User Guide - ACS Group
Contents
1. A HAMMER TANK ARRESTOR OPTIONAL RETURN eno EXCHANGER PRESSI ANT STRAINE l l RETURN P l i gt gt l L OPTIONAL ues VENTICOOL COOLING SOLENOID VALV SOLENOID VALVI 4 poems E E DRAIN 4 4 l 4 i I T l K 34 p OPTIONAL DRAIN Sh Sa ag ee al N N L l PRESSURE l REGULATOR VALVE 4 OPTIONAL i l WATER p NY STRAINE La l SUPPLY j r gt TH gt gt 86839b PRESSURE l OPTIONAL RELIEF VALVE l RAW ye ee ee A WATER l g l SUPPLY qm E 1 N N EN E J OPTIONAL REGULATORIRELIEF Compact and Upright Water Temperature Control Units Page 25 Figure 4 Pump Curves 60 Hz TOTAL HEAD PERFORMANCE CURVE z 1 0 S G wrRs Psr reer wuMBER 40 000 675 200 RPM 70 F 60 Hz 614 874200 ER 10 22 99 551 784180 494 695 437 617 577 92 307 437 24 357 1847 2647 127 177 40 67 97 20 U S GALLONS Q 15 30 45 60 75 90 105 120 PER MINUTE T T T T T T T T T T T T LITERS PER MINUTE 57 114 171 228 285 342 399 Pump Curves 50 Hz Consult Factory for 10 hp Curves 4 874 10 22 99 4784 497 697160 434 6111407 5HP 571527120 304 43 1100 12HP 247 357 80 TT1HP 181 267 60 1241 174 40 67 97 202. provides years of reliable operation Please read and follow the instructions in this manual to get the most satisfaction from your temperature control system 2 2 Necessary Documents The following documents are necessary for the operation installation and maintenance of a Compact and Upright water temperature control units Additional copies are available from ACS Group Familiarize the appropriate personnel with these documents M This manual M The controller operation manual M The electrical schematic and connection diagram placed inside the control enclosure M The operation and installation manuals for accessories and options selected by the customer M The Customer Parts List included in the information packet 2 3 Models Covered This manual provides operation installation and maintenance instructions for the TrueTemp Series TCU CWT Series TCU and Royal Series 2010 2012 TCU water temperature control units 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 temperature control unit if you contact the ACS Group 2 4 Standard TCU Series Features Compact rugged cabinet with easy access side panels e Cast and flange design to reduce connection points e Half and full heat capability e Over Current Protection for moto
3. If any appear remove panel and verify cause of degradation and repair Mandatory Description Explanation Read Operators Manual This equipment must be operated and maintained 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 O90 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 Page 8 1 2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes This may include but is not limited to OSHA NEC CSA SPI and any other local national and international regulations To avoid possible personal injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices e Mi Read and follow these operation and installation instructions when installing operating and maintaining this equipment If these instructions become d
4. Responsibility Page 10 These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machines should become familiar with their operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Each individual must take responsibility for observing the prescribed safety rules as outlined All warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor General Responsibility No mater who you are safety is important Owners operators and maintenance personnel must realize that every day safety is a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in a negative way following an accident The following are some of the ways that accidents can affect your production Loss of a skilled operator temporarily or permanently Breakdown of shop morale Costly damage to equipment Downtime An effective safety program is responsible and economically sound Organize a safety committee or group and hold regular meetings Promote this group from the management level Through this group the safety program can be continually reviewed maintained and
5. 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 1 847 273 7804 Fax 91 20 40147576 Europe Middle East Africa ACS New Berlin Manufacturing Facility 2900 S 160 Street ACS Warsaw New Berlin WI 53151 Ul Dzia kowa 115 Page 57 Phone 1 262 641 8600 02 234 Warszawa Fax 1 262 641 8653 Phone 48 22 390 9720 Fax 48 22 390 9724
6. for 300 F 149 C units prior to leaving the factory 4 4 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 Compact and Upright Water Temperature Control Units Page 33 The controller has been fully factory tested and loaded with preset tuning parameters To quickly adapt the controller to your process you may elect to tune the controller at start up Refer to the Auto tune section 5 3 Built in range of operation on the controller is 0 F to 250 F 18 C to 121 C 4 5 Controller Display Figure 7 Typical 3216 Microprocessor Controller Eurotherm 3216 IBU 180 See Figure 7 Measured Temperature Value Numeric LED During normal operation the large green 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 if an error occurs Required Temperature Numeric LED During normal operation the smaller green SP 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 See Figure 7 Page Key From any display press to return to the HOME display Scroll Key Press to select a ne
7. improved Keep minutes or a record of the meetings Hold daily equipment inspections in addition to regular maintenance checks You will keep your equipment safe for production and exhibit your commitment to safety Please read and use this manual as a guide to equipment safety This manual contains safety warnings throughout specific to each function and point of operation Operator Responsibility The operator s responsibility does not end with efficient production The operator usually has the most daily contact with the equipment and intimately knows its capabilities and limitations Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates or through a casual attitude toward machinery formed over a period of months or years Your employer probably has established a set of safety rules in your workplace Those rules this manual or any other safety information will not keep you from being injured while operating your equipment amp Learn and always use safe operation Cooperate with co workers to promote safe practices Immediately report any potentially dangerous situation to your supervisor NEVER place your hands or any part of your body in any dangerous location NEVER operate service or adjust the temperature control unit without appropriate training and first reading and understanding this manual NEVER try to pull material out of the temperature control unit with your hands while it is runn
8. it is not in use Turn the switch to the OFF position or unplug it from the power source Compact and Upright Water Temperature Control Units Page 11 Page 12 Maintenance Responsibility Proper maintenance is essential to safety If you are a maintenance worker you must make safety a priority to effectively repair and maintain equipment Before removing adjusting or replacing parts on a machine remember to turn off all electric supplies and all accessory equipment at the machine and disconnect and lockout electrical and pneumatic power Attach warning tags to the disconnect switch and air shutoff valve When you need to perform maintenance or repair work on a temperature control unit above floor level use a solid platform or a hydraulic elevator If there is a permanently installed catwalk on your temperature control unit use it The work platform should have secure footing and a place for tools and parts DO NOT climb on the temperature control unit machines or work from ladders If you need to repair a large component use appropriate handling equipment Before you use handling equipment portable A frames electric boom trucks fork trucks overhead cranes be sure the load does not exceed the capacity of the handling equipment or cause it to become unstable Carefully test the condition of lifting cables chains ropes slings and hooks before using them to lift a load Be sure that all non current carrying parts are
9. red PUMP OVERLOAD indicator lights if the pump motor overload opens from high amp draw The pump motor contactor drops out protecting the motor HEATER ON Indicator The red HEATER ON indicator lights during heater operation The HEAT LED on the controller lights at the same time OVER TEMPERATURE Indicator The red OVER TEMPERATURE indicator lights if the process temperature rises above the safety thermostat setting COOLING VALVE ON Indicator The green COOLING VALVE ON indicator lights during cooling valve operation If the unit has a standard solenoid not motorized cooling valve the OUT 2 LED on the controller lights at the same time LOW WATER PRESSURE Indicator The red LOW WATER PRESSURE indicator lights if cooling water pressure drops below 16 psig 110 32 kPa 11 03 bars The pressure switch opens and shuts down the 115 VAC control power VENT CYCLE Indicator The green VENT CYCLE indicator lights during vent cycle operation PURGE VALVE ON Indicator Units with Optional System Purge The amber PURGE VALVE ON indicator lights when the AIR PURGE switch is ON This option purges water from the process When control power is OFF and the AIR PURGE switch is pressed the system purge solenoid and cool vent valves open Air displaces the water in the Water Temperature Control system and the process piping pushing the water out the WATER OUT line A check valve in the Water Temperature Control system piping and a shutoff va
10. runaway heating If overheating occurs the safety thermostat shuts down heater outputs The unit continues to pump water through the system to prevent heater damage The ACS Group recommends that you install an audible or visual alarm to the terminals provided Factory installed alarms are available see the electrical schematics in the installation packet for more information Pressure Relief Valve If the combined pressure of the cooling supply water and pump discharge exceeds 150 psig 1 034 25 kPa 10 34 bars the pressure relief valve opens and relieves the pressure This is a non adjustable ASME construction valve with a stainless steel spring Route a pipe from the pressure relief valve to a suitable drain to reduce potential scalding hazard The drain line must not have any restrictions or back pressure Page 30 Low Pressure Cutout Switch This switch set at 16 psig 2 psig differential 110 3 kPa 1 10 bars with a 13 79 kPa 0 14 bars differential shuts down the unit if the COOLING WATER IN or MAKEUP water pressure drops below 16 psig 110 3 kPa 1 10 bars Pumps Pumps range in power from hp to 7 2 hp 0 56 kW to 5 59 kW and are equipped with 3 phase ODP motors and seal flush lines as standard The pump is a bronze fitted straight centrifugal type It features a split case design to facilitate replacement of the seal It has a high output capacity with excellent discharge pressure helping it facilitate turbulence to
11. 0 1893 206 9 3 Full load amps at 460 volts Pressure drop flow and loss 2 3 224 60 227 71 35 2413 750U 7 560 90 3407 50 3448 0 Model hp kW j 9kWhtr 12 kW htr 18 kW htr 24 kW htr flow gpm flow Ipm loss psi loss kPa To calculate full load amps at 230 volts multiply by 2 0 Compact and Upright Water Temperature Control Units Page 19 Chapter 3 Installation 3 1 Installation Location Considerations The Compact and Upright Temperature control systems are portable and can be installed almost anywhere As with all equipment installations follow all applicable codes and regulations M The recommended ambient temperature range from 14 F 10 C to a maximum operating ambient temperature of 131 F 55 C Recommended ambient storage temperature range is from 13 F to 149 F 25 C to 65 C If storing the unit below freezing temperatures make sure the unit has an antifreeze mixture circulated inside M Provide a minimum of twelve inches 12 or about 30 cm clearance on all side of the cabinet to allow circulation of cooling air M Locate the unit as close to the process as is practical 3 2 Process Approach Temperature Considerations If the differential between COOLING WATER IN and TO PROCESS temperatures is less than 10 F 7 C consult our Sales Department for advice on how to control low approach applications 3 3 External Piping Sizing Considera
12. 25 psig 172 38 Insufficient cooling or kPa 1 72 bars water makeup water pressure pressure on WATER IN or CITY WATER MAKEUP Jump power across switch Switch is broken and see if unit starts Replace Switch if needed Undersized connectors Increase size of connectors water lines water lines Move the unit closer to the mold and shorten connecting lines Serpentine flow through Connect lines for parallel flow mold instead of series flow Temperature fluctuations Blocked water line in mold Cheek ma for metal chips or lime buildup Clean mold Pressure switch circuit is open Long connecting lines between unit and mold fabictevelng TORNO CORE Quick disconnect fitting with Remove and replace fitting or check valve valve Lime buildup in unit piping Check unit by connecting 74 line directly from delivery to Faulty TCU return line Run unit to determine if TCU controls set point temperature Drain is plugged or excessive back pressure is in drain line back pressure condition Test solenoid valve by pressing VENT button and listen for valve operation Replace if faulty Faulty solenoid valve Controller Cool output relay Replace output relay Solenoid valve is not Set process temperature to operating but COOL LED is minimum and check for mag Unit overheats or does not on netism on solenoid coil top cool ONE heck coi i Y Solenoid coil circuit is open Check coil resistance If MS range re
13. 51 Chapter 7 Troubleshooting Condition Possible cause Solution Check main disconnect No power fuses wiring and power lead to unit Voltage must be within plus Unit does not turn on puc voltage supped 1e or minus 10 of nameplate rating Defective on off switch Control circuit fuse blown Defective control transformer Check transformer Broken or loose wire in pump Locate and repair motor control circuit Pump motor contactor IP me Repair or replace holding coil is open Check for at least 16 psig 110 32 kPa 1 1 bars water pressure on WATER IN or CITY WATER MAKEUP Reset and test each leg for Verify proper rotation If not Pump running in reverse clockwise reverse any two incoming power leads Foreign matter in the system System has minimal back As long as there is pressure and is operating at satisfactory process the far end of the pump temperature control there is curve no problem Foreign matter obstructing Gleamilid system system y i Check for closed valves etc Restricted water flow Be sure all lines are properly High pump pressure sized System has high back As long as there is pressure and is operating at satisfactory process the near end of the pump temperature control there is curve a low flow condition no problem Unit does not run Low water pressure light on Low pump pressure Page 52 Condition Possiblecause Solution Check for
14. 6 1 Preventive Maintenance cccccceecccceceeeeeeeeeeeseeeeseeeeeeeeeeeeeeeeeaneeeaessseneess 45 6 2 Corrective Maintenance oio ooo stb Un pud ee Dag lage upon pU aUe Do ra pads gc d 46 Bp Electrical CONNECtONS icsse ca ctia ERE ee RO ERO ARE HD EB Cue ERE EA 48 6 5 Safety Device Seid e caf QR D iQ dep Dg bau od tinier Ua uad ocius ie 48 6 6 Cleaning and Storage sssssssseeeeeeeme enne nnn nnns 51 Chapter 7 Troubleshooting 52 Technical Assistance a eine aoas dio Derrot ee api g ioa dece Bede ne Dt e dog ai cw av vb te pete a epa ie boda On cQ su ads dshrines 57 Parts and Service Department ics cssheagssedacchastesvedaadocaaseds deans ad edtoaadesotedeadocastoteens 57 Sales and Contracting Departtients esee e eite a Ra oet bae 57 Page 6 Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining the water temperature control unit 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 prev
15. Compact and Upright Water Temperature Control Units Models Covered TrueTemp TCU CWT Royal Series 2010 2012 Part Number 882 12041 00 Bulletin Number WTR1 605 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 2012 All rights reserved Page 2 Shipping Info Unpacking and Inspection You should inspect the water 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 is attached to our original invoice If the ship
16. U S GALLONS Q 15 30 45 60 75 90 105 PER MINUTE LITERS 4 4 7 p DIES ure 0 57 114 17 228 285 342 399 Figure 5 Pressure Drops Mode Pressure drop flow and loss hp kW 9kWhtr flowgpm flowlpm losspsi JlosskPa Page 26 3 10 Making Electrical Connections Compact and Upright temperature control systems are designed for three phase voltage operation Refer to the unit nameplate for proper voltage and amperage requirements Make sure you provide a correctly sized and protected supply of electrical power to the unit Refer to National Electric Code NEC Article 430 24 through 430 26 for proper feeder conductor and supply disconnect sizing Maintain a safe ground and disconnect the power supply before servicing the unit A qualified electrician should make electrical connections and disconnect and lock out electricity using OSHA 29CFR 1910 147 standards when you need a service call Check serial tag voltage and amperage requirements and make sure your electrical service conforms before making any electrical connections Total running amps for Compact and Upright temperature control systems are listed on the nameplate Customer connections can be run to the supply terminals from either side of the unit Make sure that all three phases are wired correctly If not wired properly the unit will run backwards Again check the unit nameplate for correct voltage and amperage DANGER Im
17. a listing of spare parts for purchase Have your serial number and model number ready when ordering Compact and Upright Water Temperature Control Units Page 7 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 indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation or AWARNING practice that if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation or NCAUTION practice that if not avoided may result in minor or moderate injury or in property damage Temperature control unit Safety Tags Hazard Alert Description Explanation Preventative Maintenance 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 E F n Me J e Hot Surface Hazard When the unit operates above 212F 100C the surface of the unit may reach excessive temperatures Use caution when using or maintaining this product Every six months inspect all surfaces for signs of heat degradation
18. able for the unit to operate properly MI Connect the main power to the unit disconnect switch and press the START switch to check for proper pump rotation direction as described in Section 5 6 on Page 44 Pump rotation should be clockwise viewed from the motor end M Check your work and proceed to the Startup Procedure section on the following page 5 3 Starting the Temperature Control Unit You can also use these steps to AUTO TUNE the Controller and operate the Unit with the Controller The Auto Tune function lets you fine tune the control PID to process requirements Activate the Auto Tune function whenever the process under control changes Don t be alarmed by control response It may take the process temperature above and below the set points as many as three 3 times It will then level off and control to the process set point Auto tuning can take up to 45 minutes and is best done before any product is run 1 Push the ON OFF rocker switch to the ON to energize the unit and begin the temperature control cycle The switch will be illuminated whenever the unit is on 2 The unit will automatically vent for approximately one minute 3 If needed press and hold the vent button to purge any additional air from the process loop 4 Set process temperature PV by pressing the Scroll key until SP1 appears in the upper display Then press the Up Arrow or v Down Arrow keys to adjust the setpoint 5 Ifthe unit does not ma
19. ak at the pump seal when the pump is started but in most cases the surfaces will mate again after the pump is allowed to run for a short period of time If they do not reseal you may need to open the pump and free the seal by hand It is seldom necessary to install a replacement seal in a new unit unless the seal has been damaged because the unit was started without water Our pump seals have a long period of service life Some conditions of course can shorten seal life including the presence of grit operation of the unit without water sustained high water temperature or presence of certain chemicals in the water Our pump seal assembly has been developed to resist abrasive particles that are present in many water systems This is done by a special flushing system that uses water exiting the pump to constantly wash the seal area It is also fitted with high temperature flexible components for maximum heat resistance These same components remain flexible even at low temperatures Thus the standard seal is a fine combination of heat resistant and wear resistant components Unfortunately even under normal use the seal will eventually wear and require replacement A small puddle underneath the unit is a sign of rotary seal wear and if investigation confirms the pump as the source the seal should be replaced as soon as practical The water slinger is intended to provide temporary protection against this but a continued and substantial leak w
20. amaged or unreadable additional copies are available from the manufacturer Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES 0 Work only with approved tools and devices NANA A Disconnect and or lock out power before servicing or maintaining the equipment Use care when LOADING UNLOADING RIGGING or MOVING this equipment Mi Operate this equipment within design specifications M OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you ISl Mi Make sure the equipment and components are properly GROUNDED before you switch on power v1 When welding or brazing in or around this equipment make sure VENTILATION is ADEQUATE PROTECT adjacent materials from flame or sparks by shielding with sheet metal An approved FIRE EXTINGUISHER should be close at hand and ready for use if needed M Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled 1 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 Compact and Upright Water Temperature Control Units Page 9 1 3
21. ater Temperature Control Unit and Specifications Process water supply To and From p Process FromProcess J gauges To Process i Y KID 28 3 4 am 73 0cm 17 3 4 45 1 cir TT 13 a 33cm 602 86848 Dimensions Shipping Model H w D weight number hp kw gpm Ipm psig kPa in cm in cm in cm Ibs Kg 075 056 30 1136 25 1724 28 73 0 13 33 28 71 1 210 96 100 1 075 35 1325 30 2069 28 73 0 13 33 28 71 1 210 96 1 50 50 1893 30 206 9 28 73 0 13 33 28 71 1 210 96 60 227 1 35 2413 28 73 0 13 33 28 71 1 210 96 90 3407 50 3448 28 73 0 13 33 28 71 1 240 109 60 120 Page 18 Figure 2 Typical Upright Series Water Temperature Control Unit and Specifications 33H 10 cm 33 cm 71 cm Model ad a 460 230 hp kW gpm pm psig kPa in cm in cm 127 113 6 497 8 13 33 28 71 1 Additional Specifications 100U 206 9 200 2 f50 5
22. ater may be used in the system without problems in other cases it can result in large deposits of scale and corrosion ACS offers a complete line of water treatment equipment Contact your ACS sales representative for water testing and treatment options Distilled Water Non ferrous brass copper or high temperature plastic piping is recommended for distilled water processes Deionized Water Stainless steel 316 SS minimum or PVC plastic components must be used with deionized water Stainless steel is recommened because of the temperature constraints with plastic Page 22 3 Making Process Water Connections Closed Circuit Direct Injection For both types of systems the connections are basically the same On the back of each unit the connections are labeled appropriately Connect the DELIVERY hookup to the entrance of the process and the RETURN hookup to the exit of the process Connect the WATER SUPPLY to your plant water supply Connect the DRAIN line to an open drain or to the return line of your central water system Make sure you carefully select the connecting lines and connectors between the temperature control unit and the process to suit the needs and requirements of your application If your unit has a maximum operating temperature of 250 F 121 C the connecting lines and connectors should have a service rating of at least 250 F 121 C and 150 psig 1 034 25 kPa 10 34 bars If it has a maximum temperature
23. cator should illuminate Press the RESET button The unit is now ready for operation Page 48 Pressure Switch With the unit running program a set point of 30 F 1 C Allow the process temperature to drop under 100 F 38 C When the process temperature reaches that point turn off the water supply The pump should stop and the Low Water Pressure indicator should illuminate Turn the water supply on to reset the pressure switch Adjusting the Pressure Switch The pressure switch used in your Water Temperature Control Unit is factory set at 16 psig 110 3 kPa 1 1 bars However if the process does not require the unit to operate at 250 F 121 C you can adjust the switch to meet your process needs Tools Required e 5 64 8 Hex Key HAZARDOUS ELECTRICAL CURRENT PRESENT Maintain a safe ground and disconnect the power supply before servicing the unit Make sure a qualified electrician makes electrical connections disconnect lock out electricity using OSHA 20CFR 1910 147 standards when servicing the unit To adjust the pressure switch Figure 9 Compact and Upright Water Temperature Control Units Page 49 Pressure Switch Side View and Top View EX l 1L Adjusting Knob eel n Q 348 18 Socket Set Screw N FI E Turn the set screw counter clockwise to loosen unlocking the adjusting knob To adjust pressure switch turn adjusting knob clockwise to inc
24. cess return 1 Water supply Ya Drain depends on solenoid used Common black pipe is recommended for permanent installations The temperature control unit water circuit piping is primarily ferrous iron and reacts electro chemically with non ferrous metallic materials such as copper Some water contains dissolved minerals that greatly accelerates the reaction between dissimilar metals Ferrous piping is recommended to minimize galvanic action If piping must be copper use dielectric unions at the unit Compact and Upright Water Temperature Control Units Page 21 3 5 Piping Considerations for High Mobility Installations Mobile temperature control systems must use high quality hose rated for at least 150 psig and 250 F 1 034 25 kPa 10 34 bars and 121 C Special 300 F 149 C high temperature control systems must use hosing rated at 150 psig and 300 F 1 034 25 kPa 10 34 bars and 149 C or greater Quick disconnects may be used for mobility although they cause a drop in pressure If used they must be sized carefully to minimize pressure drop Don t use quick disconnects with check valves unless absolutely necessary Non relieving quick connect fittings or check valves on the water supply must have a pressure relief piped to the drain Failure to do so could result in a dangerous over pressure condition 3 6 Process Water Considerations Raw Water Water treatment is vital in any piping system In some cases raw w
25. correctly connected to earth ground with an electrical conductor that complies with current codes Install in accordance with national and local codes When you have completed the repair or maintenance procedure check your work and remove your tools rigging and handling equipment Do not restore power to the temperature control unit until all persons are clear of the area DO NOT start and run the temperature control unit until you are sure all parts are functioning correctly BEFORE you turn the temperature control unit over to the operator for production verify all enclosure panels guards and safety devices are in place and functioning properly Reporting a Safety Defect If you believe that your equipment has a defect that could cause injury you should immediately discontinue its use and inform the manufacturer The principle factors that can result in injury are failure to follow proper operating procedures 1 e lockout tagout or failure to maintain a clean and safe working environment Notes Compact and Upright Water Temperature Control Units Page 13 Chapter 2 Functional Description 2 1 Introduction Page 14 The Compact and Upright Series water temperature control units are reliable accurate and easy to use process temperature control units They are self contained portable and shipped ready to use The Compact and Upright Series water temperature control units are designed to circulate water through you
26. e ceva erat Er tret 32 4 3 Water Hammer Arrestor Shock Stop seseeeeeeeenennee 32 4 4 The Microprocessor Controller sess 33 4 5 Controller DISpIayi neuer dodi 0s eek oleate het oo po Roc Desi ek Cece Se eect eesti 34 4 6 Digital Flow Meter ieee ete Her Bina Pr etexeiin con eno eddies 35 4 7 Identifying Graphic Panel Indicators ecceeeeoresseeeeeeeeeeeeeeee 36 420 Using Graphic Panel BUUOMS aces o2 iaceo hU nd dee ee ened 38 4 9 PAULING oes ete ice eu site ch pt d etus tec cabo ch caa eee A dcr etd 39 4 10 Controller Internal Switches eeeececeeeenen rennen tete nte ee 39 4 11 COMMUNMIGAUONS 55 5 0263599209 9 000 DMsi aros qun Maia e ero otal 39 Chapter 5 Startup and Operation 40 OP IptFOOHOGU OT aa ie ep db ot rot bd lett red bus b fep tab ntes tat dendo 40 5 2 Startup CheekliSLss iudei etit pa ee oq Ud audeo Pre ae Fu cee DH ton 40 Compact and Upright Water Temperature Control Units Page 5 5 3 Starting the Temperature Control Unit eese 41 5 4 Sequence of Operation 3 open ea n eee Lr e EXE Ex Pekin es 42 5 5 Checking Motor Rotation Direction 2 0 22 ccceceee eee e eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 43 5 6 Shutting Down the Temperature Control Unit sseeeeeeeueeeeeessssus 43 Chapter 6 Unit Maintenance een 45
27. els GC OVeF OQ eei e i Eid et an DX OSCAEK CAEN e ERRORES BARRE SER CAE MDRRT ERG SAL ULR 15 2 4 Standard TCU Series Features recenter in Sce et eo pectet Ere t pen 15 250 Available Apos pot o bra D Ue nta tetris ieee 16 Chapter 3 Installation ssss 20 3 1 Installation Location Considerations eeseeeeeeee 20 3 2 Process Approach Temperature Considerations seeeeeususss 20 3 3 External Piping Sizing Considerations ssseeesee 20 3 4 Piping Considerations for Permanent Installations ssssssssse 21 3 5 Piping Considerations for High Mobility Installations 22 3 6 Process Water Considerations ccccccceseeeseceseeseeeeesceccccceeeeneeeeeeeeeeeeeeeenees 22 3 7 Making Process Water Connections 2 2 ccccececceeeeeeeeceeecnececeeeeeeceeeeeeeeeeeenes 23 8 Making Cooling Water Connections cccceeee cece eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 24 3 9 Making System Purge Conmections 2 ccecesseeeeeeeeeeeeeeceececeeeceeeeeeeeeeenees 25 3 10 Making Electrical Connections 00 0 0 eee cece cece eee eeeeeeeaaaaaaaaeeeeeeeeeeeeeeeeeeeeees 27 Chapter 4 Identifying Controls and Features 30 4 1 Identifying Mechanical Controls and Features ssesseeseseseesss 30 4 2 Motorized Modulating Valves ie to
28. entive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the Compact and Upright Series temperature control unit We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the temperature control unit 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 temperature control unit 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 the temperature control unit 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
29. h to toggle between local and remote temperature sensor probe operation Page 38 4 9 Alarms Audible Visual General Fault Alarm Optional The audible visual general fault alarm sounds if any fault triggers such as low water pressure over temperature or pump overload A signal from any of the safety devices activates a horn and flashing strobe E Push the ALARM SILENCE button to silence the alarm The optional mechanical high temperature safety alarm is interlocked with the heater When triggered the heater cuts out and the pump continues to run 4 10 Controller Internal Switches The controller is set up and tested at the factory for optimum operation and adjusting the internal switches is not necessary If the controller does not work properly or you suspect someone has accidentally changed some settings there are two things to do First perform the Auto Tune procedure described in Section 4 10 If that doesn t work restore the controller to the orig inal factory settings as described in Section 6 3 4 11 Communications A connection port on the electrical cabinet permits easy hook up to the host computer for RS 485 communications The connection port is a direct pin to pin extension from the back of the controller For pin outs consult the Communication Manual for the PID controller Compact and Upright Water Temperature Control Units Page 39 Chapter 5 Startup and Operation 5 1 Introduction The checklist bel
30. he water prior to any servicing Failure to do so can result in SERIOUS INJURY OR DEATH 6 1 Preventive Maintenance Draining Drain the TCU thoroughly if you are taking it out of service for a long period of time or you expose it to freezing Drain plugs are provided at the base of the heater tank and at the base of the pump pedestal Compact and Upright Water Temperature Control Units Page 45 Periodic Checks Every Six Months Inspect all electrical connections for secure attachment and for safe and secure ground connections Inspect the power cable especially at the entrance point to the unit This inspection should be made by a qualified electrician Check for leaks especially under the pump as it may indicate a worn pump seal 6 2 Corrective Maintenance Page 46 Pumps and Seals Before leaving our factory we test each unit extensively then we calibrate each unit Afterwards the unit is drained and blown out with air to remove water from piping systems If the unit is allowed to stand idle for a long time before being installed in your factory the housing gasket at the pump can dry out and can possibly leak when the unit is started In most cases these gaskets will soon swell and form a tight seal In other cases it may be necessary for you to tighten the pump bolts to stop a leaking condition Pump seal surfaces can separate slightly because of rough handling or from vibration during transit This could cause a le
31. ill ruin the motor bearing and cause further damage After the unit has been in service for a period of years where abrasive conditions are present you may find that the pump bracket the top half of the pump casting can be eroded away in the area around the seat of the rotary seal This area should provide a straight smooth bearing surface for the cup seal Should your casting show signs of erosion in this area the casting needs to be replaced The replacement cost of the casting is very modest compared to the down time and maintenance cost for frequently replacing the seal Under some conditions the pump may not start After turning off the power supply check the motor shaft to be certain it is free to turn By removing the drip cover on top of the motor you ll have access to the end of the shaft It has been slotted to make it easy to turn with a screwdriver If the shaft is free to turn next check that the motor overloads are set check for blown fuses and finally check the power supply on each leg to the motor A qualified electrician should check the motor and its circuit If the pump motor wiring is disconnected for removal from the unit make sure that you check the actual rotation direction when the motor is rewired to the unit A phase sensor does not always indicate proper rotation if motor wire leads are reversed at installation Consult the elementary wiring diagram for more information Compact and Upright Water Tempe
32. infinite positioning 4 3 Water Hammer Arrestor Shock Stop Page 32 Optional Shock waves from fast operating solenoid valves may damage some process systems For these applications a welded metal bellows type shock stop with a pre charged and sealed nitrogen blanket can be installed in the cooling piping Pump Starter Compact and Upright temperature controllers high quality IEC rated pump motor starters are industrial grade motor controls with overload and overcurrent protection with manual reset Transformer High quality industrial design transformers are specified to suit incoming voltage on the application and provide 115 VAC control voltage The transformer is protected by primary fusing with secondary grounding Heater Contactor Your TCU unit uses high quality IEC rated industrial grade electromechanical contactors for heater controls Cooling The controller automatically regulates cooling by opening and closing the solenoid valve or modulating valve For direct injection the unit cools by removing the required amount of warm water from the system This process permits an equal amount of cool plant water to enter the system well ahead of the pump allowing it to blend with the system water The water supply temperature governs the minimum operating temperature of the unit For closed circuit operation the unit cools by automatically releasing cooling water through the tubes of the specially designed shell and tube hea
33. ing Before you start the temperature control unit check the following Remove all tools from the temperature control unit Be sure no objects tools nuts bolts clamps bars are laying in the area If your temperature control unit has been inoperative or unattended check all settings before starting At the beginning of your shift and after breaks verify that the controls and other auxiliary equipment are functioning properly Keep all safety guards in place and in good repair NEVER attempt to bypass modify or remove safety guards Such alteration is not only unsafe but will void the warranty on your equipment When changing control settings to perform a different mode of operation be sure selector switches are correctly positioned Locking selector switches should only be adjusted by authorized personnel and the keys removed after setting Report the following occurrences IMMEDIATELY unsafe operation or condition unusual temperature control unit action leakage improper maintenance NEVER stand or sit where you could slip or stumble into the temperature control unit while working on it DO NOT wear loose clothing or jewelry which can be caught while working on the temperature control unit In addition cover or tie back long hair Clean the temperature control unit and surrounding area DAILY and inspect the machine for loose missing or broken parts Shut off power to the temperature control unit when
34. intain its process value allow your process to reach the set point temperature Then Autotune the control by pressing the the Scroll key until SP1 appears in the upper display Then press the Up Arrow or Cw Down Arrow keys to activate the tune Compact and Upright Water Temperature Control Units Page 41 NCAUTION 1 Your Water Temperature Control system operates with hot water under pressure To reduce the risk of scalding Always wear work gloves and safety glasses when operating the unit Never operate the unit with panels or shields removed Pipe the relief valve to an open drain Never install a fitting or hose that is rated less than 150 psig and 250 F 1 034 25 kPa 10 34 bars and 121 C 2 To reduce the risk of electrical shock All electrical installation and repairs should be done by a qualified electrician Ground the unit in accordance with electrical codes Never attempt any repairs without first opening and locking out the main disconnect Never deactivate or neutralize any safety device 5 4 Sequence of Operation The simplicity of design and the highly engineered controller make this unit almost self operating The START STOP and VENT buttons and the temperature controller buttons are all that is required to operate this unit After you complete all connections turn the water supply ON then turn control power ON The unit automatically vents for a preset time of one 1 minute If you need addi
35. lve on the Water In line insure that the water has only one path to follow To activate system water purge Turn the unit off with the stop button on the graphic panel Close the COOLING WATER IN line shutoff valve Open the compressed air line shutoff valve Turn on the AIR PURGE switch ee E n When water no longer comes out of the cooling WATER OUT line and only air comes out the purge is complete Use caution when removing these lines air pressure is still present inside Compact and Upright Water Temperature Control Units Page 37 4 8 Using Graphic Panel Buttons Figure 8 START Button Push the START button to energize the unit and begin the temperature control cycle STOP Button Push the STOP button to de energize the unit and stop the temperature control cycle VENT Button Push the VENT button for additional manual venting The VENT CYCLE indicator lights during the vent cycle ALARM SILENCE Button Optional Turn on ALARM SILENCE switch to silence the alarm You should investigate the alarm condition and restore the unit to normal operation before continuing with the temperature control cycle AIR PURGE Button Optional Turn on the AIR PURGE switch to purge the system of air The PURGE VALVE ON indicator lights during the air purge cycle QUICK COOL Button Optional Turn on the QUICK COOL switch to open the cooling valve and quickly cool the process LOCAL REMOTE Button Optional Turn on the LOCAL REMOTE switc
36. maximize heat transfer and is well suited for the conditions under which it was designed to operate Heaters The specially designed 9 kW three phase low watt density electrical immersion heater heats the water and the controller regulates the temperature The standard heater has an incolloy sheath for best heat transfer Low watt density immersion heaters at 12 kW 18 kW dual 9 kW heaters or 24 kW dual 12 kW heaters are available options for these models depending upon the heating needs of the process All models are built to provide full or partial heat as required by the process and determined by the controller providing more precise temperature control Solenoid Valves Compact and Upright temperature control systems use rugged industrial design solenoids with replaceable coils and or internal components Depending on required cooling capacity solenoid valves are available in sizes ranging from 2 to x Ae and 77 x solenoid valves are slow closing Compact and Upright Water Temperature Control Units Page 31 4 2 Motorized Modulating Valves Optional Optional motorized modulating valves are recommended for large cooling applications where the process temperature is very near the cooling water supply temperature The gradual shutoff they provide also eliminates water hammer The option includes a complete valve and motor package in place of a long life solenoid valve The motorized modulating valve has
37. ment was prepaid write us fora 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 Water Temperature Control Unit i Bill of lading T Packing list Mi Operating and Installation packet mi Electrical schematic and panel layout drawings i 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 Compact and Upright Water Temperature Control Units Page 3 Page 4 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 1596 75 00 minimum re
38. of 300 F 149 C the lines and connectors should have a service rating of at least 300 F 149 C and 150 psig 1 034 25 kPa 10 34 bars TO PROCESS 172 NPT This is the outlet for the tempered water leading to the process being controlled FROM PROCESS 172 NPT Water from the process re enters the water temperature control system to be tempered and re circulated back into the process Compact and Upright Water Temperature Control Units Page 23 3 8 Making Cooling Water Connections Water In 75 The cooling water supply inlet from a cooling tower a chiller or a city water supply NCAUTION If a non relieving device such as a regulator ball valve or check valve is installed on the WATER IN line you MUST install an expansion tank of at least 1 2 gallon about 2 liters capacity Failure to do so can result in system overpressure from thermal expansion Install the tank configured as shown below Expansion tank D TrueTemp TCU Series P E unit Check the expansion tank frequently to make sure it is not flooded Water Out Size Depends on Solenoid Used The cooling water return outlet leading back to the cooling tower chiller or drain Net supply pressure must be between 25 psig and 55 psig 172 38 kPa 1 72 bars and 379 21 kPa 3 79 bars Net supply below 15 psig 103 43 kPa 1 03 bars may allow water to flash to steam cavitate the impeller and damage the pump which prevents the unit f
39. or 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 1 262 641 8600 or 1 847 273 7700 Monday Friday 8am 5pm CST e 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 ACS Schaumburg Corporate Offices ACS Suzhou ACS India 1100 E Woodfield Road 109 Xingpu Road
40. ow outlines start up procedures for Compact and Upright Series water temperature control units This list assumes that installation information located in this manual has been read and followed 5 2 Startup Checklist MI Check the shipping papers against the serial tag to make sure that system size type and voltage is correct for the process under control MI Check the transformer primary voltage connections to be sure they are configured for the electrical power you are using The voltage at the main power connection must be within plus or minus ten percent 10 of the voltage listed on the serial tag Electrical connections must conform to all applicable codes Make sure that a qualified electrician checks all electrical connections M The safety thermostat is preset at the factory to 250 F or 300 F 121 C or 149 C depending on configuration It trips at 265 F or 315 F 129 C or 157 C depending on configuration M The relief valve should be piped to an open unrestricted drain M TO PROCESS FROM PROCESS WATER IN WATER OUT and MOLD PURGE connections should be complete Only use components rated at a minimum of 150 psig and 250 F 1 034 25 kPa 10 34 bars and 121 C Mi All outer panels must be in place M All external process valving should be set for proper operation of the unit Page 40 M Cooling and or makeup water between 16 psig and 55 psig 110 32 kPa 1 1 bars and 379 23 kPa 3 79 bars must be avail
41. place solenoid coil Modulating valve is not Set process temperature to operating but OUT2 LED is minimum and check for on complete travel of valve Insufficient pressure Find a means to get less differential between cooling back pressure in the WATER WATER IN and OUT lines OUT line Replace cooling valve with a Cooling valve is undersize larger valve Compact and Upright Water Temperature Control Units Page 53 Condition Possible cause Solution Visually inspect coil and Defective heater contactor contacts repair replace defective contactors Check resistance on all three 3 legs of the heater with an ohm meter If not all equal contact factory for replacement heater Check the heater output with an ohm meter to ground It should read in the mega ohm range Infinite or zero readings indicate a defective output Heater contactor is not Set process temperature to energizing but HEAT LED maximum and check for control is on voltage at heater contactor Immersion heater elements Remove heater and clean dirty elements Unit does not heat cannot Check heater tank for achieve set point scorched discolored paint Check resistance on all three 3 legs of the heater with an Immersion heater element ohm meter Replace heater as is burned out required Check for balanced amp draws and supply voltage If not present replace immersion heater voltage on heater contact controller Set proces
42. proper electrical connections can damage the unit and cause serious operator injury or death Compact and Upright Water Temperature Control Units Page 27 Bring properly sized power leads and ground from a fused disconnect installed by your electrician to the unit Provide external overcurrent protection to the unit using circuit breakers or fuses If you use fuses make sure that they are dual element time delay fuses sized according to your electrical code Make sure that all electrical connections are fight Electrical connections must comply with all applicable electrical codes The temperature control unit must be grounded in accordance with NEC Article 250 Voltage must be within plus or minus ten percent 10 of the nameplate rating Make sure your installer provides external protection Page 28 Figure 6 Typical Electrical Wiring Schematic Please refer to the electrical wiring diagrams supplied with your unit s Customer Information Packet Compact and Upright Water Temperature Control Units Page 29 Chapter 4 Identifying Controls and Features 4 1 Identifying Mechanical Controls and Features To Process Thermocouple A type K ungrounded thermocouple with a 304SS probe is downstream from the heater to sense process temperature Safety Thermostat The safety thermostat mounted on the side of the heater tank protects against thermal runaway The thermostat guards against the unlikely event of
43. r and transformer e Dual stage Incoloy immersion heater with IEC contactors e NEMA 12 electrical enclosure Compact and Upright Water Temperature Control Units Page 15 2 5 Available Options Temperature control unit systems are available with options to tailor the unit to your requirements Some are factory installed some can be retro fitted in the field Consult ACS Group sales for more information Available TCU options include Page 16 Forward facing liquid filled To and From Process pressure gauges Independent high temperature safety thermostat Non fused lockable rotary disconnect Off the shelf microprocessor based PID temperature controller with Process and Set Point LED readouts 4 cooling solenoid valve on 74 to 3 hp 0 56 to 2 24 kW models 2 slow close cooling solenoid valve on 5 amp 7 2 hp 3 73 amp 5 60 kW models Graphic control panel with indicator and warning status lights Adjustable low supply water pressure switch factory set at 16 psig 110 kPa 1 1 bars 150 psig 1 034 kPa 10 3 bars pressure relief valve Choice of 208 575 operating voltages 34 water supply and drain connections 1 2 process connections Automatic vent sequence 2 51 mm casters Operating range of 0 F to 250 F 17 C to 121 C PID Auto tunning temperature controller Digital flow meter with B Up to 30 gpm 114 Ipm flow indicator or M 30 to 60 gpm 114 to 227 Ipm flow indicator or BI Greate
44. r process and to precisely automatically and reliably maintain it at a specified temperature Standard unit operating range is from 0 F 17 C to 250 F 121 C or up to 300 F 149 C as an option The unit is suited for use with city water water from portable or central chillers or towers or well water These units are designed for rapid recirculation of a relatively small amount of water to provide close and uniform temperature relation between delivery and return lines This performance of course depends on the configuration of your process and any restrictions within the mold The recirculation combined with the large immersion heater and cooling capability gives fast and accurate response to bring the water up to temperature or to changes in the settings when needed The water temperature control unit is a self contained system consisting of a centrifugal pump electric immersion heater cool vent solenoid valve and electrical control including a PID microprocessor controller and thermocouple It is designed for use in process temperature control applications using water or a water glycol mix Any other use or fluid is prohibited Some standard safety devices include a mechanical overtemperature safety thermostat a pressure relief valve motor overload protection a low pressure cutout switch branch fusing and non fused lockable rotary disconnect A properly installed operated and maintained water temperature control system
45. r than 60 gpm gt 227 lpm flow indicator e 1 16 1 8 1 4 DIN PID Temperature controller with B 4 20 mA current control output E Retransmission and remote set point 4 20 mA 2 10 V B RS 232 or RS 485 communications Modbus SPI Ethernet B Remote sensor 10 ft 3 m e Remote controller enclosure Heaters available in 12 kW 18 kW and 24 kW 18 kW and 24 kW heaters available on 5 hp and 7 hp 3 73 kW 5 60 kW direct injection models only e Closed loop heat exchangers available in 3 7 sq ft and 7 4 sq ft 0 135 sq m and 0 271 sq m Quick Cool function e Auto system water purge mold purge e Y strainer Hammer arrestor water hammer shock stop Remote start stop control e Rubber feet available in lieu of casters e Non ferrous brass construction e Slow close cooling solenoid valves available in 2 x Ae Cy 3 5 and 2 x Cy 5 5 e Modulating valves available in Cy 0 4 1 3 2 2 or 4 4 Cy 5 5 or 7 5 1 Cy 11 and 17 Cy 16 e Two zone stack rack with casters common wiring and piping available e 300 F 149 C operation includes silicon carbide seal e Audible and visual general fault alarm Electrical operation available in 208 460 and 575 volts 60 Hz 200 380 and 415 volts 50 Hz e UL cUL listed electrical subpanel CE Compliance per EMC Low Voltage Directive Compact and Upright Water Temperature Control Units Page 17 Figure 1 Typical Compact W
46. rature Control Units Page 47 Heaters Heaters may need to be cleaned chemically or mechanically to remove deposits and dirt that reduce heat transfer and cause hot spots Hot spots cause premature heater failure Install a new gasket when reassembling Make sure a qualified electrician disconnects and reconnects heater wires Solenoid Valves M Clean annually more often if using high mineral content water or on high service level units M Sluggish operation excessive leakage and or noise indicate cleaning is necessary Inspect the components for excessive wear while the valve is disassembled M Rebuild kits are available from the ACS Group Parts Department 6 4 Electrical Connections Make sure that a qualified electrician inspects all electrical components and connections every six 6 months for secure attachment and ground connections Inspect all wiring for fraying or damage especially power lines where they enter the unit All wiring connections must be tight 6 5 Safety Devices Make sure that only qualified electricians test safety devices Safety devices should be tested for function every six 6 months Perform the following procedures for testing Motor Overload Disconnect main power Open the electrical enclosure and rotate the manual TEST button on the motor overload to the tripped position Close the enclosure and reconnect main power Push the START button The unit should not start and the Pump Overload indi
47. rease the pressure 0r E Turn adjusting knob counter clockwise to decrease the pressure A quarter turn 90 rotation approximates 10 psi 68 9 kPa 0 7 bars E Turn the set screw clockwise to tighten locking the adjusting knob Page 50 Make sure that the high limit on the controller is set to the values listed in the following table based on the switch adjustment This prevents the pump from cavitating and damaging the seal the switch and heater element s psig kPa f Max temp F_ Max temp C 34 4 kPa 227 F 108 C 10 psig 68 9 kPa 240 F 116 C 15 psig 103 4 kPa 250 F 121 C Safety Thermostat Disconnect main power Open the electrical enclosure and disconnect the neutral lead on the safety thermostat from the terminal strip Protect the stripped lead to prevent short circuits Close the enclosure reconnect main power and push the START button The heater should not turn on and the Over Temperature indicator should illuminate Disconnect main power before reconnecting the thermostat lead 6 6 Cleaning and Storage Inspect the unit daily for leaks Wipe down the unit periodically to remove dirt and dust buildup especially the motor casing Drain and flush the unit every six 6 months to remove sediment buildup Completely drain the unit and carefully blow out the piping with pressurized air before placing the unit in storage Compact and Upright Water Temperature Control Units Page
48. rom cooling properly Operation above 55 psig 379 21 kPa 3 79 bars may cause premature opening of the relief valve from pump pressure and pressure surges Page 24 Pressure Relief 25 The pressure relief valve must be piped to an open and unrestricted drain Terminate in a manner to prevent scalding of nearby personnel in the event that the relief valve trips 3 9 Making System Purge Connections Compact and Upright temperature control systems equipped with the System Purge option have a compressed air inlet marked MOLD PURGE Connect to a clean dry 100 psig 689 50 kPa 6 90 bars air line Install your own shutoff valve to prevent process liquid from backing up into the plant air piping if the compressed air is turned off and the check valve fails Don t depend on the solenoid valve to hold water pressure in the temperature control unit Figure 3 Typical Piping Schematic OPTIONAL DELIVERY Ei DEL PRESSURE PRESSURE RELIEF VALVE SAFETY ipli ee ee e ENSOR GAUGE THERMOSTAT IMMERSION l CHECK HEATER OG e E P QJ DELIVERY f t 6 I i T l I l VALVE ly PUMP I AIR SUPPLY l SOLENOID VALVE l I l l I l ECL z N Jya CIRCULATING 4 BEER 2 MOTOR PRESSURE l per A93 ay SWITCH supPLY gt 83m o gt a RETURN l j S70 OPTIONAL in RETURN SENSOR L 2
49. s temperature to operating but COOL LED is nimum and check tor on A on top of solenoid coil Magnetism on coil Press VENT button several Faulty dirty solenoid valve imes to fish the valve Foreign material under Manually open valve to clear allatus Tsai valve seat seat of material i Reduce WATER IN or MAKEUP High system pressure water pressure Unit runs continuously cooling or heating and cannot attain set point Defective immersion heater Controller heat output open Solenoid valve is not Unit under sized for application Call sales representative Service Notes Page 54 Compact and Upright Water Temperature Control Units Page 55 Service Notes Page 56 Technical Assistance Parts and Service 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 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 F
50. stocking charge ALL returns are to be shipped prepaid The invoice number and date or purchase order number 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 Table of Contents SMI B LAIKO atc 3 Chapter T Salety i uus e on ka Es i aeae 7 1 1 How to Use This Manual ot iode p tene ue nde iore otecine eee 7 Safety Symbols Used in this Manual 5 rere eene tte ener sno 8 1 2 Warnings and Precaullons pectet ute ete eot aree nd tede ce etes 9 1 3 Responsibility ooo ene eee hee ees 10 Chapter 2 Functional Description 14 N Inirseiiie o nM ES 14 2 2 Necessary DOCUMEIIS 1 uci odede eus crt ro rien ipd eR PEU eor trdde Fette xd Fue d earn 15 2 3 Mod
51. t exchanger in each zone The process fluid such as water glycol or other similar fluid is circulated through the shell of the heat exchanger The plant water supply temperature governs the minimum operating N O TI C E temperature of the unit Electricals The pump motor and the immersion heater operate on three phase 50 60 cycle nominal voltages with the control circuit operating at 115V single phase The control circuit voltage is provided by a single phase machine tool transformer with a grounded secondary The 115V control circuit is fuse protected The pump motor is controlled by a full voltage magnetic non reversing motor starter with overcurrent and thermal overload protection Automatic Vent This feature automatically triggers a quick and complete purge of air from the system before you start the unit The vent actuates the solenoid valve and forces trapped air and water out through the drain properly filling and priming the unit prior to startup Complete venting is necessary to prevent damage to the pump and heater Pressure Switch A pressure switch built into each unit keeps the system from starting until the water supply is turned On and subjected to the minimum water supply pressure This feature protects the pump seal and the heater from damage through attempted operation without water The pressure switch is set at approximately 16 psig 110 32 kPa 1 10 bars for 250 F 121 C units or 55 psig 379 23 kPa 3 79 bars
52. tional vent time press the VENT button on the control panel As the water comes in the water supply line the water must enter the pump up through the tank and out through the delivery line through the process back through the return line and through the solenoid line and out the drain line At this time watching the drain for bubbles or erratic flow will indicate whether or not the system has been properly vented If a steady stream flows from the drain line it is certain that all the air is out of the system M TCU systems provide temperature control on processes by directly heating the process water and injecting cooling water into the process water Page 42 MI When the unit is energized the pump starts and a one minute vent sequence opens the cooling vent valve to remove any air trapped in the process piping M If the cooling water supply pressure is insufficient the low cooling water pressure cutout switch set at 16 psig 10 psig differential 110 32 kPa 1 10 bars 68 95 kPa 0 69 bars differential opens the LOW WATER PRESSURE indicator lights and the unit does not operate until the pressure is 16 psig 110 32 kPa 1 10 bars or more You need at least 16 psig 110 32 kPa 1 10 bars for the best cooling capacity and to prevent water boiling in the process circuit at high temperatures particularly at the pump suction M After venting the microprocessor controller monitors the TO PROCESS sensor cycling open the cooling
53. tions MI All external hose and piping should be adequately sized to assure minimum external pressure drop MI Low external piping pressure drop is needed for best operation Page 20 NO TIC E Use a backup wrench to support the Compact or Upright temperature control system piping when making process piping connections All external valves fittings and hoses must be rated at a minimum of 150 psig and 250 F 1 034 25 kPa 10 34 bars and 121 C The exception is when the temperature control unit is optionally rated for 300 F 149 C operation external valves fittings and hoses must then be rated at a minimum of 150 psig and 300 F 1 034 25 kPa 10 34 bars and 121 C 3 4 Piping Considerations for Permanent Installations ACS recommends an optional or customer installed strainer on the COOLING WATER IN inlet The unit must have at least 16 psig 110 32 kPa 1 1 bars water supply pressure to prevent pump cavitation that can be caused by the water flashing to steam To avoid damage to the pump or other components make sure that maximum supply pressure does not exceed 55 psig 379 2 kPa 3 79 bars Keep restrictions to a minimum by using proper inlet pipe sizing If the water supply piping is larger than 74 reduce the size at the unit The table below contains the pipe sizes that are used in the unit Pipe sizes for 74 hp to 10 hp 0 56 kW to 7 46 kW units Location Size in inches NPT Process delivery 1 Pro
54. vent valve to discharge warm water or energizing the immersion heater to maintain the process set temperature 5 5 Checking Motor Rotation Direction Check for correct pump rotation direction by looking at the motor impeller Press the START button and the STOP button and note the direction that the motor turns Rotation should be clockwise when viewed from the motor end Note Make sure that a qualified electrician performs the following steps To change rotation direction 1 Disconnect and lock out power at the fused disconnect 2 Reverse any two incoming leads at the power terminal blocks 3 Donot switch leads at the motor or motor starters 5 6 Shutting Down the Temperature Control Unit Cool the unit down by selecting a set point of zero 0 Let the unit stabilize at one temperature close to the incoming water temperature then press the STOP button Now press the VENT button to relieve any remaining pressure in the system Compact and Upright Water Temperature Control Units Page 43 Notes Page 44 Chapter 6 Unit Maintenance Never attempt to service a unit until a qualified electrician has opened and locked out the main disconnect using OSHA 1910 147 standards The water supply should be turned off and internal pressure should be relieved before you remove panels All electrical connections must be done by a qualified electrician Disconnect all power to the unit let the unit cool down and turn off t
55. w parameter If held down it will continuously scroll through the parameters Page 34 Do not change any of the control settings without consulting the ACS Group Service Department The ACS Group warranty does not cover temperature control unit failures from tampering with controller settings Down Key Each press of the Down Arrow key decrements or reduces the values or settings on the SV Set Value display Up Key Each press of the Up Arrow key increments or advances the values or settings on the SV Set Value display 4 6 Digital Flow Meter Optional The optional digital flow meter measures process flow in gallons per minute gpm or liters per min Ipm Controls are set at the factory no adjustment by customer is necessary Depending on option level and setup flows can be measured at rates reaching and exceeding 60 gallons per minute 227 Ipm Compact and Upright Water Temperature Control Units Page 35 Figure 8 Typical Graphic and Button Panels Optional Digital Flow Meter Shown POWER OW Pur O O dre A i O lt over EATER OM d O J l TEN PERATURE O poq cote O D LOW WATER VALUE ON PREJJURE O pre O Dodge o ne o O bd bd aan pir LOCALIREBOTE b N O O wW O 4 7 Identifying Graphic Panel Indicators Page 36 POWER ON Indicator The green POWER ON indicator lights when the temperature control unit is energized PUMP OVERLOAD Indicator The
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