882.12042.00 Midsize Hot Oil Units WTR2-635
Contents
1. For example if you observe a rapid cycling of the Heater and Cool Solenoid indicators the unit is operating with a process inefficiency see the Troubleshooting section for more information What follows is a description of system status board indicators Status Indicator Lights Pump Reverse Indicator Light The Pump Reverse indicator light illuminates when the unit pump runs in reverse Pump Forward Indicator Light The Pump Forward indicator light illuminates when the unit pump runs in the normal forward direction This indicator typically illuminates continuously during normal operation Heater On Indicator Light The Heater On indicator illuminates when the heater energizes Cool Solenoid Indicator Light The Cool Solenoid indicator illuminates when the cooling solenoid energizes It is used only on the optional heat exchanger Vent Solenoid Indicator Light The Vent Solenoid indicator illuminates when the venting solenoid energizes during venting sequences Mode Indicator Lights Select the unit operating mode by using the selection switch Power On Mode Indicator Light The Power On mode indicator light illuminates to indicate that the control circuit is energized in the unit Auto Mode Indicator Light The Auto mode indicator light indicates that the Auto mode is active and the controller is monitoring the system and controlling the process If the Auto light is off and the Cool Solenoid indicator light is illuminated th2. M 550 F Pilot Lights 715 10074 00 PILOT LED 120 V RED N 12 36 LEAD 715 10075 00 PILOT LED 120 V AMBER N 12 36 LEAD 715 10076 00 PILOT LED 120 V GREEN N 12 36 LEAD LED Light Board Part number 581 88170 00 PCB LED MSO CTR BACK Casters Description 042 00016 00 CASTER SWIVEL 3 042 00017 00 CASTER STATIONARY 3 Sight Glass Assembly Part number 037 00046 00 GLASS SIGHT 15 Please give model and serial numbers when ordering parts N O TI CE Prices are subject to change without notice 43 of 49 WTR2 635 Chapter 6 Maintenance Figure 8 Customer Recommended Spare Parts Cont d Controller 724 00589 01 LTR MPB 1 16 2 T C Omron E5CK Selector Switches and Push Buttons Pressure Switches 733 00029 00 SWITCH PRESSURE Pump 075 00370 01 MECH SEAL VIKING HV2972 0 30 GPM Motors 720 09240 00 MOTOR 1 HP 3 60 208 230 460 V 720 09242 00 MOTOR 1 HP 3 60 208 230 460 V 720 09218 00 MOTOR 2 HP 3 60 208 230 460 V Replacement Belts 100 00031 00 BELT 5L 35LG 60 Hz units gt 100 00025 00 ELT 5L 36LG 50 Hz units Please give model and serial numbers when ordering parts NOTICE Prices are subject to change without notice 44 of 49 WTR2 635 Chapter 6 Maintenance Figure 8 Customer Recommended Spare Parts Cont d Solenoid Valves 732 00007 03 Y VALVE 115 V COIL 0 125 PSI 300 F 732 00
3. Using a lubricant and adding a chamfer on the bushing and the mating part will help in installation The additional precautions listed below must be followed for proper installation 1 A press must be used for installation 2 Becertain bushing is started straight 3 Do not stop pressing operation until bushing is in proper position Starting and stopping will result in a cracked bushing 4 Check bushing for cracks after installation Carbon graphite bushings with extra interference fits are frequently N O TI C E furnished for high temperature operation These bushings must be installed by a shrink fit 1 Heat bracket or idler to 750 F 2 Install cool bushings with a press 3 If facilities are not available to reach 750 F temperature it is possible to install with 450 F temperature however the lower the temperature the greater the possibility of cracking the bushing 38 of 49 WTR2 635 Chapter 6 Maintenance Preventative Pump Maintenance You can extend the life of your pump and reduce the cost per gallon pumped if you perform a few preventive maintenance procedures Lubricating the Pump Using 72 ball bearing grease and a hand operated grease gun gently lubricate all grease fittings after every 500 hours of operation or after 60 days whichever comes first If pump service occurs in severe conditions lubricate more frequently Use an appropriate type of grease for hot or cold applications Adjusting End Cl
4. With Autovent Solenoid If the unit is to be moved from one process to another 1 e mold changes etc the following steps must be taken to drain the mold and process lines Note that this is just the opposite of unit start up air purge 1 Cool fluid to 100 degrees F maximum 2 Depress the PUMP STOP push button 3 Depress and hold the PUMP REVERSE push button The pump will then run in reverse drawing fluid from the mold and lines and into the reservoir tank 4 Watch the sight glass to prevent overflow of the reservoir tank The reservoir tank may not have adequate volume to contain the total system capacity of fluid An overflowing reservoir allows hot fluid to escape and become a potential fire and slip hazard The total capacity of the tank is 7 gallons 26 5 liters If it appears that the tank may overfill connect a line from the FILL port of the reservoir tank to a clean auxiliary container Returning Fluid To Tank With Manual Vent Valve If the unit is to be moved from one process to another 1 e mold changes etc the following steps must be taken to drain the mold and process lines Note that this is just the opposite of unit start up air purge 1 Cool fluid to 100 degrees F maximum 2 Open the Vent Valve to allow in fresh air into the pipes 3 Depress the PUMP STOP push button 4 Depress and hold the PUMP REVERSE push button The pump will then run in reverse drawing fluid from the mold an
5. for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the granulator These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the granulator safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your granulator provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics parts lists and available options A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death A DANGER DANGER indicate
6. receipted transportation bill Advise customer service regarding your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list You should have M Bill of lading M Packing list M Operating and Installation packet M Electrical schematic and panel layout drawings M Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact the shipping department immediately For immediate assistance please contact the correct facility located in the technical assistance section of this manual Have the order number and item number available Hold the items until you receive shipping instructions WTRI 935 111 WTRI 935 Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department Credit Returns Prior to the return of any material authorization must be given by the manufacturer A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given ALL returned material purchased from the manufacturer returned is subject to 15 75 00 minimum restocking charge ALL returns are to be shipped prepaid The invoice number and date or purchase order number
7. Failure to purge the system of air before heating may result in serious injury or critical system and equipment damage Make sure you properly purge the system of air before starting the heater cycle Pressure Switch A pressure switch is built into each unit to guard against heater damage This feature prevents the heater elements from being energized unless the pump is running and fluid is in the system After a preset time the pump shuts down if the fluid pressure is not re established The pressure switch is preset at the factory do not tamper with it Safety Thermostat The safety thermostat is a J Thermocouple sensing adjustable fail safe device located in the heater tank This is to guard against the unlikely event of runaway heating If overheating does occur the safety thermostat shuts down the heater outputs and sounds an audible alarm A red pilot light on the status board also illuminates The unit continues to pump fluid through the system to prevent heater damage Auxiliary factory installed alarms such as beacons and klaxons are available as options All controller functions are locked out until the main supply power is disconnected Resetting the alarm condition 1s initiated by depressing the red pump stop button The reset button is located inside the electrical enclosure mounted on the left wall of the enclosure It is imperative that a qualified maintenance technician determine and correct the cause of the fault
8. With the pump running you can select the AUTO position or the Maintained manual cooling position with the Mode Select switch Select AUTO mode to energize the controller permitting it to monitor and control the process The switch automatically returns to the Center Default position when in AUTO mode The switch stays in the Maintained position in Manual Cooling mode Always let the pump run for at least one I minute before switching to AUTO mode Never switch to AUTO mode when filling or venting the unit except as described in the Unit Startup chapter Improper switching can seriously damage the heater as it could become energized with air in the system Alarm Silence Press the ALARM SILENCE fi button to silence the audible alarm on the console After you silence the alarm make sure you locate and correct the alarm condition before continuing with unit operation 5 4 Identifying System Status Board Indicators The system status board is located next to the controller panel It displays indicator lights to show current operation status letting you analyze system performance Figure 5 System Status Board Indicators PUMP OVERLOAD PUMP REVERSE Q POWER ON AUTO PUMP FORWARD Q BYPASS RELIEF VALVE TO PROCESS PRESSURE SAFETY THERMO O STRAINER No o do Sy rex WATER COOL 4 DRAIN SOLENOID HEAT EXCHANGER LOW VENT WATER LEVEL SOLENOID O SUPPLY Q Use the status board to optimize unit performance
9. and date must be supplied No credit will be issued for material that is not within the manufacturer s warranty period and or in new and unused condition suitable for resale Warranty Returns Prior to the return of any material authorization must be given by the manufacturer A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied After inspecting the material a replacement or credit will be given at the manufacturer s discretion If the item is found to be defective in materials or workmanship and it was manufactured by our company purchased components are covered under their specific warranty terms 1V Table of Contents CHAPTER 15 SAFE raras 7 151 CROW io Use This Manuals 2 3 peel sc bene o ep eeneenee aii T Safety Symbols Used in this Manual sessi eene nnn nnns 7 eZ VWVAININGS ANG DrecautloriS us cond rencontre eee arabe dne esee in dete etm rotas lie eg 9 CHAPTER 2 FUNCTIONAL DESCRIPTION 10 2 1 Models Covered in This Manual oocccocccncccccncccnconnconnconnnonncncnoncnoncnonononnnnnnnnnnnncnnncnnns 10 2 2 General DeseriDUO L cuneo nei EE reser bwin a utere Fora se ia 10 2 3 Typical Features and COMpPONeNES cocccoccncnccccccncoccncncononcnnnnnnononnoncnnnnonnnonnnnnnnaninnnnane
10. before resuming operation Reservoir Tank A reservoir tank with sight gauge is standard usable capacity is seven 7 gallons 26 5 liters The tank permits thermal expansion of the heat transfer fluid and provides make up fluid The reservoir tank may cause serious injury if it ruptures from not being properly vented Make sure that the reservoir tank is always properly vented to prevent tank rupture The reservoir tank drain is extended beyond the base of the unit for ease of draining Optional ball valves are available to further simplify draining WTR2 635 Chapter 2 Functional Description 14 of 50 Figure 1 Midsize Hot Oil Portable Temperature Control Unit RESERVOIR TANK FILL PORT SUB ASSEMBL Y PLUG WHEN RUNNING VENT ON IMMERSION HEATERS amp HEATER TANK SUB ASSEMBL Y SIDE PANEL MANUAL BYPASS eA RESERVOIR TANK TO PROCESS VENTZOVERFLOW TEMP PROBE DO NOT PLUG 1 nR WM TANK DRAIN PLUG SIDE PANEL TOP PANEL Y STRAINER ER E lr n E lt VENT TEMP RETURN CHECK VALVE PRESSURE GAUGE J FRONT PANEL CODLING WATER SUPPLY CONSOLE SUB ASSEMBL Y PANEL SUB ASSEMBLY L iL Lr PA COULING WATER DRAIN HEAT EXCHANGER SUB ASSEMBL Y MAIN DISCONNECT Y Y TO PROCESS BACK PANEL DRIVE SUB ASSEMBLY ie EBD ANI PUMP SUB ASSEMBLY AE s EOL SEL GA DT UNIT DIL DRAIN FULFLO SUB ASSEMBL Y BA
11. bundles clean by lime deposits replace as required Test solenoid valve by switching to Manual Cool mode and listen for valve operation Replace if faulty Leaks in connecting lines Inspect replace faulty line or connection A RUE Cen aa dE Perform venting sequence in 9 Section 4 1 on Pages 27 29 Check fluid level in sight glass medi Add fluid if required Defective Ful Flo valve Replace Ful Flo valve Drain water from low point in Water in fluid piping Section 4 1 on Pages 27 29 or boil water off Allow vent timer to run out or Faulty solenoid valve Rapid drop in pressure no pressure Vent solenoid open check valve operation when unit is cold by opening the fill port Check motor rewire if Pump running in reverse necessary See electrical diagrams Pump repair adjustment needed Adjust head spacing or replace worn pump components V belt broken worn Replace as required Drain water from low point in Water in fluid piping Section 4 1 on Pages 27 29 or boil water off Drain and flush system Replace fluid Noisy pump Severely degraded fluid 48 of 48 WTR2 635 Chapter 7 Troubleshooting Chapter 8 Appendix 8 1 Technical Assistance Parts Department The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist
12. in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service For immediate assistance please contact North Central and South America 8am 5pm CST 1 800 483 3919 for drying conveying heating and cooling and automation For size reduction 1 800 229 2919 North America emergencies after 5pm CST 847 439 5855 North America email acsuscanadacustserv corpemail com Mexico Central amp South America Email acslatinamericacustserv corpemail com Europe Middle East amp Africa 48 22 390 9720 Email acseuropecustserv corpemail com India 91 21 35329112 Email acsindiacustserv corpemail com Asia Australia 86 512 8717 1919 Email acsasiacustserv corpemail com Sales and Contracting Department Our products are sold by a worldwide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations For assistance with your sales or system contracting needs please Call North Central and South America 1
13. the BROWNING belt tension checker is 35 Ibs Other means of applying force must be used if force requirement is greater than this SHEAVE DIAM INCHES DEFLECTION FORCE LBS 3000 2 50 2 41 61 501 4000 34 50 1000 2300 50 iA 2501 4000 43 6 4 3000 2500 57 a4 2501 4000 7 76 115 17 0 2A a4 13 8 17 5 134 1 259 5 8 2 5 1725 18 5 2 26M UJ 212 3 3 310 493 48 A9 36 50 2 33 m 4 of 49 Customer Recommended Spare Parts Immersion Heaters Part number 722 00138 07 722 00138 08 722 00138 09 722 00138 10 TR IMM 12 KW 415 V 3 6 ELE 722 00138 11 TR IMM 12 KW 480 V 3 6 ELE 722 00138 12 TR IMM 12 KW 600 V 3 6 ELE Note 6 kW heaters are modified 12 kW heaters jumpers are remove from one leg Heater Gasket Description 542 00007 08 GASKET FLANGE 3 Heater Tank Description 0 2 87548 00 TANK HEATER M 3 Manual Reset Safety Thermostat Description 724 00041 00 THERMOSTAT 200 F 550 F Please give model and serial numbers when ordering parts N O TI C E Prices are subject to change without notice 42 of 49 WTR2 635 Chapter 6 Maintenance Figure 8 Customer Recommended Spare Parts Cont d Pressure Gauge Part number 037 00119 00 GAUGE PRESSURE 0 100 PSI Optional Heat Exchangers Tube Bundle Only Ass y part no Tube bundle only part no 106 00267 00 162 00047 10 3 9 SQ FT M 550 F 106 00268 00 162 00047 11 6 7 SQ FT
14. 013 01 4 VALVE 115 V COIL 0 125 PSI 300 F Sensing Probe Equipment 701 00036 00 SENSOR TC TYPE IC 701 00003 00 SENSOR TC TYPE J Disconnect Switches 728 00153 00 SWITCH DISCONNECT 45 AMP 728 00168 00 SWITCH DISCONNECT 100 AMP Heater Tank Insulation Part number 542 88062 00 INSULATION TANK HEATER Ful Flo Relief Valves Part number 044 00239 00 VALVE RELIEF FUL FLO 1 Please give model and serial numbers when ordering parts N O TI C E Prices are subject to change without notice 45 of 49 WTR2 635 Chapter 6 Maintenance Chapter 7 Troubleshooting 7 1 Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components All normal trouble shooting must be accomplished with the power off line fuses removed and with the machine tagged as out of service The use of good quality test equipment cannot be over emphasized when troubleshooting is indicated Use a good ammeter that can measure at least twice the AC and DC current that can be encountered for the machine Be sure that the voltmeter has at least minimum impedance of 5 000 OHMS per volt on AC and 20 000 OHMS per volt on DC scales Popular combination meters VOM and VTVM can be selected to provide the necessary functions Before making haphazard substitutions and repairs when defective electrical components are malfunctioning we recomme
15. 10 of 50 To Process pressure gauge Independent safety thermostat Y strainer on From Process line Automatic venting sequence Positive displacement pumps capable of reversing to evacuate the process Low level alarm for reservoir Easily removable panels for quick access to internal components Audible alarm Available Options WTR2 635 Drain valve Hour meter measures total pump run time hours General fault visual alarm Autovent sequence deducts available Low level alarm deducts available High level indicator light Manual bypass deducts available Heat exchanger options of 3 9 sq ft 0 3627 sq m and 6 7 sq ft 0 6231 sq m Remote controller Lexan cover Optional operating voltages of 208 3 60 230 3 60 575 3 60 380 3 50 and 415 3 50 Chapter 2 Functional Description 11 of 50 2 4 Feature Descriptions Immersion Heaters The fluid is heated by the specially designed three phase low watt density electrical immersion heater and regulated by the controller The standard heater has a steel sheath for low watt density and good heat transfer These models can be supplied with 6 12 18 24 kW low watt density immersion heaters depending upon the heating needs of the process The 18 and 24 kW models are built to provide full or partial heat as required by the process and determined by the controller to provide more precise control Heater Tank The M features a single pass heater tank The tank is designe
16. 102 C until no more steam appears and pressure has stabilized 9 When fluid level has stabilized and air and water is purged from the system close the Vent Valve Do not open the Vent Valve above 250 F With the system properly purged only 4 6 of fluid should be visible in the sight glass This will allow for expansion of the fluid as it heats as well as capacity for process fluid when the pump is reversed and fluid withdrawn from the mold The Model M is now ready for use All that is required is to select a process set point on the controller as described in the controller manual If all traces of water are not removed from the system severe cavitation may N O Tl CE occur at elevated temperatures Indications are a gravely sounding pump fluctuating or dropping pressure or rapidly rising fluid level in the expansion tank Repeat Step 7 if this occurs 4 2 Shut down Unit Shut Down With Autovent Solenoid or Manual Vent Valve Cool the unit down by switching the Mode switch to the Manual Cool position This will disable the heaters 1 e prevent the controller from turning them on and open the cool solenoid if equipped with optional heat exchanger Fluid temperature can be monitored on the controller display during cool down When fluid temperature is below 120 F depress the PUMP STOP button to turn the unit off WTR2 635 Chapter 4 Operation 24 of 50 4 3 Returning Fluid to the Tank Returning Fluid to Tank
17. 262 641 8600 or 1 847 273 7700 Monday Friday 8am 5pm CST Europe Middle East Africa 48 22 390 9720 India 91 21 35329112 Asia Australia 86 512 8717 1919 Facilities ACS offers facilities around the world to service you no matter where you are located For more information please visit us at www acscorporate com United States Asia Australia India Middle East ACS Schaumburg Corporate Offices ACS Suzhou ACS India Hec NOONE RORE 109 Xingpu Road SIP Gat No 191 1 Sandbhor Complex Suite 588 Suzhou China 215126 Mhalunge Chakan Tal Khed Schaumburg IL 60173 Phone 86 8717 1919 Dist Pune 410501 India Phone 1 847 273 7700 Fax 86 512 8717 1916 Phone 91 21 35329112 Fax 1847 273 7804 Fax 91 20 40147576 Europe ACS New Berlin Manufacturing Facility 2900 S 160 Street ACS Warsaw New Berlin WI 53151 UI Dzia kowa 115 Phone 1 262 641 8600 02 234 Warszawa Fax 1 262 641 8653 Phone 48 22 390 9720 Fax 48 22 390 9724 50 of 50 WTR2 635 Chapter 8 Appendix
18. 7 V ll a A LIN HU PI LOCKNUT NS AAS Z VA REA J pese 7 ES NS 50019 PEN LIT 4 l ENN KAY ZZ ol OF BEARING SNAP RING HOUSING ASSEMBLY P N 162 00008 49 WTR2 635 2227777 ha EA 22 ROTOR amp SHAFT ASSE ped 20 CASING PT d 26 HEAD W I 27 HEAD CAPSCRE es IDLER PIN IDLER W BUSHING ER PIN 23 IDLER W BUSHING 21 HEAD GASK EY 18 BRACKET GASKE 17 BRACKET ITEM QTY PART NUMBER BEARING ESGBENEONSSEMBLY 162 00008 49 62 00008 35 162 00008 40 A LOCK WAS BRO 162 00008 17 E COL SPARSKNUT 162 00008 19 3 CABR BRG HSG 162 00008 20 5 BRG BALL OF 2 162 00008 14 HSG BRG 162 00008 24 d 5 RING SNAP 162 00030 108 9 BOLT SEAL HLDR 162 00030 160 10 SEAL HLDR FOR VIKING PMP 162 00030 159 11 SEAL UP 162 00030 153 12 PL SEA 162 00030 154 15 SL MECH HI TEMP 162 00030 144 14 BUSH BRKT 162 00008 98 gu S CPSC PRESS RLF VLV SET 162 00008 18 ii BRKT amp BUSH 162 00030 155 ME GSKT FLNG BACK UF 4 162 00008 09 NE PL
19. ED The orange OUTI LED lights when the controller output energizes the immersion heater OUT2 LED The orange OUT2 LED lights when the controller output energizes the cooling valve MANU LED The orange MANU LED lights when you place the controller in Manual mode STOP LED The orange STOP LED is not used RMT LED The orange RMT LED is lit during remote operation AT LED The orange AT LED flashes during auto tuning SUB1 LED The orange SUBI LED is lit during high temperature conditions 5 3 Identifying Control Panel Switches Control Panel Switches START Y STOP REVERSE 4 VENT MCX AUTO OFF ok SILENCE X U OU U LU oe WTR2 635 Aam aa y MU Select Vent Cycle Start Pump Reverse Pump Stop Pump Start Pump Start Press the START button to start the pump in the normal forward direction Pump Stop Press the STOP O button to stop the pump and de energize the controller Always press the Pump Stop button and allow the pump to come to a complete stop before pressing the Pump Reverse button Failure to let the pump stop before reversing may damage the pump and drive Pump Reverse Press the REVERSE button to start the pump in the reverse direction Use this feature to purge oil from the mold Chapter 5 Using Controls and Indicators 27 of 50 Vent Cycle Start Press the VENT tO button to start the vent cycle timer Use this feature to purge air and water from the unit and process Mode Select
20. Midsize Hot Oil Temperature Control Units Models Covered TCO 2016M COT Part Number 882 12042 00 Bulletin Number WTR2 635 Effective August 1 2012 an ACS company Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No O Copyright 2013 All rights reserved WTRI 935 11 Shipping Info Unpacking and Inspection You should inspect your hot oil temperature control unit for possible shipping damage Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In the Event of Shipping Damage According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a claim with the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading 1s attached to our original invoice If the shipment was prepaid write us for a
21. SE SUB ASSEMBL Y WTR2 635 Chapter 2 Functional Description 15 of 50 2 5 WTR2 635 Safety Features This section includes information on safety devices and procedures that are inherent to the portable hot oil tcu This manual is not intended to supersede or alter safety standards established by the user of this equipment Instead the material contained in this section is recommended to supplement these procedures in order to provide a safer working environment At the completion of this section the operator and maintenance personnel will be able to do the following e Identify and locate specific safety devices e Understand the proper use of the safety devices provided e Describe the function of the safety device Safety Circuit Standards Safety circuits used in industrial systems protect the operator and maintenance personnel from dangerous energy They also provide a means of locking out or isolating the energy for servicing equipment Various agencies have contributed to the establishment of safety standards that apply to the design and manufacture of automated equipment The Occupational Safety and Health Administration OSHA and Joint Industrial council JIC are just a few of the organizations that have joined with the plastics industry to develop safety standards Every effort has been made to incorporate these standards into the design of the portable hot oil tcu however it is the responsibility of the personnel operatin
22. UG PIPE STL SQ HD SOLD 1 8 012 00001 00 nns CASING HL PMP 162 00008 47 GSKT HEAD 162 00008 08 e RTR amp SFT ASSY 162 00030 156 i 162 00030 56 En BUSH IDL GRAPHITE 62 00030 02 24 IBI I SU 162 00008 36 22 PIN HEAD amp IDL 162 00030 92 26 CPSC PRESS RLF VLV SET OF 4 162 00008 18 2 NUT PACK GL SET OF 2 62 00008 43 78 34 of 50 Chapter 6 Maintenance Disassembling the Pump WTR2 635 l 10 11 12 13 14 15 1 Mark head and casing before disassembly to insure proper Peru The idler pin which is offset in pump head must be positioned toward and equal distance between port connections to allow for proper flow of liquid through pump Remove head from pump Do not allow idler to fall from idler pin Tilt top of head back when removing to prevent this Avoid damaging head gasket Remove idler and bushing assembly Insert length of hardwood or brass through port opening between rotor teeth to keep shaft from turning Bend up tang of lockwasher and with a spanner wrench remove locknut and lockwasher from shaft Loosen Allen head setscrews in the face of the thrust bearing assembly Remove the thrust bearing assembly by threading out of the bracket Figure 7 Thrust Bearing Assembly Loosen the radial setscrews in the thrust bearing assembly and remove the end cap using the spanner wrench Remove the bearing spacer collars and the ball bearing Using snap ring pliers remove snap ring from s
23. You must provide cooling water at 25 psi to 75 psi 172 4 kPa to 517 1 kPa 1 7 bars to 5 2 bars for proper operation Untreated water can foul or corrode the heat transfer surfaces slowing water flow and causing fluid temperature control problems ACS Group sells a complete line of water treatment equipment that can reduce downtime and maintenance costs Run properly sized cooling water lines never smaller than the outlets on the M unit If external piping is larger than M unit connections reduce the size of the piping at the unit Connecting Vent Piping You must leave the vent connection open to the atmosphere at all times The vent connection is located on top of the reservoir On systems with piping above the reservoir level you must run vent piping to a minimum height of one foot 1 31 cm above the highest point in the system Run the piping down into an auxiliary vented overflow chamber such as a vented covered 55 gallon 208 liter drum This practice ensures that overflow will not create a hazard to personnel Remember All external piping must be supported independently of the M unit The reservoir tank must be vented to prevent pressurization A pressurized reservoir could rupture allowing hot fluid to escape and become a potential fire and slip hazard Heat transfer fluids expand when heated Expansion rates vary depending on fluid types and NO TIC E p p y dep g yp temperatures For more information on expansio
24. and possibly leak when you start the unit In most cases these gaskets soon swell and form a tight seal If not you may need to tighten the bolts to stop the leak similarly rough handling in shipping may sometimes cause minor leaks upon startup you may need to re tighten bolts or fittings to stop the leak You should expect to periodically replace the pump seal If the pump 1s properly lubricated and used at moderate temperatures the seal should last several years The following section describes the proper procedures for replacing the seal Mechanical seal part no 162 00030 160 Periodic replacement of the pump drive V belt is also to be expected Note If the pump motor wiring is disconnected for removal from the unit you must check the actual direction of rotation when the motor is rewired to the unit Consult Elementary Diagram provided in unit for more information Chapter 6 Maintenance 32 of 50 6 5 Maintaining the Pump Disassembly Before opening the pump chamber NWARNING e Make sure that any pressure in the chamber has been completely vented Make sure that the motor cannot be inadvertently started while you work on the pump Failure to follow these precautions may result in serious injury or death WTR2 635 Chapter 6 Maintenance 33 of 50 Figure 6 18 24 GPM Pump Construction 075 00370 02 BRKT CAPSCR w co 18 BRKT BUSHING 14 7 5 o EY amd E AN LLL 277
25. ate the pump at the grease fittings with a high quality lithium grease rated at 400 F 204 C or higher Use only Dow Corning 44 or a high temperature grease rated at 400 F or higher that is compatible with Dow Corning 744 Do not over lubricate e Adjust the pump drive belt tension Make sure that the motor pulley is properly aligned with the pump pulley use a straightedge to check Tighten motor mounting bolts after realignment e Inspect the screen in the Y strainer for accumulations of debris Clean as needed Servicing the Unit Every Three Months Remove and clean the screen in the Y strainer Replace the screen if it is damaged Draining the Unit for Storage You should thoroughly flush and drain the M unit if you need to take it out of service for a long time or if you expect it to become exposed to freezing temperatures We recommend TrueFlush flushing fluid or equivalent for flushing your M unit follow unit flushing instructions that comes with TrueFlush flushing fluid Drain plugs are provided at the base of the heater tank reservoir tank and on the pump You should also remove drain and reinstall the heat exchanger tube bundle before storage Corrective Maintenance Pumps and Seals Each M unit is completely tested and calibrated before leaving the factory The unit is then cooled drained and packed for shipment If the unit stands idle for a long time before being installed in your factory gaskets can dry out
26. d lines and into the reservoir tank 5 Watch the sight glass to prevent overflow of the reservoir tank If it appears that the tank may overfill connect a line from the FILL port of the reservoir tank to a clean auxiliary container WTR2 635 Chapter 4 Operation 25 of 50 Chapter 5 Using Controls and Indicators 9 1 WTR2 635 The Microprocessor Controller The controller is an easy to operate microprocessor based PID control device When the process reaches the set point the PID control cycles the cooling valve and or immersion heater to maintain the proper leaving water temperature The controller has been fully factory tested Set the desired process temperature set point and the control does the rest Built in range of operation on the controller is 0 F to 550 F 18 C to 288 C Controller Display Figure 3 Typical Microprocessor Controller Kk o DIG PV or Process Value Numeric LED During normal operation the large red PV Process Value LED on the controller displays the actual process temperature at the To Process thermocouple It also lists parameter symbols during setup and error messages 1f an error occurs SV or Set Value Numeric LED During normal operation the green SV Set Value LED on the controller displays the process set point you want the chiller to maintain It also displays parameter and pre set function values during setup Chapter 5 Using Controls and Indicators 26 of 50 OUTI L
27. d to maintain an optimum balance of fluid velocity versus watt density and turbulence for excellent heat transfer and minimal pressure drop The high fluid velocity will greatly prolong the life of the heater and fluid Pump The pump is a mechanical seal positive displacement pump It features a nearly maintenance free design and was selected after extensive testing to provide superior performance flexibility and low maintenance It is well suited for use with a variety of commercially available heat transfer fluids The pump has only two internal moving parts and a specially designed seal to give years of trouble free service even at high temperatures The only routine maintenance required is the monthly greasing and occasional head space adjustment see Section 6 2 on Page 42 for more information The pump is capable of running in either direction Thus the pump reverse feature can be used to draw fluids back from the process It is not necessary to install a service air line to purge the lines before changing molds Since the pump is capable of achieving extremely high pressures it is necessary to regulate the pressure through use of a regulating by pass line Ful Flo valve Because the pump is a positive displacement pump it will supply the process with rated flow at or below the rated pressure The flow 1s constant until the pressure reaches the rated pressure The pressure however is a function of frictional losses through the proces
28. e controller is disabled and the cooling solenoid is open permitting maximum cooling If the Auto and Cool Solenoid indicator lights are off the unit 1s in standby Fault Indicator Lights Pump Overload Indicator Light The Pump Overload indicator light illuminates when the pump is overloaded This is an alarm condition so the audible alarm activates to notify you of the pump overload fault and the unit shuts down Always correct the alarm condition before returning to normal operation WTR2 635 Chapter 5 Using Controls and Indicators 29 of 50 WTR2 635 Low Pressure Indicator Light The Low Pressure indicator light illuminates when the unit has low heat transfer fluid pressure This is an alarm condition so the audible alarm activates to notify you of the low pressure fault and disables controller outputs permitting the pump to continue to circulate fluid to avoid damage If low pressure continues past five minutes elapsed time the pump shuts off Always correct the alarm condition before returning to normal operation Safety Thermo Indicator Light The Safety Thermo indicator light illuminates when the unit is overheating This is an alarm condition so the audible alarm activates to notify you of the safety thermo fault and disables controller outputs permitting the pump to continue to circulate fluid to avoid damage Always correct this alarm condition before returning to normal operation High Level Indicator Light Optio
29. e heat transfer fluid for deterioration If the fluid is noticeably darker or it seems significantly thicker drain the system and replace the fluid with fresh new recommended heat transfer fluid Do a routine check of the fluid every 1 000 hours of operation or every three 3 months whichever comes first Contact a facility s Services for information on fluid testing Making Six Month Checks e Inspect electrical connections for secure tight electrical terminations and ground connections Inspect the power cable especially at the entrance point to the electrical enclosure Have a qualified electrician perform this inspection e Check the mounting bolts on the pump the motor and the heater flange for tightness e Remove the heat exchanger tube bundle and check it for lime and mineral deposits Carefully clean the bundle as needed Chapter 6 Maintenance 31 of 50 6 3 WTR2 635 Routine Servicing Your hot oil temperature control unit requires little in preventive maintenance and servicing To keep it in good reliable working order make sure you follow the following scheduled preventive maintenance procedures Keep surfaces clean and free of any excessive accumulations of dirt oil or debris This is especially true for the pump It relies on free air circulation for proper cooling Check the motor air intake screen for any accumulation of dirt clean it as needed Servicing the Unit Monthly or Every 500 Hours e Lubric
30. earance After long periods of service the running clearance between the end of the rotor teeth and head may be increased from wear The pump may lose some capacity of pressure as a result If you reset the end clearance pump performance should improve Examining Internal Parts Remove the head occasionally and examine the idler bushing head and pin for wear Replace the idler bushing and idler pin after moderate wear to avoid replacing more expensive parts later Make sure the idler doesn t slide off the idler pin during head removal to N O TI C E avoid damage and personal injury WTR2 635 Cleaning the Pump A clean pump is easier to inspect lubricate and adjust it runs better and looks better Storing Your M Unit If you anticipate that your unit will be out of service or stored for a long time flush and drain the pump and circulating system to protect it from freeze ups or rusting 39 of 49 Chapter 6 Maintenance 40 of 49 WTR2 635 Chapter 6 Maintenance How to increase Belt Life Keep sheaves and belts clean Abrasive dust rust oil and acids reduce service ife Give drives elbow room Never let belts run against belt guards or other obstructions Use large diameter sheaves and fewer belts You save money and increase drive life Never force belts Move motor on adjustable base so belts can go on easily Eliminate slack Adjust motor and tighten belts in position Slack belts wear excessi
31. ed by properly trained personnel The information contained within this manual must be read and understood prior to operating this equipment Lock Out This equipment is operated with 3 phase electrical power Therefore when performing any maintenance operations we recommend following the local standards for performing a lock out tag out procedure Wear Safety Gloves This equipment operates above 212F 100C and its surfaces may reach excessive temperatures We recommend that technicians use safety gloves while performing maintenance to protect hands from being exposed to these hot surfaces WTR2 635 Chapter 1 Safety 8 of 50 WTR2 635 Warnings and precautions Our units are designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes To avoid possible personal injury or equipment damage when installing operating or maintaining this granulator use good judgment and follow these safe practices v M M E KR NR IS T Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Disconnect and or lock out power before servicing or maintaining the hot oil temperature control unit Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you Make sure t
32. el to avoid scalding Carefully select connecting lines and connectors between the M untt and the process to best meet the needs and requirements of your application Make sure lines and connectors have a service rating of at least 100 psig 689 5 kPa 6 9 bars and a temperature rating at least equal to the maximum operating temperature of your M unit To prevent debris from fouling reservoir fluid the M unit 1s equipped with an NOTICE internal vent on the reservoir tank Use the plug provided to close off the external fill port after filling the unit with heat transfer fluid WTR2 635 Chapter 3 Installation 21 of 50 3 4 Making Electrical Connections These units are designed for three phase voltage operation Refer to the unit nameplate for proper ACAUTION voltage and amperage requirements and make sure your electrical service conforms 1 Provide a correctly sized and protected power supply to the unit 2 If an electrical supply disconnect is not installed as a factory option the customer is responsible to properly size and install a suitable disconnect 3 Refer to National Electric Code NEC 430 24 26 for proper feed conductor and supply disconnect sizing 4 Voltages must be within plus or minus ten percent 10 of the nameplate rating 5 Maintain a safe ground and disconnect the power supply before servicing the unit A qualified electrician should make electrical connections and disconnect the electricity when se
33. emperature silicon grease Thrust Bearing Adjustment WTR2 635 l Loosen axial setscrews in face of end cap on the thrust bearing assembly If rotor shaft cannot be turned by hand back off the thrust bearing assembly until there is a noticeable drag of the shaft Note mechanical seal will provide some drag and this is a normal condition The thrust bearing assembly must be turned in until it can just be turned over by hand This ensures the rotor is against the head and a zero end clearance condition exists Make a mark on the OD of the bearing housing and a corresponding mark on the bracket Back off thrust bearing housing the required number of marks or distance on the OD as shown below 37 of 49 Chapter 6 Maintenance 3 Tighten the axial setscrews in the face of the thrust bearing assembly Make sure the rotor shaft turns freely If it does not repeat steps 1 and 2 Lime Turn Outer End Cap C C W 0 75 No of Notches or Length on O D Inches Each small notch on outer end cap represents 001 inch end clearance Before starting the pump make sure that all drive equipment guards are in place Failure to properly install the guards may result in serious injury or death Installation of Carbon Graphite Bushings When installing carbon graphite bushings extreme care must be taken to prevent breaking Carbon graphite is a brittle material and easily cracked If cracked the bushing will quickly disintegrate
34. es not heat properly can Switch to Manual Cool mode not achieve set point Faulty dirty solenoid valve several times to flush valve If usually detected when there isa the leak continues disconnect steady stream or trickle of water the power to the unit turn off the out of the drain line water supply and clean or replace the solenoid Degraded fluid Drain and replace fluid Visual inspection of coil and Defective heater contactor contacts Repair replace defective contactors Check resistance on all three 3 legs of heater with an Defective immersion heater ohmmeter If not all equal Unit does not heat contact factory for replacement heater Check heater tank for scorched Faulty TCU discolored paint Check Heater burnout resistance on all three 3 legs of heater with an ohmmeter Replace heater as needed 47 of 47 WTR2 635 Chapter 7 Troubleshooting Condition Possiblecause Solution Check the heater output with an ohmmeter to ground It should Unit does not heat Controller heater output open read in the mega ohm range cont d Infinite or zero readings indicate a defective output Clogged Y strainer Clean Y strainer Water supply to unit is turned Open water supply OFF Water drain Is plugged 2 Clear drain line or eliminate excessive back pressure in drain back ee line ack pressure condition Unit overheats unable to cool Heat exchanger tubes plugged Remove tube
35. g and maintaining the equipment to familiarize themselves with the safety procedures and the proper use of any safety devices Fail Safe Operation If a safety device or circuit should fail the design must be such that the failure causes a Safe condition As an example a safety switch must be a normally open switch The switch must be held closed with the device it is to protect If the switch fails it will go to the open condition tripping out the safety circuit At no time should the safety device fail and allow the operation to continue For example if a safety switch is guarding a motor and the safety switch fails the motor should not be able to run Chapter 2 Functional Description 16 of 50 WTR2 635 Safety Device Lock Outs Some safety devices disconnect electrical energy from a circuit The safety devices that are used on these temperature control units are primarily concerned with electrical power disconnection and disabling of moving parts that may need to be accessed during the normal operation of the machine Some of the safety devices utilize a manual activator This is the method of initiating the safety lock out This may be in the form of a plug lever or a handle Within this lockable handle there may be location for a padlock Personnel servicing the equipment should place a padlock in the lockout handle In addition to the safety devices listed above these temperature control units are equipped with a
36. haft Remove two nuts holding seal gland plate and seal gland in place Slide seal gland off of shaft being careful not to damage the lip seal Using a soft headed hammer gently tap on the end of the rotor shaft until the rotor and shaft assembly can be completely removed from the pump Note the mechanical seal may stick to the shaft causing initial resistance when the shaft is removed Remove the mechanical seal parts from the bracket Clean all parts thoroughly and examine for wear and damage Check lip seals ball bearing bushings and idler pin and replace if necessary Check all other parts for nicks burrs excessive wear and replace 1f necessary Wash bearings in clean solvent Blow out bearings with compressed air Do not allow bearings to spin turn them slowly by hand Spinning bearings will damage race and balls Make sure bearings are clean then lubricate with non detergent SAE 30 weight oil and check for roughness Roughness can be determined by turning outer race by hand Casing can be checked for wear or damage while mounted on bracket Chapter 6 Maintenance 35 of 50 WTR2 635 Pump Assembly The seal used in this pump is simple to install If you take care during installation good performance will result The principle of the mechanical seal is to make contact between the rotary and stationary members These parts are lapped to a high finish and their sealing effectiveness depends on complete contact When reque
37. he hot oil temperature control unit and components are properly GROUNDED before you switch on power Do not jump or bypass any electrical safety control Do not restore power until you remove all tools test equipment etc and the hot oil temperature control unit and related equipment are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality Chapter 1 Safety 9 of 50 Chapter 2 Functional Description 2 1 2 3 WTR2 635 Models Covered in This Manual This manual lists installation operation and maintenance instructions for the hot oil portable temperature control unit Model numbers are listed on the serial tag A model number followed by Q indicates a specially constructed unit and not all information in this manual may apply Make sure that you know the model number serial number and operating voltage of your unit if you contact us General Description Your hot oil temperature control unit circulates thermal transfer type oil through your process and to precisely automatically and reliably maintain it at a temperature you can select The operating range of your temperature control unit is fro
38. is designed to operate with an open unrestricted drain line Steam rapidly expands within the heat exchanger so any overpressure condition from backpressure or standing columns of water against the drain must be avoided If you must use a pipe joint compound use a compound that can withstand the high temperatures and pressures of your M unit Always insulate all piping to prevent burn hazards and to retain heat Make sure insulation is properly rated for maximum operating temperatures of your M unit Piping Considerations for Mobile Installations Because your M unit is fitted with casters its portability is well suited for multiple applications You can purchase high quality flexible metal hose to enhance the mobility of your M unit state the length you want when ordering Although they cause a drop in pressure you can also install quick disconnects to your M unit However do not install check valves with quick disconnects unless absolutely necessary WTR2 635 Chapter 3 Installation 19 of 50 Connecting Process Piping Hoses valves and other components in your process must be able to withstand M unit maximum temperatures and pressures e Maximum temperatures and pressures are listed on the unit nameplate Carefully inspect all components before installation e Ifin doubt about component suitability obtain factory components Fix all leaks Fluid can be a potential fire and slip hazard Connecting Cooling Water Piping
39. line cord plug This allows the operator or maintenance personnel to unplug the tcu from its power source and tag it out The plug can then be tagged with any number of approved electrical lockout tags available at most electrical supply stores Always disconnect and lockout all electrical power and pneumatic i e compressed air sources prior to servicing or cleaning the temperature control unit Failure to do so may result in serious injury No one but the person who installed the lockout may remove it Chapter 2 Functional Description 17 of 50 Chapter 3 Installation 3 1 Work Rules The installation operation and maintenance of this equipment must be conducted in accordance with all applicable work and safety codes for the installation location This may include but is not limited to OSHA NEC CSA and any other local national and international regulations Read and follow these instructions when installing operating and maintaining this equipment If the instructions become damaged or unreadable obtain additional copies from ACS Group Only qualified personnel familiar with this equipment should work on or with this hot oil temperature control unit Work with approved tools and devices Disconnect the electricity before maintenance or service If the unit 1s installed with a power cord that can be un plugged unplug it If the unit 1s permanently wired to a power main make sure that a fused power disconnect is i
40. m 100 F to 550 F 38 C to 288 C The unit is best suited for use with TrueTherm Heat Transfer Fluid A recommended list of commercially available heat transfer fluids can be obtained through customer service Rapid recirculation of the relatively small amount of fluid provides a close and uniform temperature relationship between the TO PROCESS and FROM PROCESS lines This does of course depend on the configuration of your process and any restrictions within the mold This recirculation combined with the immersion heater and optional cooling capability gives fast and accurate response to bring the fluid up to temperature or to changes in the settings when needed Performance is assured through matching the unique controllers to the high temperature system The two systems are fully integrated to achieve accurate control along with efficient use of water and electricity Typical Features and Components Standard Features e Off the shelf microprocessor based PID temperature controller with Process and Set Point LED readouts e Non fused lockable rotary disconnect e Dual stage immersion heater with IEC contactors e 550 F 288 C maximum operating temperature 400 F 244 C maximum operating temperature for 6 kW heater e Manual bypass e Branch fusing e System status graphic display e Pressure switch for low pump pressure shut down e NEMA 12 electrical enclosure e UL listed subpanel Chapter 2 Functional Description
41. n rates refer to specification information for the heat transfer fluid you select Generally most heat transfer fluids expand at the rate of 2 5 for every increase of 50 F C from temperatures above 60 F 16 C WTR2 635 Chapter 3 Installation 20 of 50 Vent solenoid Fill port must be plugged except T when filling 1 NPT Sight glass reservoir level gauge Manual bypass valve Oil reservoir drain 1 2 NPT Figure 2 M Unit Piping Setup I Connect the TO PROCESS hookup to the entrance of the process and the FROM PROCESS hookup to the exit of the process Connect the COOLING WATER SUPPLY to your plant water supply Connect the COOLING WATER DRAIN line to an open drain or to the return line of your central water system If returning to a central water system use a condensate return tank to 1 Cooling water supply 3 4 NPT CODL IN 3 4 NF Cooling water drain 3 4 NPT LII 3 4 NI From Process oil 1 NPT FRE 1 NF To Process oil 1 NPT LN Oil drain 1 NPT avoid a standing water column on the heat exchanger drain line ACAUTION If you are routing the drain line to an open drain make sure that the line is directed away from personn
42. nal The High Level indicator light illuminates when the heat transfer fluid level in the reservoir tank 1s too high Carefully remove just enough fluid so this indicator light shuts off Low Level Indicator Light The Low Level indicator light illuminates when the heat transfer fluid level in the system is too low This is an alarm condition so the audible alarm activates to notify you of the low fluid level fault and the controller outputs are disabled Always correct the alarm condition before returning to normal operation Chapter 5 Using Controls and Indicators 30 of 50 Chapter 6 Maintenance ZA WARNING Make sure that your maintenance technicians comply with lock out tag out procedures during any servicing or maintenance of this unit and related equipment per OSHA As A 6 1 WTR2 635 article ART 1910 147 Before you begin servicing this unit disconnect all power to the unit let the unit cool down completely and turn off the water Failure to follow these directives can result in serious injury or death Periodic Checks Making Daily Checks e Check fluid level add fluid as needed e Check all connecting lines hoses and connectors for wear or damage Making Monthly Checks e Check for leaks developing at the pump seal gaskets and other similar locations e Check the pump drive V belt for any wear e Check the reservoir tank vent for any obstructions Making Quarterly Checks e Check th
43. nd that you check the associated circuitry and assemblies for other defective devices It is common to replace the obviously damaged component without actually locating the real cause of the trouble Such hasty substitutions will only destroy the new component Refer to wiring diagrams and schematics Locating mechanical problems should they occur is relatively straightforward When necessary refer to the parts catalog section 46 of 46 WTR2 635 Chapter 7 Troubleshooting Condition Possiblecause Solution l Increase size of connectors Undersized connectors lines water lines Long connecting lines between Move the unit closer to the mold unit and mold and shorten connecting lines Serpentine flow through mold Connect les for parallel flow instead of series flow Bloereditsadm mold Check mold for metal chips or deposits Clean mold Temperature fluctuations rapid Quick disconnect fitting with Remove and replace fitting or cycling from hot to cold check valve valve Carbon build up in unit piping or Clean or replace affected piping fittings Replace fluid Check unit by opening the manual bypass to determine if the TCU controls the set point temperature Reversed probes Switch Return and Delivery probes mo Check all lines connections Loss of fluid in process ds fittings Allow vent timer to run out or Vent valve open check valve operation when unit is cold by opening the fill port Unit do
44. nnnconncnnncnnnnnnnoncnnnanonnnnnnnnnnnnncnnncnnns 32 6 4 Corrective Maintenance esessssssssseeseeseen nenne nenne nne nenne sse sii nennen ae sr enses 32 09 r afceiselin dutap oee ttr 33 CHAPTER 7 TROUBLESHOOTING 46 TS JIntrOdUuctlOD uie ern a Da C Mei nth canes 46 CHAPTER 8 APPENDIX iiissio teri Pexiexko usa DUE Sau eni xMo Un aa DUEB Ss 49 WTRI 935 V 8 1 Technical Assistance Parts Department Sales and Contracting Department esses seen nns Facilities WTRI 935 vi Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your granulator The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the equipment We can also provide the assistance of a factory trained technician to help train your operator s
45. ns 10 24 Feature DescaplOns eter 12 2 5 Dale FOAM CS cecinere etr e cacas 16 CHAPTER 3 INSTALLATION eere 18 SU MER el ADIRE mE 18 3 2 Installation Requirements secet et eM b Fon Idee rre te EE En Dinar ete e bb ente ons 18 9 9 lt COMMECUMOG PIPING lt a is 19 CHAPTER 4 OPERATION suscitada 23 dAl la o e ee ee en eee 23 42 SDUEbdoWll A Pme laria ana 24 Unit Shut Down With Autovent Solenoid or Manual Vent Valve 24 4 3 Returning Fluid to th Tank icto ete ette s e Eo QE ne cheer eui eene cte ae esaet in 25 CHAPTER 5 USING CONTROLS AND INDICATORS 26 5 1 The Microprocessor Controller ooccoccconcccnconiccnconccononnoncnconconnnononnnnnnonnnnanonnnnnnos 26 5 2 Controller Display sese oeiks actu aee sc Reda ha co fe ERES QUE ae AE e EES ATAS 26 5 9 Identifying Control Panel SWIICheS ium be Te id 27 5 4 Identifying System Status Board Indicators coocccoccconnconnconnconnononcnnnoncnonnnnnannnanos 28 CHAPTER 6 MAINTENANCE eere nee 31 6 1 APSO CIC GN ci TEE mmm 31 Making Dally ChecKS ati A nO te EXTR UR BEP Ss entend o iuret 31 Making Monthly CHECKS sta bbs nee ei FAR dn apis n iata iue had 31 Making Quaneny Check Sasons iee trie ceca tette tendant 31 Making SIX IV OMG OCKS Sas 31 6 2 iol ila i e ladlelcpem mc 32 6 3 Draining the Unit for Storage ooccccccccccccncccncncncnonc
46. nstalled to allow the disconnect to be locked in the OFF position Open and lock out the disconnect installed in the control enclosure 3 2 Installation Requirements Make sure that you meet the following requirements when installing and operating your M hot oil temperature control unit Installation Location Considerations Locate the M unit as close as possible to the process for proper circulation and temperature control Take care when selecting a location The area surrounding the unit must be free of obstructions to ensure proper ventilation of internal components Allow a minimum clearance of at least 30 inches 76 cm Make sure that the unit location is not in a confined space to ensure proper air circulation Special air circulation ventilation 1s required for units operating at temperatures exceeding 500 F 260 C Vapors can escape from areas such as the reservoir tank during high temperature operation Harmful vapors may be generated from thermal fluid during high temperature operation Prolonged or repeated exposure of these hot generated vapors may result in eye and respiratory tract irritation Avoid contact or inhaling harmful amounts of material Consult the Material Safety Data Sheet MSDS for precautions and instructions for the thermal fluid you are using N O TI C E Before storing your M temperature control unit make sure you remove all residual water with compressed air to avoid a potential freezing hazard See Sec
47. owing start up procedures This will ensure that all air is vented from the system to prevent fluid degradation and damage to the heater 1 Add fluid to the reservoir tank until the level is near the top of the sight glass 2 Open the Vent Valve on the back of the unit WTR2 635 Chapter 4 Operation 23 of 50 3 Depress the Pump Start button to start the pump Check motor rotation by observing the pressure gauge If the gauge indicates positive pressure rotation is correct If not disconnect power and reverse the incoming power leads 4 As fluid is drawn out of the reservoir tank to fill the process the fluid level will fall in the tank Continue to add fluid to maintain the level about 4 inches from the bottom of the sight glass You must purge the system of air before the heating cycle Personal injury and system damage can occur from a pressurized system 5 Air and Oil will be vented through the Vent Valve and into the reservoir tank 6 2 minutes after the unit has built at least 5psi of pressure select a set point of 100 F and switch unit into the Auto mode As the oil warms up viscosity will decrease and the pressure will fall 7 With 2 minute intervals increase the setpoint to 150 and 200 F 8 If any water is present in the system it must be boiled off before continuing operation Select a setpoint of 215 F 102 C and observe the reservoir tank vent for any signs of escaping steam Continue to run at 215 F
48. r unit The alarm will sound in the event of the following conditions e motor overload safety thermostat trip over temperature e low fluid pressure e low fluid level high fluid level optional Push the ALARM SILENCE button to silence the alarm See Section 5 1 on page 26 for more information on control functions Electrical Panel and System Components The pump motor and immersion heater operate on three phase 50 60 cycle nominal voltage with the control circuit at 115 V single phase The control circuit voltage is provided by a single phase machine tool transformer with primary fuse protection and a grounded secondary A main power disconnect is included as for ease of service The electrical panel is UL listed and complies with N F P A 79 provisions All components are IEC rated for long life and reduced maintenance The heater elements are branch fused and protected from contactor welding by a separate primary voltage contactor WTR2 635 Chapter 2 Functional Description 13 of 50 The pump motor is controlled by a full voltage magnetic reversing starter with fused branch circuit overcurrent and thermal overload protection Many additional features are available as options A NEMA 12 enclosure is standard with NEMA 4 available as an option Air Purge Upon initial start up and mold process change out you ll need to purge all air and water from the system The M unit has appropriate valving to ensure complete purging
49. rain or into the water supply piping The controller automatically regulates cooling by opening and closing the cooling solenoid This allows the proper amount of cooling water to pass through the tubes of the heat exchanger and out the drain A water supply of 75 psi 517 1 kPa 5 2 bars maximum is required for connection to the heat exchanger Connection Lines Connections for TO PROCESS and FROM PROCESS lines are 1 NPT 25 4 mm Water connections for COOLING WATER SUPPLY and COOLING WATER DRAIN are 0 75 NPT 19 1 mm see Section 3 The customer is responsible for conversions to metric standards We stock many lengths of flexible metal hose the part number is 572 16969 State the length of hose you want when ordering Component failure may result in high temperature oil spray causing serious injury or death Make sure hoses valves and other components installed in your process can withstand maximum temperature and pressure of the M unit check unit nameplate for specific capacities All components must be carefully inspected for condition before installing Make sure you have factory components if you have any doubt Electrical System Controls simplicity of operation The switches are clearly labeled as to their function Your M unit has a system status board so you can evaluate the status and performance of the unit at a glance Pilot lights are provided to indicate key unit functions An audible alarm is standard with you
50. rvice calls are needed Locate disconnects in an easily accessible location Operators should not have to squeeze around the M unit to reach disconnects especially in case of emergency When running conduit whips to the M unit make sure that whips are routed away from hot piping ACAUTION Check the unit nameplate for correct voltage and amperage before making electrical connections Make all electrical supply connections at the front of the unit An access panel covers all electrical connections Run electrical connections to the supply terminals from either side of the unit Make sure that all three phases are wired correctly The pump runs backwards if not wired properly Improper electrical connections can damage the unit and cause serious operator injury or death Make sure that all electrical connections are made by a qualified electrician and that all connections are tight WTR2 635 Chapter 3 Installation 22 of 50 Chapter 4 Operation 4 1 Start up Unit Start up With Autovent Solenoid The highly engineered controls and controller make this unit almost self operating Before you can begin heating it will be necessary to perform the following start up procedures This will ensure that all air is vented from the system to prevent fluid degradation and damage to the heater 1 Add fluid to the reservoir tank until the level is near the top of the sight glass 2 Depress the Pump Start button to start the p
51. s an imminently hazardous situation that if not avoided will result in death or serious injury ZA WARNING WARNING indicates a potentially hazardous situation or practice that if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation or practice that if not avoided may result in minor or moderate injury or in property damage WTR2 635 Chapter 1 Safety 7 of 50 Hazard Alert Description Explanation Preventative Maintenance Symbol High Voltage Hazard The electrical Every six months inspect all electrical enclosure is supplied with 3 phase electrical connections for secure attachment For power Use caution when using or further information see the maintaining this product Maintenance Chapter in this manual Hot Surface Hazard When the unit operates Every six months inspect all surfaces above 212F 100C the surface of the unit for signs of heat degradation If any may reach excessive temperatures Use appear remove panel and verify cause caution when using or maintaining this of degradation and repair product Pinch Point Entanglement The pump and Every month inspect the belt s for any motor are linked using v groove belts Use type of wear For further information caution when using or maintaining this see the Maintenance Chapter in this product manual Mandatory Description Explanation Symbol A Read Operators Manual This equipment must be operated and maintain
52. s that it is attached to Systems with large process connections ports and piping will operate at low pressures While systems with small process connections ports and piping will operate at higher pressures Once the pressure requirements exceed the rated pressure the fulflow valve will open and bypass the necessary fluid to prevent high pressures Ful Flo Valve A regulating by pass line featuring a Ful Flo valve is standard in all units This is a safety device to prevent excessive pressure in the event that the delivery line is obstructed Each Ful Flo is factory preset to limit system pressure as specified by the customer It must not be tampered with in any way In the event of an obstruction in the line the Ful Flo will open and divert fluid from the delivery TO PROCESS line to the return From Process line A constant flow of fluid is maintained through the heater tank to prevent damage to the heating elements and fluid WTR2 635 Chapter 2 Functional Description 12 of 50 Cooling Optional The specially made shell and tube heat exchanger 1s provided as optional equipment in this unit The design features U tube construction and copper nickel tubes for durability and optimal heat transfer The modular construction allows the tube bundle to be easily removed for periodic cleaning Additionally check valves are installed on the water supply and drain lines to prevent water from back flowing into the heat exchanger from a closed d
53. sting special seal information make sure that you give the pump model number and serial number 1 Install bracket bushing if required If bracket bushing has a lubrication groove install bushing with groove at 6 00 o clock position in bracket If carbon graphite Refer to Installation of Carbon Graphite Bushings page 50 2 Coat shaft of rotor shaft assembly with non detergent SAE 30 weight oil Start end of shaft in bracket bushing turning from right to left slowly pushing rotor in casing MECHANICAL SEAL 13 SEAL HOLDER 10 LIP SEAL GD 3 Coat idler pin with non detergent SAE 30 weight oil and place idler and bushing on idler pin in head If replacing with carbon graphite bushing Refer to Installation of Carbon Graphite Bushings page 50 4 Using a 010 to 015 inch head gasket install head and idler assembly on pump Pump head and casing were marked before disassembly to insure proper reassembly If not be sure idler pin which is offset in pump head is positioned toward and equal distance between port connections to allow for proper flow of liquid through pump Tighten head cap screws evenly Chapter 6 Maintenance 36 of 50 10 ti 12 13 Place the mechanical seal installation tapered half rings over the shaft and apply P 80 oil supplied with the replacement seal grease is not recommended on the sleeve and rotor shaft Slide the rotating portion of
54. the mechanical seal on the shaft until it bottoms on the shaft step See FIGURE 6 Remove the seal installation tapered half rings It is important when using the rings to make sure the thin edge is facing the direction of the shaft end and that the thick end is facing the rotor Apply lubricant to the seal seat o ring and push it in the bracket Note the shinny side of the seat goes towards the carbon graphite seal face Apply Dow Corning 44 high temperature silicon grease to the lip seal area in the seal gland and install on the shaft Install the seal gland plate and secure with two nuts Pack ball bearing with Dow Corning 744 high temperature silicon grease and install in the thrust bearing housing Place bearing spacer collars inside the lip seals Thread the end cap into the bearing housing and tighten with a spanner wrench Tighten the radial set screws that lock the end cap in place Using the snap ring pliers install the snap ring onto the shaft Thread the thrust bearing assembly into the bracket Turn in until hand tight This forces the rotor against the head Put lockwasher and locknut on shaft Insert length of hardwood or brass through port opening between rotor teeth to keep shaft from turning Tighten locknut to 50 70 ft Ibs torque and bend one tang of lockwasher into slot Adjust pump end clearance Refer to section on Thrust Bearing Adjustment Lubricate all grease fittings with Dow Corning 44 high t
55. tion 6 3 for more information WTR2 635 Chapter 3 Installation 18 of 50 NO TIC E Note the following table of ambient temperature ranges permitted for storage and operation Ambient storage range Ambient operation range DOE ee J CF CCo 40 F to 185 F 40 C to 85 C 4 F to 120 F 20 C to 49 C You should preheat the process heat transfer fluid first 1f you want to start the unit below an ambient temperature of 30 F 1 C 3 3 Connecting Piping Make sure that all external piping is properly sized to reduce external pressure drop as much as possible Do not install process or water supply drain piping smaller than the fittings on the unit If the water supply piping is larger than unit fittings reduce the pipe size at the unit The following table lists M TCU pipe sizes Size diameter Connection inches NPT mm approx c 1 NPT 25 4 mm 1 NPT 25 4 mm Cooling Water Supply 0 75 NPT 19 1 mm Cooling Water Drain 0 75 NPT 19 1 mm 0 5 NPT 12 7 mm Fill Port 1 NPT 25 4 mm c Customer is responsible for converting to metric Always use a backup wrench to support M unit piping when making N O TI CE connections Make sure all external piping is supported independently of the M unit It is recommended that you have strainers installed on the cooling water inlets and customer supplied shut off valves on all piping connections Use common black welded pipe for permanent installations The M
56. ump Check motor rotation by observing the pressure gauge If the gauge indicates positive pressure rotation is correct If not disconnect power and reverse the incoming power leads 3 As fluid 1s drawn out of the reservoir tank to fill the process the fluid level will fall in the tank Continue to add fluid to maintain the level about 4 inches from the bottom of the sight glass 4 Air and Oil will be vented through the Vent Solenoid and into the reservoir tank You must purge the system of air before the heating cycle Personal injury and system damage can occur from a pressurized system 5 2 minutes after the unit has built at least 5psi of pressure select a set point of 100 F and switch unit into the Auto mode As the oil warms up viscosity will decrease and the pressure will fall 6 With 2 minute intervals increase the setpoint to 150 and 200 F 7 If any water is present in the system it must be boiled off before continuing operation Select a setpoint of 215 F 102 C and observe the reservoir tank vent for any signs of escaping steam Continue to run at 215 F until no more steam appears and pressure has stabilized 8 When fluid level has stabilized and air and water is purged from the system allow the vent timer to run out Unit Start up With Manual Vent Valve The highly engineered controls and controller make this unit almost self operating Before you can begin heating it will be necessary to perform the foll
57. vely cause slippage and deliver less power Use matched belts Matched belts run smoother and last longer because the load is evenly distributed Never replace just part of a set of belts Avoid belt idlers Belt idlers decrease belt life Always maintain proper tension through motor adjustment Mount belts straight Shafts must be parallel and sheave grooves in alignment to prevent unnecessary belt wear Don t overload An overloaded belt drive is like a one ton truck with a two ton load both are sure to break down Always use ample capacity Operating drives without guarde in place can result in severe Injury or death Emerson Power Transmission Manufacturing L P 1998 1999 All Rights Reserved WTR2 635 Chapter 6 Maintenance 2 nl BELT TENSIONING INSTRUCTIONS A WARNING Disconnect power before inataliztion and maintenance Falbure to do so cen result in severe Injury or death Measure the belt span Calculate deflection See tables below for correct deflection force Apply force at right angles to the center of the span see diagram below The BROWNING belt tension checker shown at left is ideal for this procedure 5 Check the tension at least twice during the first day of operation and periodically thereafter Be sure opn m Ug op BELT SPAN use the inexpensive BROWNING Belt Tension Checker j See Form 5453 ICE for more detail o Mu EO The capacity of
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