User Guide - ACS Group
Contents
1. Servicing the Unit Every Three Months Remove and clean the screen in the Y strainer Replace the screen if it is damaged 6 3 Draining the Unit for Storage You should thoroughly flush and drain the 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 ACS Group recommends TrueFlush or SterlFlush flushing fluid or equivalent for flushing your hot oil unit follow unit flushing instructions that comes with TrueFlush SterlFlush 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 6 4 Corrective Maintenance Pumps and Seals Each unit is completely tested and calibrated before leaving the factory The unit is then cooled drained and packed for shipment Hot Oil Portable Temperature Control Units Page 39 If the unit stands idle for a long time before being installed in your factory gaskets can dry out 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 is properly lubricated and use2. Never let belts run against belt guards or other obstructions 1 Measure the belt span 2 Calculate deflection 3 See tables below for correct deflection force 4 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 Th f F Use large diameter sheaves and fewer belts You save money and increase drive life Not This Be sure DEFLE TION BELT SPAN use the agp eis Never force belts 3 Move motor on adjustable base a R dy so belts can go on easily BROWNING Belt Tension Checker See Form 5453 F s Eliminate slack Adjust motor and tighten belts in position Slack belts wear excessively cause slippage and deliver less power for more detail The capacity of the BROWNING belt tension checker is 35 lbs Other means of applying force must be used if force requirement is greater than this SHEAVE DIAM INCHES DEFLECTION FORCE LBS Use matched belts Matched belts run smoother and last longer because the load is Belt Deflection Force ietri Super Gripnotch evenly distributed Never replace Belt Smallest Groote Bolts j Sheave RPM ani ani just part of a set of belts rors Diameter Range Unnotched Notched Range Gripbands Gripbands Avoid belt idlers Used New U
3. 1998 1999 av 851 150 22 8 29 i 200 850 39 6 59 2 All Rights Reserved 18 0 22 4 851 1500 35 3 52 7 Hot Oil Portable Temperature Control Units Page 49 Figure 8 Customer Recommended Spare Parts Immersion Heaters Part number Description 722 00138 01 TR IMM 6 KW 208 V 3 6 ELE 722 00138 02 TR IMM 6 KW 240 V 3 6 ELE 722 00138 03 TR IMM 6 KW 380 V 3 6 ELE 722 00138 04 TR IMM 6 KW 415 V 3 6 ELE 722 00138 05 TR IMM 6 KW 480 V 3 6 ELE 722 00138 06 TR IMM 6 KW 600 V 3 6 ELE NO TIC E 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 572 92405 00 TANK HEATER TCO 3 Manual Reset Safety Thermostat Description 724 00041 00 THERMOSTAT 200 F 550 F N O TIC E Please give model and serial numbers when ordering parts Prices are subject to change without notice Page 50 Hot Oil Portable Temperature Control Units Figure 8 Customer Recommended Spare Parts Cont d Pressure Gauge 037 00158 00 GAUGE PRESSURE 0 100 PSI Heat Exchanger Ass y part no 106 00024 00 1 5 SQ FT 400 F Casters 042 00016 00 CASTER SWIVEL 3 042 00017 00 CASTER STATIONARY 3 Sight Glass Assembly 037 00047 00 GLASS SIGHT 27 NO TIC E Please give model and serial numbers when ordering parts Prices are subject to change without not
4. Page 41 Disassembling the Pump Page 42 Mark head and casing before disassembly to insure proper reassembly The idler pin which is offset in the 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 To prevent this tilt top of head back when removing 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 Loosen Allen head setscrews in the face of the thrust bearing assembly Remove the thrust bearing assembly by threading Loosen the radial setscrews in the thrust bearing assembly and Remove the bearing spacer collars and the ball bearing 1 Avoid damaging head gasket 2 Remove idler and bushing assembly 3 lockwasher from shaft 4 out of the bracket Figure 6 Thrust Bearing Assembly 5 remove the end cap using the spanner wrench 6 7 Using snap ring pliers remove snap ring from shaft 8 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 Hot Oil Portable Temperature Control Units 9 Using a soft headed hammer gently tap on the end of the rotor sh
5. Preventive Maintenance cccccccssssesseeeessneeeeeneees 37 6 1 Penodi CHECKS brunes nn diamants ans 37 6 2 Routine Servicing s 38 6 3 Draining the Unit for Storage 0 2 000 0c ccccccceceeeteeeneeeeeeeeseteneeeeeeeees 39 6 4 Corrective Maintenance 24e 39 6 5 Maintaining the Pump a nes eine nt ceeded 40 7 Troubleshooting ati en sers tenir aenne 54 Hot Oil Portable Temperature Control Units Page 5 Charts and Figures Figure 1 Portable Hot Oil Temperature Control Unit and Specifications 15 Figure 2 Unit Piping Sep Rs dla ted E St tan 23 Figure 3 Typical Eurotherm 3216 Controller 33 Figure 4 Control Panel Smiehes ssh ate c seed bees heel nseteeetedaeeeelideud ladies 35 Figure 5 18 24 GPM Pump Contrustion 075 00370 02 41 Figure 6 Thrust Bearing Assembly huile 42 Figure 7 Mechanical Seal Assembly eeeeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeenaaaaaaaaeeeees 44 Figure 8 Customer Recommended Spare Parts 50 Page 6 Hot Oil Portable Temperature Control Units 1 General Information 1 1 Introduction 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 from 100 F to 400 F 38 C to 205 C The unit is best suited for use with Tr
6. 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 discolored paint Check Heater burnout resistance on all three 3 legs of heater with an ohmmeter Replace heater as needed Faulty TCU Page 54 Hot Oil Portable Temperature Control Units Troubleshooting Cont d Condition Possible cause 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 te supply to unit is turned Open water supply Water drain is plugged or j Clear drain line or eliminate excessive back pressure in drain oe lind back pressure condition Unit overheats unable to cool Heat exchanger tubes plugged Remove tube 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 Er Inspect replace faulty line or Leaks in connecting lines connection Faulty solenoid valve Airin circulatia lines Perform venting sequence in 9 Section 4 1 on Pages 27 29 Check f
7. 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 Hot Oil Portable Temperature Control Units Page 3 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 Safety Tags and warning features DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury 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 Hazard Alert Symbol Description Explanation Preventative Maintenance High Voltage Hazard The electrical enclosure is supplied with 3 phase electrical power Use caution when using or maintaining this product Every six months inspect all electrical connections for secure attachment For further information see the Maintenance Chapter in this manual Hot Surface Hazard When the unit operates above 212F 100C the surface o
8. 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 Hot Oil Portable Temperature Control Units Page 33 5 3 Using Controller Keys See Figure 3 Page Key From any display press to return to the HOME display Scroll Key Press to select a new parameter If held down it will continuously scroll through the parameters Do not change any of the control settings without consulting the 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 5 4 Identifying Control Panel Switches This section lists the descriptions and functions of the control panel switches These switches control the operation of the unit Page 34 Hot Oil Portable Temperature Control Units Figure 4 Control Panel Switches PUMP O f A O Ce O ESET d u TEMPERATURE Low Q Poe oo Lc Q AD TR VOLWE ON verrevere O D ek PUMP CONTROL OFF OFF ALARM REV FWD cooLauTto VENT SILENCE Turn the Pump Rev Off Fwd switch to Fwd to start the pump in the normal forward direction Pump Rev Off Fwd Turn the Pump Rev Off Fwd s
9. potential fire and slip hazard Connecting Cooling Water Piping 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 Install properly sized cooling water lines never smaller than the outlets on the unit If external piping is larger than the 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 and on the back of the unit 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 unit Page 22 Hot Oil Portable Temperature Control Units 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
10. rotation is correct If not disconnect power and reverse the incoming power leads 3 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 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 Two minutes after the unit has built at least Spsi 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 Hot Oil Portable Temperature Control Units Page 27 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 following start up procedures This wi
11. the shaft step See Figure 5 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 Hot Oil Portable Temperature Control Units 7 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 8 Pack ball bearing with Dow Corning 44 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 9 Using the snap ring pliers install the snap ring onto the shaft 10 Thread the thrust bearing assembly into the bracket Turn until hand tight This forces the rotor against the head 11 Put lock washer 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 lock washer into slot 12 Adjust pump end clearance Refer to section on Thrust Bearing Adjustment 13 Lubricate all grease fittings with Dow Corni
12. transfer fluids expand when heated Expansion rates N O TI CE vary depending on fluid types and temperatures For more information on expansion 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 Figure 2 Unit Piping Setup Connect the TO PROCESS hookup to the PILES entrance of the process and the FROM Vapi PROCESS hookup to the exit of the process Cooling Water out Connect the COOLING WATER SUPPLY to A x f your plant water supply Connect the HU 2 ihrer COOLING WATER DRAIN line to an open A drain or to the return line of your central ed water system If returning to a central water system use a condensate return tank to avoid a standing water column on the heat exchanger drain line From Process A Cooling Water In Drain Hot Oil Portable Temperature Control Units Page 23 If you are routing the drain line to an open drain make sure that the line is directed away from personnel to avoid scalding Carefully select connecting lines and connectors between the unit and the process to best meet the needs and requirements of your application Make sure lines and connect
13. 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 unit 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 N O TI CE severe cavitation may 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 any of this occurs 4 2 Shutting Down the Unit 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 i 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 Turn the Pump Rev Off Fwd switch to Off to turn the unit off Hot Oil Portable Temperature Control Units Page 29 4 3 Returning Fl
14. If the unit is installed with a power cord that can be un plugged unplug it If the unit is permanently wired to a power main make sure that a fused power disconnect is installed 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 hot oil temperature control unit Installation Location Considerations Locate the hot oil 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 Hot Oil Portable Temperature Control Units Page 19 Make sure that the unit location is not in a confined space to ensure proper air circulation 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 Before storing your temperature con
15. Ou A ASK fo _ 26 HEAD W IDLER PIN Ne eed ot B Q LA XX LLL LE ity ZAN F E HEAD CAPSCREW LL N A CAPSC x N Lit pe JA N NN D N oy LZ J 7 i RES TS 21 HEAD GASKET Le 18 BRACKET GASKET hae ee FEN HN BRACKET f lt TIN 7 6 BALL BRNG ITEM QTY DESCRIPTION PART NUMBER OLLAR f EEN BEARING HOUSING ASSEMBLY 62 00008 49 Va T 62 00008 35 LOCKWASHER E a couter 1 LOCKNU 62 00008 35 A Pa 2 LOCKWASHER 62 00008 40 LOCKNUT E CAP END BRG 62 00008 17 4 2 62 00008 19 5 2 62 00008 20 6 62 00008 14 T 62 00008 724 8 162 00030 108 g BOLT SEAL HLDR 162 00030 160 B SNAP N SECTION OF BEARING SF SNP RING 0 SEAL HLDR FOR VIKING PMP 162 00030 159 HOUSING ASSEMBLY P N 162 00008 49 1 SEAL LIP 162 00030 153 12 PL SEAL 162 00030 154 13 SL MECH HI TEMP 162 00030 144 4 BUSH BRKT 62 O00008 98 6 1 CPSC PRESS RLF VLV SET OF 4 62 00008 18 17 BRKT amp BUSH 162 00030 155 8 GSKT FLNG BACK 62 00008 09 9 2 PLUG PIPE STL SQ HD SOLD 1 8 012 00001 00 20 CASING HL PMP 62 00008 47 21 GSKT HEAD 62 00008 08 22 RTR amp SFT ASSY 162 00030 156 23 IDL amp BUSH 62 00030 56 24 BUSH IDL GRAPHITE 62 00030 25 PIN IDL 62 00008 36 26 PIN HEAD amp IDL 62 00030 92 DA CPSC PRESS RLF VLV SET OF 4 62 00008 18 28 NUT PACK GL SET OF 2 62 00008 43 Hot Oil Portable Temperature Control Units
16. Portable Hot Oil Temperature Control Units Models Covered TCO C COT C 2016C Part Number 882 12045 00 Bulletin Number WTR2 645 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 Copyright 2012 All rights reserved Page 2 Hot Oil Portable Temperature Control Units Safety Considerations Portable hot oil temperature control 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 personnel injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices Mi O M 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 the hot oil temperature control unit and components are properly GROUNDED before you switch on power Do
17. ack welded pipe for permanent installations The unit 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 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 unit Piping Considerations for Mobile Installations Because your unit is fitted with casters its portability is well suited for multiple applications You can purchase high quality flexible metal hose from ACS Group to enhance the mobility of your unit state the length you want when ordering Although they cause a drop in pressure you can also install quick disconnects to your unit However do not install check valves with quick disconnects unless absolutely necessary Hot Oil Portable Temperature Control Units Page 21 Connecting Process Piping Hoses valves and other components in your process must be able to withstand unit maximum temperatures and pressures Maximum temperatures and pressures are listed on the unit nameplate Carefully inspect all components before installation If in doubt about component suitability obtain factory components Fix all leaks Fluid can be a
18. acket If carbon graphite Refer to Installation of Carbon Graphite Bushings page 47 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 Hot Oil Portable Temperature Control Units Page 43 Page 44 Figure 7 Mechanical Seal Assembly MECHANICAL SEAL 13 SEAL HOLDER 10 LIP SEAL 11 g ZN NUT 8 Z N BOLT 9 WZ SEAL HOLDER gt K 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 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 capscrews evenly 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 the mechanical seal on the shaft until it bottoms on
19. aft 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 10 Remove the mechanical seal parts from the bracket 11 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 if 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 12 Casing can be checked for wear or damage while mounted on bracket 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 requesting 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 br
20. 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 6 2 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 Page 38 Hot Oil Portable Temperature Control Units Servicing the Unit Monthly or Every 500 Hours Lubricate the pump at the grease fittings with Dow Corning 44 or a high quality lithium grease rated at 400 F 204 C or higher that is compatible with Dow Corning 44 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
21. ary Documents 7 Ted Models Covered as een nnreeainln aies 8 1 4 Standard Features rende nt ann ren edie 8 15 Available Options neien ant en anti tees 9 16 Feature Descriptions on ce aveueideatenerexe werdetiacerustt do scheveveceaeeeheeennacedeee 9 2 Shipping Information 16 2 1 Unpacking and Inspection asser enorme rein 16 2 2 In the Event of Shipping Damages 0 cccecceceeeeeeeeeeeteeeeeeeeeeeeeee 16 2 3 If the Shipment is Not Complete cceeeeeeeeeeeeeeeeeeeeeeees 17 2 4 Ifthe Shipment is Not Correct 17 2207 RETIN Se e iis Andevncaeer nia a 17 3 UNSTAHNQUON Een eee 19 FT Work RUES sr Rat rer nn cites Re tre ent 19 3 2 Installation Requirement cccccccceeeeseeeeeeeeeeeeeeeeeeeeeeeeeeaeeeaes 19 393 Connecting PIPING tice ee ht nes Ree eels 20 3 4 Making Electrical Connections 24 4 Startup Preparations 27 Bed Sin he Unies ee ses ee eects Ae etic bd ie ee he 27 4 2 Shutting Down the Unit ieee se iss ans RS tote cn 29 4 3 Returning Fluid to the Tank 30 5 Using Controls and Indicators 33 5 1 The Microprocessor Controller 33 5 2 Controller BISDIAVe rene oc Nine ee A de ete 33 5 3 Using Controller Keys tes rimes inerte 34 5 4 Identifying Control Panel Switches 34 6
22. bor 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 e India 91 21 35329112 e 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 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 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 Page 64 Hot Oil Portable Temperature Control Units
23. d occasional head space adjustment see Section 6 5 on Page 40 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 is constant until the pressure reaches the rated pressure The pressure however is a function of frictional losses through the process to which it is attached 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 Ful Flo valve will open and bypass the necessary fluid to prevent high pressures 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 wi
24. d 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 NO TIC E 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 6 5 Maintaining the Pump Disassembly Before opening the pump chamber 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 Page 40 Hot Oil Portable Temperature Control Units Figure 5 18 24 GPM Pump Construction 075 00370 02 BRKT CAPSCREW 4 16 eae Nes IN r pe a BRKT BUSHINC
25. e Hot Oil Portable Temperature Control Units Page 17 Page 18 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 Hot Oil Portable Temperature Control Units 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
26. e subject to change without notice Hot Oil Portable Temperature Control Units Page 53 7 Troubleshooting Condition Possible cause Solution 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 Sonnen lines Tor paralieiniow instead of series flow Blocked line in 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 contols the set point temperature Reversed probes Switch Return and Delivery probes ps Check all lines connections Loss of fluid in process we fittings Allow vent timer to run out or Vent valve open check valve operation when unit is cold by opening the fill port Unit does 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 is a 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
27. f 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 If any appear remove panel and verify cause of degradation and repair Pinch Point Entanglement The pump and motor are linked using v groove belts Use caution when using or maintaining this product Every month inspect the belt s for any type of wear For further information see the Maintenance Chapter in this manual Mandatory Symbol 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 6190 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 4 Hot Oil Portable Temperature Control Units Table of Contents 1 General Information 7 Tel _ MATEO GUICHION SE Sas dominante hate 7 1 2 Necess
28. gle 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 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 Page 12 Hot Oil Portable Temperature Control Units Air Purge Upon initial start up and mold process change out you ll need to purge all air and water from the system The hot oil unit has appropriate valving to ensure complete purging procedures are covered in Section 4 on Page 27 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 es
29. ice Hot Oil Portable Temperature Control Units Page 51 Figure 8 Customer Recommended Spare Parts Cont d Controller Part number 724 00671 01 LTR MPB 1 16 2 T C Omron E5CK Selector Switches and Push Buttons 721 01026 00 VENT 721 01029 00 PUMP REVERSE 717 10055 00 HALF FULL HEAT LOCAL REMOTE OPTIONAL 717 01016 00 MODE SELECT Pressure Switches 733 00029 00 SWITCH PRESSURE Pump 075 00381 02 MECH SEAL VIKING G4125 0 10 GPM Motors 720 09217 00 MOTOR HP 3 60 208 230 460 V 720 09024 00 MOTOR HP 3 60 575 V Replacement Belts 100 00309 00 BELT 4L 27 1 2LG Please give model and serial numbers when ordering parts N 0 TI C E Prices are subject to change without notice Page 52 Hot Oil Portable Temperature Control Units Figure 8 Customer Recommended Spare Parts Cont d Solenoid Valves 732 00007 03 4 VENT VALVE 115 V COIL 0 125 PSI 300 F 732 00012 02 77 VENT VALVE 115 V COIL 0 125 PSI 300 F Sensing Probe Equipment 701 00036 00 SENSOR TC TYPE K 692 07369 28 SENSOR RTD 1000 OHM Disconnect Switches 728 00153 00 SWITCH DISCONNECT 45 AMP 728 00168 00 SWITCH DISCONNECT 100 AMP Heater Tank Insulation 542 08133 00 INSULATION TANK HEATER Ful Flo Relief Valves Description 044 00304 00 VALVE RELIEF FUL FLO 2 N O TI C E Please give model and serial numbers when ordering parts Prices ar
30. in severe conditions lubricate more frequently Use an appropriate type of grease for hot or cold applications Adjusting End Clearance 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 Note Make sure the idler doesn t slide off the idler pin during head removal to avoid damage and personal injury Cleaning the Pump A clean pump is easier to inspect lubricate and adjust it runs better and looks better Storing Your Hot Oil 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 See Section 6 3 on Page 39 for more information Page 48 Hot Oil Portable Temperature Control Units 4 D How to increase Belt Life y BELT TENSIONING INSTRUCTIONS A WARNING Disconnect power bsfors Installation and maintenance Fallure to do o can result In severe Injury or death eae Keep sheaves and belts clean Abrasive dust rust oil and acids reduce service life Give drives elbow room
31. ken to prevent breaking Carbon graphite is a brittle material and easily cracked If cracked the bushing will quickly disintegrate 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 Be certain 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 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 Hot Oil Portable Temperature Control Units Page 47 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 2 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
32. ll 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 3 Turn the Pump Rev Off Fwd switch to Fwd 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 Two minutes after the unit has built at least Spsi 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 Page 28 Hot Oil Portable Temperature Control Units 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
33. ll 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 The designed shell and tube heat exchanger is provided as optional equipment in this unit The design features straight tube construction and copper nickel tubes for durability and optimal heat transfer Hot Oil Portable Temperature Control Units The modular construction unique to ACS Group units 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 drain 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 72 NPT 12 5 mm Water connections for COOLING WATER SUPPLY and COOLING WATER DRAIN are 2 NPT 12 5 mm see Section 3 The customer is responsible for conversions to metric standards ACS Group stocks many lengths of flexible metal hose the part number is 572 16969 State the length of hose you want whe
34. luid level in sight glass Low fald Add fluid if required Defective 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 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 hoad spacimg 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 Noisy pump 27 29 or boil water off Severely degraded fluid ta and flush system Replace Rapid drop in pressure no pressure Hot Oil Portable Temperature Control Units Page 55 DIAGRAMS FLOW amp ELEMENTARY ELECTRICAL Please refer to Electrical Drawings Provided in Packet with Unit Page 56 Hot Oil Portable Temperature Control Units Service Notes Hot Oil Portable Temperature Control Units Page 57 Service Notes Page 58 Hot Oil Portable Temperature Control Units Service Notes Hot Oil Portable Temperature Control Units Page 59 Service Notes Page 60 Hot Oil Portable Temperature Control Units Service Notes Hot Oil Portable Temperature Control Units Page 61 Page 62 Hot Oil Portable Temperature Control Units Technical Assistance Parts and Service Department The ACS Customer Service Group will pro
35. n 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 hot oil 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 The electrical controls of your hot oil unit are specially engineered for reliability safety and simplicity of operation The switches are clearly labeled as to their function Your hot oil 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 Hot Oil Portable Temperature Control Units Page 11 An audible alarm is standard with your unit The alarm will sound in the event of the following conditions e motor overload e safety thermostat trip over temperature e low fluid pressure e low fluid level e high fluid level optional Push the ALARM SILENCE button to silence the alarm See Section 5 on page 33 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 sin
36. n before continuing with unit operation Hot Oil Portable Temperature Control Units 6 Preventive Maintenance 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 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 6 1 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 Hot Oil Portable Temperature Control Units Page 37 Making Quarterly Checks e Check the 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 the Service Department for information on fluid testing Making Six Month Checks e Inspect electrical connections for secure tight electrical terminations
37. n running conduit whips to the unit make sure that whips are routed away from hot piping Check the unit nameplate for correct voltage and amperage before making electrical connections DANGER 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 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 Hot Oil Portable Temperature Control Units Page 25 Notes Page 26 Hot Oil Portable Temperature Control Units 4 Startup Preparations 4 1 Starting the Unit 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 Turn the Pump Rev Off Fwd switch to Fwd to start the pump Check motor rotation by observing the pressure gauge If the gauge indicates positive pressure
38. ng 44 high temperature silicon grease Hot Oil Portable Temperature Control Units Page 45 Thrust Bearing Adjustment 1 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 2 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 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 PUMP Turn Outer End Cap C C W SIZE No of Notches or Length on O D Inches G 0 75 HL HV 6 4 KK 10 1 38 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 Page 46 Hot Oil Portable Temperature Control Units Installation of Carbon Graphite Bushings When installing carbon graphite bushings extreme care must be ta
39. ons E Remote sensor 10 ft 3 m e Y strainer on From Process line external to unit e Remote controller e Lexan cover e Optional operating voltages of 208 3 60 230 3 60 575 3 60 380 3 50 and 415 3 50 1 6 Feature Descriptions Immersion Heaters Heater Tank 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 are supplied with a 6 kW low watt density immersion heater The hot oil unit features a single pass heater tank The tank is designed 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 Hot Oil Portable Temperature Control Units Page 9 Pump Ful Flo Valve Cooling Page 10 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 an
40. or reshipment if necessary 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 case of breakage damage shortage or incorrect shipment refer to the following sections 2 2 Inthe Event of Shipping Damages According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment M Notify the transportation company s local agent if you discover damage M Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods to ACS Group before the transportation company inspection and authorization M File a claim against 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 shipment was prepaid write us for a receipted transportation bill M Advise ACS Group regarding your wish for assistance and to obtain an RMA return material authorization number Page 16 Hot Oil Portable Temperature Control Units 2 3 If the Shipment is Not Complete Check the packing list The apparent shortage may be intentional Back ordered items are noted on the packing list You should have M hot oil portable temperature control unit Bill of lading Packing lis
41. ors 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 unit N O TIC E To prevent debris from fouling reservoir fluid the unit is equipped with an 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 3 4 Making Electrical Connections These units are designed for three phase voltage operation Refer to the unit nameplate for proper voltage and amperage requirements and make sure your electrical service conforms Provide a correctly sized and protected power supply to the unit If an electrical supply disconnect is not installed as a factory option the customer is responsible to properly size and install a suitable disconnect Refer to National Electric Code NEC 430 24 26 for proper feed conductor and supply disconnect sizing Voltages must be within plus or minus ten percent 10 of the nameplate rating 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 service calls are needed Page 24 Hot Oil Portable Temperature Control Units e Locate disconnects in an easily accessible location Operators should not have to squeeze around the unit to reach disconnects especially in case of emergency e Whe
42. p Rev Off Fwd switch to Rev The pump will then run in reverse drawing fluid from the mold and 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 Hot Oil Portable Temperature Control Units Page 31 Notes Page 32 Hot Oil Portable Temperature Control Units 5 Using Controls and Indicators 5 1 The Microprocessor Controller The controller is an easy to operate microprocessor based PID control device When the process reaches the set point the controller cycles the cooling valve or the immersion heater to maintain the proper To Process 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 400 F 18 C to 205 C 5 2 Controller Display Figure 3 Typical 3216 Microprocessor Controller Eurotherm 3216 IBD 180 See Figure 3 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
43. ration 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 ACS Group 1 4 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 400 F 205 C maximum operating temperature 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 e To Process pressure gauge e Independent safety thermostat e Automatic venting sequence e Positive displacement pumps capable of reversing to evacuate the process e Low level alarm for reservoir e Easily removable panels for quick access to internal components e Audible alarm Page 8 Hot Oil Portable Temperature Control Units 1 5 Available Options e Drain valve e Hour meter measures total pump run time hours e General fault visual alarm e Auto vent sequence deducts available e Low level alarm deducts available e High level indicator light e Manual bypass e DIN controller with M 4 20 mA current control output E RS 232 or RS 485 communicati
44. sed Now i ife Belt idlers decrease belt life aa TET 27 55 FT T Always maintain proper tension 2501 4000 28 4 2 34 5 0 i 1000 2500 45 6 8 5 0 7 4 through motor adjustment AAX 38 48 2501 4000 38 57 23 64 50 70 mawo 47 70 81 76 Mount belts straight 860 2500 49 72 34 42 2501 4000 42 62 Shafts must be parallel and 260 2500 5 abies BBX 44 56 5 3 7 9 7 1 10 5 sheave grooves in alignment to 2501 4000 4 5 6 7 6 1 9 1 860 2500 6 3 9 4 8 5 12 6 prevent unnecessary belt wear 5 8 8 6 5501 4000 80 89 73 10 9 7 0 9 0 oora aa 10 DE 21 8 1741 4 13 11 17 5 Don t overload GEX 500 1740 14 1 21 0 15 9 23 5 os 35 160 4741 3000 12 5 18 5 14 6 21 6 An overloaded belt drive is like a 00880 To TO one ton truck with a two ton 5 120 160 851 1500 21 2 31 3 200 850 30 4 45 2 load both are sure to break 180 200 851 1500 25 6 38 0 down Always use ample capacity 5354 7000 2500 33 49 i 2501 4000 29 43 1000 2500 3 6 5 1 42 6 2 AWARNING NWX 265 365 2501 4000 3 0 4 4 38 56 1000 2500 4 9 7 3 53 7 9 4 12 6 90 2501 4000 44 66 49 7 3 Operating drives without guarde 500 1749 i 102 152 In place can result In 44 6 7 1750 3000 88 13 2 severe Injury or death 2001 1000 39 B5 5V 5VX 74 109 500 1740 12 7 18 9 14 8 22 1 ey 1741 3000 11 2 16 7 13 7 20 1 500 1740 15 5 23 4 17 1 25 5 118 160 4741 3000 146 21 8 16 8 25 0 S 12 5 17 0 200 850 33 0 49 3 Emerson Power Transmission Manufacturing L P
45. t Operating and Installation packet Electrical schematic and panel layout drawings KR ARAR Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking Determine that the item was not inadvertently taken from the area before you checked in the shipment Notify ACS Group immediately of the shortage 2 4 If the Shipment is Not Correct 2 5 Returns Credit Returns 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 Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department 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 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 resal
46. tablished 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 is 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 Hot Oil Portable Temperature Control Units Page 13 determine and correct the cause of the fault before resuming operation Reservoir Tank A reservoir tank with sight gauge is standard usable capacity is one 2 gallon 7 6 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
47. tank drain is extended beyond the base of the unit for ease of draining Optional ball valves are available to further simplify draining Page 14 Hot Oil Portable Temperature Control Units Figure 1 Hot Oil Portable Temperature Control Unit RESERVOIR TANK TANK SIGHT ee NT amp HEATER TANK SUB ASSEMLBY FILL DT UE Se Ol Se TO PROCESS TEMP PROBE COOLING SOLENOID VALVE Fa PRESSURE switcH NN VENT SOLENOID VALVE y HEAT EXCHANGER ASSEMBLY COOLING WATER OUT TO PROCESS ROM PROCESS 4 COOLING WATER IN IL PUMP ASSEMBLY Temperature Control Unit Specifications Model Pump Dimensions Shipping Number Heater Power Pressure Flow H W D Weight 460 230 6 kW KW PSI Bar gpm lpm in cm in cm in cm lbs Kg hp TCO C Std 0 75 0 56 50 345 6 228 28 71 13 33 31 79 265 120 COT C 2016C Hot Oil Portable Temperature Control Units Page 15 2 Shipping Information 2 1 Unpacking and Inspection You should inspect your hot oil portable temperature control unit for possible shipping damage If the container and packing materials are in re usable condition save them f
48. trol unit make sure N O TI CE you remove all residual water with compressed air to avoid a potential freezing hazard See Section 6 3 on Page 39 for more information Note the following table of ambient temperature ranges permitted for storage and operation Ambient storage range Ambient operation range PC C 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 if 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 Page 20 Hot Oil Portable Temperature Control Units The following table lists pipe sizes Connection To Process From Process Cooling Water Drain 0 5 NPT Oil Drain 0 5 NPT Fill Port 0 5 NPT Customer is responsible for converting to metric Always use a backup wrench to support the unit piping N O TI CE when making connections Make sure all external piping 1s supported independently of the unit Cooling Water Suppl 0 5 NPT ACS Group recommends that you have strainers installed on the cooling water inlets and customer supplied shut off valves on all piping connections Use common bl
49. ueTherm Heat Transfer Fluid A recommended list of commercially available heat transfer fluids can be obtained through ACS GROUP 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 ACS Group controllers to the ACS Group high temperature system The two systems are fully integrated to achieve accurate control along with efficient use of water and electricity 1 2 Necessary Documents The following documents are necessary for the safe installation operation and maintenance of your hot oil portable temperature control unit You can obtain additional copies from ACS Group Make sure that appropriate personnel are familiar with these documents M This manual M The electrical schematic and connection diagram in the control enclosure M The manuals for accessories and options you ve selected M The customer parts list in the control enclosure Hot Oil Portable Temperature Control Units Page 7 1 3 Models Covered This manual lists installation ope
50. uid to the Tank Returning Fluid to Tank With Autovent Solenoid Page 30 If the unit is to be moved from one process to another i 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 Turn the Pump Rev Off Fwd switch to Off 3 Turn the Pump Rev Off Fwd switch to Rev 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 Hot Oil Portable Temperature Control Units Returning Fluid To Tank With Manual Vent Valve If the unit is to be moved from one process to another i 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 Turn the Pump Rev Off Fwd switch to Off 4 Turn the Pum
51. vide 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 e 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 e Mexico Central amp South America Email acslatinamericacustserv corpemail com e Europe Middle East amp Africa 48 22 390 9720 Email acseuropecustserv corpemail com e India 91 21 35329112 Email acsindiacustserv corpemail com e 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 la
52. witch to Off to stop the pump and de energize the controller Always turn to Pump Off and allow the pump to come to a complete stop before turning to Pump Reverse Failure to let the pump stop before reversing may damage the pump and drive Turn the Pump Rev Off Fwd switch to Rev to start the pump in the reverse direction Use this feature to purge oil from the mold Vent Cycle Start Press the VENTbutton to start the vent cycle timer Use this feature to purge air and water from the unit and process Hot Oil Portable Temperature Control Units Page 35 Mode Select Alarm Silence Page 36 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 1 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 Press the ALARM SILENCE button to silence the audible alarm on the console After you silence the alarm make sure you locate and correct the alarm conditio
Download Pdf Manuals
Related Search