Temptek PTK Series Instruction Manual Download

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INSTRUCTION MANUAL

TOUGH TANK ‘PPT’

for TOWER WATER SYSTEMS

and CHILLED WATER SYSTEMS

With Checkmate Controller

COVERING

INSTALLATION

OPERATION

MAINTENANCE

TEMPTEK, INC.

525 East Stop 18 Road Greenwood, IN 46142

317-887-0729 fax: 317-881-1277

Service Department fax: 317-885-8683

www.Temptek.com

E-mail: [email protected]

Summary of Contents for PTK Series

Page 1: ...oad Greenwood IN 46142 317 887 6352 fax 317 881 1277 Service Department fax 317 885 8683 www Temptek com E mail sales Temptek com I O M 129 updated 09 30 2019 INSTRUCTION MANUAL INSTALLATION OPERATION MAINTENANCE Model Serial Number ...

Page 2: ...S and CHILLED WATER SYSTEMS With Checkmate Controller COVERING INSTALLATION OPERATION MAINTENANCE TEMPTEK INC 525 East Stop 18 Road Greenwood IN 46142 317 887 0729 fax 317 881 1277 Service Department fax 317 885 8683 www Temptek com E mail sales Temptek com ...

Page 3: ... 3 Plant Water Distribution 8 2 4 Water Treatment 8 2 5 Vacuum Breakers 9 2 6 Process Connections 9 2 7 Water Supply Connection 10 2 8 Drain And Overflow Connections 10 2 9 Electrical Connection 10 2 10 Probe Installation 11 3 0 OPERATIONS 12 3 1 General 13 3 2 Start Up Operations Procedure 13 3 3 Instrument And Controls 16 4 0 MAINTENANCE 19 4 1 Preventive Maintenance 19 4 2 Pump Seal Service 20 ...

Page 4: ...mp Tank Station with Checkmate Control System Page 4 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 Safety 1 2 Efficiency 1 3 Component Placement ...

Page 5: ...C A water treatment system must be part of any pump tank system installation The services of a professional qualified water treatment company is required to prevent scale corrosion bacterial and biological growth The Factory highly recommends the services of a competent water treatment specialist be obtained and his recommendations be followed The Factory accepts no responsibility for inefficient ...

Page 6: ...a 46142 317 887 6352 Fax 317 881 1277 Email service Temptek com Service Lid Alarm Process Pump Tower Evaporator Pump CheckmateTM Control Panel Polyethylene Reservoir Control Console Polyethylene Tank Sight Glass Temperature Gauges Alarm Beacon Drain Valve Pump Assembly Pressure Gauges Electrical Cabinet CheckmateTM Control Panel ...

Page 7: ...lene Pump Tank Station with Checkmate Control System 2 0 INSTALLATION 2 1 Installation Drawings 2 2 Pump Base To Tank Mating Instructions 2 3 Plant Water Distribution 2 4 Water Treatment 2 5 Vacuum Breakers 2 6 Process Connections 2 7 Water Supply Connection 2 8 Drain And Overflow Connection 2 9 Electrical Connection 2 10 Probe Installation ...

Page 8: ...uld be rated for 150 F and 200 psi minimum Also note that the materials should have the equivalent diameter or larger of their process connections B Plant water distribution system design is critical to maximum performance of the system Careful attention should be paid to the pipe sizing length of runs number of elbows tees and valving as specified Normally the most successful installations are th...

Page 9: ...ader system full of fluid and prevent tank overflow during shut down periods B The purpose of the vacuum breaker anti siphon also called a drain back dam is to retain water in the header system during shut down periods and to allow for air purge which eliminates shock to plumbing during start up C It is necessary to install vacuum breakers in the supply and return lines The vacuum breaker must be ...

Page 10: ...ocated inside the tank provides the water supply connection E Local codes normally require a back flow prevention device be installed in the water make up line customer supplied 2 8 DRAIN AND OVERFLOW CONNECTIONS A Connect the drain and overflow ports to the plant s drainage system This is normally a sanitary sewer Consult local codes 2 9 ELECTRICAL CONNECTION A Electrical power supply requirement...

Page 11: ...roperly 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 2 10 PROBE INSTALLATION A For systems with the Checkmate control panel two probes are shipped inside the elect...

Page 12: ... with Checkmate Control System Page 12 TEMPTEK INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Email service Temptek com 3 0 OPERATIONS 3 1 General 3 2 Start Up Operations Procedure 3 3 Instruments And Controls ...

Page 13: ...OPERATIONS A System Checks 1 Before operating the pump tank station verify the unit piping installation and unit electrical installation is correct as outlined in section 2 of this manual 2 System should be leak checked prior to pump tank system operation B System Fill 1 All systems have automatic make up Some have mechanical and some system use a float switch that activates an electric solenoid v...

Page 14: ...oling towers correct rotation is counter clockwise or air should be drawn from the bottom of the tower and out the top For other tower cells check the tower cell manual for instructions on correct rotation 4 If rotation for a motor is incorrect disconnect power and reverse any two wires at the motor s starter block F Pump Flow Adjustments 1 When starting a centrifugal pump it is important to prope...

Page 15: ...on the pump tank set is divided into two sections by a baffle The sections are referred to as the hot side and the cold side The process pump suction is connected to the cold side and pumps water through the distribution system The water removes heat from the processes and returns to the hot side of the tank The evaporator pump or tower pump receives water from the hot side of pumps the water thro...

Page 16: ...to activate These switches allow for selecting primary or standby pumps as needed To turn off a selected pump simply switch off the pump Moving the power switch to the Off position will activate the system and will deactivate all pumps that have been switched on by their individual toggles 3 Each pump is controlled by dedicated motor starters To activate the pump move the power switch to the On po...

Page 17: ...verload condition is indicated by a RED light E CheckmateTM Instrument Operation 1 System information is displayed in the center screen Use the SELECT button to scroll through the different screens Use the UP or DOWN arrow buttons to set different operational parameters 2 MAIN SCREEN Displays the current To Process temperature in F The setpoint temperature is also displayed 3 TEMPERATURE STATUS SC...

Page 18: ...I to close the contacts and trigger the alarm Causes of low pump pressure are pump not operating due to tripped overloads impeller damaged or some internal pump obstruction excessive gpm SEL SEL SEL SEL SEL SEL SEL SEL Setpoints Config 1 Delays Communication System Config SEL SYSTEM CONFIG ADRESS 1 RATE 1 COMMUNICATION PRESSURE 15 LEVEL 4 DELAYS OUTPUT 1 PUMP CONFIGURE 1 OUTPUT 2 FAN OUTPUT 3 FAN ...

Page 19: ...supply insufficient 4 0 MAINTENANCE 4 1 PREVENTIVE MAINTENANCE A The following is a guide to preventive maintenance The frequency of maintenance will vary with each application installation conditions flow rates hours of use and operating temperatures B Preventive maintenance 1 Lubricate all motors Note some motors are supplied with sealed bearings 2 Tighten all wire terminations 3 Clean and check...

Page 20: ...tem flow is shut off and all pressure relieved 2 Disengage main power supply The operator must verify the Power light on the display is off 3 Close the suction and discharge valves 4 Drain pump The pump can be drained by using the drain plug located on the pump case 5 Locate and remove the three motor wire leads from the motor wiring terminals The operator should note the wire terminal locations t...

Page 21: ...rrangement to facilitate reassembly 11 Clean motor shaft and lubricate with a mild soap solution 12 Install new stationary seal member in pump casing cavity figure 4 2H The operator must be certain the stationary seal member is fully squared and seated in cavity 13 Slide the rotating member onto the lubricated pump shaft figure 4 2I The operator must be certain not to damage or tear the rubber bel...

Page 22: ...e pump casing Reinstall the pump casing bolts 18 Reconnect the water cooling lines to the pump adapter if applicable 19 Reconnect the motor power cord and leads 20 Restore all cover panels as were removed E When the pump seal replacement procedure is complete the operator may restart the unit according the section 3 In some cases a new pump seal will experience a small amount of leakage for a shor...

Page 23: ...lectrical connections intact lift the coil off of the enclosure tube and set aside 5 Use 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 ...

Page 24: ...ing meter with a probe long enough to be immersed on the system tank 2 Warning The system must be powered to perform the calibration Some of the components on the Checkmate controller board are connected to 110 VAC Toughing any components other than the potentiometers carries the risk of serious electrical shock Calibration should only be performed by a qualified technician D To Process Probe Cali...

Page 25: ...re measuring device then using a spare probe in an ice bath can be used 1 Disconnect the To Process probe from the cable and connect the spare probe to the cable 2 Submerge the probe into an ice bath for a few minutes to establish temperature An agitated probe in an ice bath is generally a good physical standard and can be assumed to be at or very close to 32 F The ice bath should be about 75 ice ...

Page 26: ...87 6352 Fax 317 881 1277 Email service Temptek com 5 1 ELECTRICAL A A specific electrical drawing has been prepared for your system The drawing is generally included with manual B If you need a copy of your electrical drawing contact the Service Department at 317 887 0729 You will need your model and serial numbers to obtain the proper drawing ...

Page 27: ...p 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Email service Temptek com PTK Series Polyethylene Pump Tank Station with Checkmate Control System 6 0 APPENDIX 6 1 Typical Press Drop 6 2 Checkmate Second Setpoint Guide ...

Page 28: ... 5 7 feet per second flow velocity and 5 10 psi pressure drop Consult engineering department for assistance when needed KEY TWS Tower Water Supply TWR Tower Water Return CWS Chilled Water Supply CWR Chilled Water Return INSULATE ALL CHILLED WATER PIPING VALVE POSITION Tower supply for auxiliary Open 1 2 Chilled water for auxiliary Open 3 4 Tower on mold Open 5 6 9 10 11 12 Chilled water on mold Op...

Page 29: ...t be added This can be done with two 820 ohm 1 4W resistors and a dry contact closure See below schematic outlined in red C The second set point input is located on J3 This is the 8 position green Phoenix header next to the large blue potentiometer with an arrow on the dial Pin 1 of this header is the pin farthest from the large blue potentiometer ON the circuit board pins 1 and 2 are labeled and ...

Page 30: ...Page 30 END 2019 TEMPTEK INC RE 09 30 2019 ...

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