be repaired immediately 2 More flow than necessary being supplied to pump seal cooling Throttle pump seal cooling to 1 2 GPM at 100 F maximum temperature 3 Heater element failure A failed heater element will not input adequate heat into the process to elevate the process water temperature The operator must check the amps at the heater contactor with the contactor energized Zero ...

Page 39: ...supply line If a back flow prevention device check valve pressure regulator closed valve is installed in the water supply line increased pressures from thermal expansion are unable to move into the water supply line This will increase the unit s internal pressure causing the pressure relief valve to leak 2 Valve contamination The pressure relief valve may become contaminated with water debris caus...

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Page 41: ...d Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Email service Temptek com 5 0 SERVICE MAINTENANCE 5 1 Preventative Maintenance 5 2 Pump Seal Replacement 5 3 Heater Replacement 5 4 Cooling Valve Service 5 5 Voltage Change 5 6 Pressure Switch Service 5 7 Electronic Instrument Repair Policy Procedure ...

Page 42: ...ing connections 3 Descale water cooling channels in the pump seal cooling adapter 4 Descale water cooling channels in the heat exchanger if installed 5 Check process fluid for degradation The operating conditions affects the usable life of the process fluid Most heat transfer fluid manufacturers have an analysis program where a sample of process fluid can be sent to the manufacturer to determine w...

Page 43: ...r should map the wire terminal locations to ensure correct rewiring The power cord should be removed from the motor housing 6 Locate and remove the 4 pump casing bolts These bolts secure the motor and motor adapter to the pump casing 7 Separate the motor and adapter from the pump casing to expose the pump impeller Remove the motor and adapter from the unit and place on a workbench to continue the ...

Page 44: ...reinstalling the impeller Be certain the spring and rotating member are aligned before the impeller is fully tightened and the impeller retaining screw is reinstalled 16 Clean the pump casing cavities impeller and O ring before reassembly 17 Mate the motor and adapter to the pump casing Reinstall the 4 pump casing bolts 18 Reconnect the motor power cord and leads E When this procedure is complete ...

Page 45: ...s 3 Remove the 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 6 Disconnect the three power leads from the heater terminals Remove the power cord from the junction box 7 Remove the heater moun...

Page 46: ...se a pair of channel lock pliers or a pipe wrench to separate the bonnet assembly from the valve body The plunger is loose inside the enclosing tube Be certain it is retained in the enclosure tube as the bonnet is removed 6 Identify the diaphragm assembly Gently remove the assembly from the valve body 7 Identify the mesh screen Gently remove the mesh screen and clean or replace as necessary 8 Clea...

Page 47: ...n 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 must be removed 5 Remove the electrical connections to the press...

Page 48: ...edit If the defective instrument is not returned you 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 Pu...

Page 49: ...nit VTO Series with G500 Series Instrument Page 49 TEMPTEK INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Email service Temptek com 6 0 COMPONENTS 6 1 Mechanical System 6 2 Electrical System ...

Page 50: ...prevents water leakage from the pump adapter The seal is made up of three items The stationary member seated in the seal cavity the rotating member placed on the motor shaft and the tension spring B HEATER The heater is a single voltage flange mounted immersion heater set in the pump discharge cylinder The heater elements have a stainless steel sheath Electrical supply to the heater is provided vi...

Page 51: ...is a mechanical style contactor On command from the instrument the contactor will close and voltage will be supplied to the heater The contactor use should be monitored and the contactor should be replaced as needed based on duty cycle Some units are provided with a solid state contactor rather than the standard mechanical contactor E PRESSURE SWITCH The water pressure switch will close when suffi...

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Page 53: ...ast Stop 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Email service Temptek com 7 0 RELATED DRAWINGS 7 1 Physical 12 27 kW Heaters 1 3 HP Pumps 7 2 Physical 16 24 kW Heaters 1 3 HP Pumps 7 3 Physical 27 48 kW Heaters 5 7 5 HP Pumps 7 4 Circuit Schematic with Cooling Circuit ...

Page 54: ... East Stop 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Email service Temptek com 7 1 PHYSICAL 12 KW HEATERS 1 3 HP PUMPS SERIES TM R ERROR STATUS TEMPERATURE 24 40 TEMPERATURE STATUS ERROR 16 PRESSURE TO PROCESS TO PROCESS FROM PROCESS OIL WATER WATER SUPPLY DRAIN DRAIN ...

Page 55: ...ontrol Unit VTO Series with G500 Series Instrument Page 55 TEMPTEK INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Email service Temptek com 7 2 PHYSICAL 16 24 KW HEATERS 1 3 HP PUMPS ...

Page 56: ...G500 Series Instrument Page 56 TEMPTEK INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Email service Temptek com 7 3 PHYSICAL 27 48 KW HEATERS 5 7 5 HP PUMPS 65 32 1 2 22 12 24 N 12 TWO PIECE CLAM SHELL CABINET ...

Page 57: ...HEATER TO PROCESS CONNECTION TO PROCESS SENSOR PROBE HIGH TEMPERATURE LIMIT SWITCH VENT TUBE LIQUID LEVEL SIGHT GLASS EXPANSION TANK FROM PROCESS CONNECTION FROM PROCESS SENSOR PROBE PUMP SEAL COOLING JACKET PUMP TO PROCESS PRESSURE GAUGE UNIT DRAIN DRAIN MANIFOLD DRAIN CONNECTION SUPPLY MANIFOLD WATER SUPPLY CONNECTION PRESSURE SWITCH COOLING ADJUSTMENT VALVE COOLING SOLENOID VALVE RELIEF VALVE H...

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Page 59: ...eries with G500 Series Instrument Page 59 TEMPTEK INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Email service Temptek com 8 0 APPENDIX 8 1 Model Coding 8 2 Water Cooled Process Pumps 8 3 Mold Purge ...

Page 60: ... GPM 3 Horsepower 70 70 GPM 5 Horsepower 100 100 GPM 7 1 2 Horsepower Heating Cooling H Heating Only HC Heating Cooling Control Instrument G500 G500 series instrument T500 T500 series instrument The data tag on your 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 other...

Page 61: ...a immediately around the seal see photograph below C As a safety precaution a pressure switch is installed in the supply line to monitor the water source If the pressure falls below 10 psi the switch cuts the control circuit and the unit stops Thus the hot oil temperature controller can only operate when there is adequate cooling supply water D Normally this temperature is well below 150 F even wh...

Page 62: ...em 1 Cool the process fluid to 100 F or below for safety 2 Turn off the unit and disconnect the power supply as outlined in this manual 3 Fully close the to process shut off valve Please note the from process valve remains open at this time 4 Connect a compressed air line to the mold purge valve The compressed air source must be regulated to a maximum of 10 psi Note the air supply for mold purging...

Page 63: ...END 2018 Temptek Inc RE 05102018 ...

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