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Sentra VE Series Product Service Manual

1. T In centrifugal pumps as compared to positive displacement pumps flow rate increases as pressure decreases mazcaoocmzuc ADVANTAGE ENGINEERING INC Page 70 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 8 4 OPERATION OF MOLD PURGE A Advantage supplies an optional MOLD PURGE kit for Sentra temperature control units The mold purge kit contains several solenoid valves and check valves When activated and supplied with compressed air the mold purge kit will expel process water from the mold to the central water supply or drain Advantage mold purge kits are supplied as a factory installed option or a field retrofitted kit B The operation of the mold purge is as follows see illustration 1 Stop the pump maintain electrical power to unit AIR AND WATER MOVEMENT DURING MOLD PURGE OPERATION 2 Close the water supply ball valve 3 Connect a regulated air supply to mold purge compressed air connection Note air supply should be regulated approximately 10 PSI above drain line pressure Sonn oomoonmv rv vco gt 2 gt 20 4 Activate mold purge with button Se located on electrical cabinet 5 When water is purged disconnect air S supply 6 Depress and hold vent button approximat
2. 083 1 08 INSTRUCTION MANUAL INSTALLATION OPERATION MAINTENANCE SSN MAA TEMPERATURE CONTROLLER 1 I SK Series TM HS EXER Zoe G n DVANTAGE I DVANTAGE MAKING WATER WORK ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood IN 46142 317 887 0729 fax 317 881 1277 Service Department fax 317 885 8683 www AdvantageEngineering com e mail sales AdvantageEngineering com 2 RE CONTROLLER n n SK Series INSTRUCTION MANUAL SENTRA SK VE SERIES INSTRUMENT COVERING INSTALLATION OPERATION MAINTENANCE MAKING WATER WORK ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood IN 46142 317 887 0729 fax 317 881 1277 Service Department fax 317 885 8683 www AdvantageEngineering com e mail sales 9 AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument TABLE OF CONTENTS SENTRA QUICK START UP GUIDE SENTRA QUICK TROUBLESHOOTING GUIDE 1 0 GENERAL 1 1 Safety 1 2 Efficiency 1 3 Typical Label Placement 1 4 Component placement 2 0 INSTALLATION 2 1 General 2 2 To and from process connections 2 3 Water supply connection 2 4 Drain connection 2 5 Electrical connection 3 0 START UP SEQUENCE 3 1 General 3 2 System fill operations procedure 3 3 Instrument operation 3 4 Shut down disconnect sequence 4 0 TROUBLESHOOTING 4 1 Unit will not start Power light off
3. Fd SPS 05 Sr em C NVL E 0s at T os ps HOLIMS EL ek e 1HM 3ALLOV SALLOVNI HOLIMS LIII 394nd In 1 2m L SIINn3WOSNO 2 Ssaooud 5151 3 HSLWSH PUZ 5 310N iw v 1281 de cd OWL j Ebaeus E MM s Te D l k z 4 7 d 1 n wos sionpoid waysks salem 39vLNVAGY uo 1 10 88 16 Ife 6 104 440M0 591195 ai mnono sunivusawai SUE A V o o 1Ssnrav 136 3univuddWal SS320Hd OL Provided for display purposes only Refer to electrical drawing supplied with unit for details Page 61 ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com SE y Temperature Control Units Sentra with VE Series Instrument 7 3 SENTRA VE CIRCUIT SCHEMATIC HEATER gt TO PROCESS 0 PRESSURE GAUGE DRAIN CONNECTION TO PROCESS SENSOR HI TEMP SAFETY PVT COOLI
4. DESCRIPTION MOTOR PUMP ASSEMBLY 1 2HP 55 2 4 3 60 Adapter iron C2 4551 AS5 Pump case iron D2 1839 AS5 Tank gasket 2 3 8 A 9159 AS5 Tank gasket 4 1 2 A2 8748 AS5 Impeller B2 5264 4 37 AS5 Motor AE5 AS5 A5W 1HP S 2771R Nut 5 4989 AS5 O ring Case S 5091 55 Shaft seal 101 173 5 8 EPT Shaft seal EPT Ceramic 4949 AE5 AS5 MOTOR PUMP ASSEMBLY AS5 3 4HP ODP 230 460 Adapter iron C2 4551 AS5 Pump case iron D2 1839 AS5 Tank gasket 2 3 8 A 9159 AS5 Tank gasket 4 1 2 A2 8748 AS5 Impeller B2 5264 4 5 AS5 Motor AE5 AS5 A5W 3 4HP S 2772R Nut 5 4989 AS5 O ring Case S 5091 AS5 Shaft seal 101 173 5 8 EPT Shaft seal EPT Ceramic 4949 AE5 AS5 MOTOR PUMP ASSEMBLY AS5 1HP AS5 2 4 3 60 Adapter iron C2 4551 AS5 Pump case iron D2 1839 AS5 Tank gasket 2 3 8 A 9159 AS5 Tank gasket 4 1 2 A2 8748 AS5 Impeller B2 5264 4 75 AS5 Motor AE5 AS5 A5W 1 HP S 2773R Nut 5 4989 AS5 O ring Case S 5091 55 Shaft seal 101 173 5 8 EPT Shaft seal EPT Ceramic 4949 AE5 AS5 ADVANTAGE ENGINEERING INC Page 73 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 8 7 SENTRA AS5 PUMP PARTS LIST 1 5 HP TO 3 HP PART 6207020 414 771599 3444400 3444401 4310604 4757864 5486522 5622271 6490000 6491000 6207030 414 771599 344
5. E HIGH TEMP LIMIT SWITCH OPEN AAA TEMPERATURE OVER 256 ALLOW UNIT TO COOL E INSTRUMENT DEFECTIVE REPLACE SENTRA STOPS L POWER LIGHT ON E MAIN POWER SUPPLY Eie nct TRANSFORME ON FUSE 4 WATER SUPPLY PRESSURE LOW PRESSURE SWITCH OPEN SUPPLY UNIT WITH 20 PSI ENGAGE POWER E MOTOR OVERLOAD RELAY OPEN RESET OVERLOADS ADJUST PROCESS FLOW E HIGH TEMP LIMIT SWITCH OPEN Cil TEMPERATURE OVER 256 ALLOW UNIT TO COOL E INSTRUMENT DEFECTIVE REPLACE SENTRA OVERHEATS 2 INADEQUATE WATER SUPPLY PRESSRE WATER SUPPLY PRESSURE MUST BE ISUFFICIENT FOR OPERATING TEMPERATURE E AVT COOLING VALVE CHECK VALVE WIRE CLEAN REPLACE kret MOTOR GEARBO DEFECTIVE HARNESS BALL VALVE ASSEMBLY ASSEMBLY DRAIN LINE OPEN23 CLOSED OBSTRUCTED DRAIN LINE VALVE R LOW PROCESS FLOW RATE CHECK FORA CLOSED PROCESS VALVE on 4 REDUCE HIGH DRAIN LINE PRESSURE KINKED HOSE OR o WATER CHANNEL EXCESSIVE PIPE FITTINGS IN TOOLING OR MOLD R CONTROL PROBE DEFECTIVE CHECK FOR WATER IN PROBE CONNECTION on 4 REPLACE PROBE E INSTRUMENT DEFECTIVE REPLACE SENTRA UNDERHEATS 1 LEAKAGE AVT COOLING VALVE PROCESS WATER roja CHECK FORA DEFECTIVE iae WATE
6. Sentra with VE Series Instrument 8 2 SENTRA MODEL AND SUFFIX CODING MODEL SUFFIX SK 104 5 HE 41CX HEATER KILOWATTS 6 6 KW 10 2 10 KW 16 2 16 KW 24 24 KW 36 36 KW GPM BY HP 35 35 GPM Q 3 4 HP 45 45 GPM 1 HP 65 65 GPM Q 1 1 2 HP 75 75 GPM 2 HP 90 90 GPM 5 HP 100 100 GPM 7 1 2 HP INSTRUMENTATION LE LE instrument HE HE instrument VOLTAGE 2 208 230 3 60 3 380 3 50 4 460 3 60 5 575 3 60 6 415 3 60 ELECTRICS 1 NEMA 1 2 NEMA 12 VALVE SIZE A None 1 4 3 8 D 1 2 E 3 4 1 SPECIAL OPTIONS Consult factory for more information MAKING WATER WORK ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Page 69 Temperature Control Units Sentra with VE Series Instrument 8 3 INTERPRETATION OF PROCESS PRESSURE GAUGES A DVANTAGE MAKING WATER WORK READ AVAILABLE WATER PRESSURE AT UNIT S LOCATION When a temperature control unit is attached to the process with the water supply on and the pump off both gauges will read the water supply pressure at the unit s location figure 7 3A READ PRESSURE DROP ACROSS PROCESS With the pump on the to process pressure gauge will rise to read t
7. 4 2 Unit will not start Power light on 4 3 Unit stops 4 4 Unit overheats 4 5 Unit underheats 4 6 Pressure relief valve leaks 4 7 Cooling valve fault 5 0 MAINTENANCE 5 1 Pump seal replacement 5 2 Heating cylinder replacement 5 3 PVT cooling valve service 54 Probe calibration 5 5 Voltage changeover 5 6 Sensor probe service 5 7 Pressure switch service 5 8 Instrument service 5 9 Celsius temperature display 6 0 SENTRA COMPONENTS 6 1 Mechanical system 6 2 Electrical system ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Far 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Page 4 Temperature Control Units Sentra with VE Series Instrument 7 0 RELATED DRAWINGS 8 0 APPENDIX MAKING WATER WORK Sentra physical Sentra electrical Sentra circuit schematic Sentra regulator bypass installation Sentra dual zone dolly Sentra stacking rack Specifications Sentra Model and suffix coding Interpretation of process pressure gauges Mold purge operation Closed Circuit Operation Sentra AS5 pump parts list 1 2 HP to 1 HP Sentra 55 pump parts list 1 1 2 HP to 3 HP Sentra parts list LE instrument ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Page 5 Temperature Control Units
8. Nema 12 units are designated by the letter J in the model number suffix These units are constructed with a dust tight electrical enclosure and branch circuit fusing Electrical power supply requirements are identified on the equipment data tag Verify that available voltage supply is the same as the unit s voltage requirements WARNING DO NOT CONNECT THE UNIT TO A VOLTAGE SUPPLY SOURCE NOT EQUAL TO THE UNIT S VOLTAGE REQUIREMENTS AS SPECIFIED ON THE UNIT S DATA PLATE Use of incorrect voltage will void the unit s warranty and cause a significant hazard that may result in damage to the unit or serious personal injury Appropriate conduit and fittings should be selected which will maintain the integrity of the cabinet Supply a power conductor sized according to the unit s power supply requirements Connect the power conductor to the unit s power supply entry terminal block OL CIRCUIT WIRING The unit s supplied control circuit is 110 volt 1 phase 60 cycle The control circuit is supplied by the factory installed transformer A control circuit fuse is provided figure 2 5C AL Make certain all ground Control circuit transformer fuse Figure 2 5C connections to the unit are properly affixed A proper connection to earth ground is required A conduit ground is not a reliable conductor Make certain the power conductor disconnecting means and fusing are properly sized according to the unit s power
9. Sentra with VE Series Instrument SENTRA QUICK START UP GUIDE INSTALLED TO CORRECT ELECTRICAL SUPPLY ELECTRICAL SUPPLY LISTED ON DATA TAG A BE CERTAIN UNIT IS INSTALLED TO PROPER ELECTRICAL SUPPLY i UNIT INSTALLED TO PROCESS CORRECTLY E TO PROCESS TO WATER IN ON PROCESS MANIFOLD J FROM PROCESS TO WATER OUT ON PROCESS MANIFOLD z WATER SUPPLY OPEN AND PRESSURE ADEQUATE SUPPLY PRESSURE MUST OVER 15 PSI FOR UNIT TO START z DRAIN LINE CORRECTLY INSTALLED CONNECT DRAIN LINE TO PROPER RETURN SYSTEM z ENGAGE POWER SUPPLY POWER LIGHT ON Em CHECK DISCONNECT FUSE OR TRANSFORMER FUSE TURN UNIT ON AND SELECT MAKING WATER WORK ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Page 6 Temperature Control Units Sentra with VE Series Instrument SENTRA QUICK TROUBLESHOOTING GUIDE SENTRA WILL NOT START 1 POWER LIGHT ON i MAIN POWER SUPPLY veo ad TRANSFORME ON FUSE i WATER SUPPLY PRESSURE LOW PRESSURE SWITCH OPEN SUPPLY UNIT WITH 15 PSI ENGAGE POWER E MOTOR OVERLOAD RELAY OPEN RESET OVERLOADS ADJUST PROCESS FLOW
10. Sentra with VE Series Instrument venting of all entrained air to the drain evidenced by a rattling sound in the unit and fluctuating pressure gauges the operator must manually vent the system by depressing and holding the Up Arrow and Down Arrow push buttons Release the the buttons to conclude the manual vent sequence If the To Process temperature exceeds 100 F the instrument will bypass the automatic system vent cycle and step immediately to process temperature control operation To display the setpoint temperature briefly touch the Up Arrow or Down Arrow push buttons To change the setpoint hold the Up Arrow or Down Arrow push buttons until the preferred setpoint temperature is indicated in the Temperature window Setpoint temperatures can be adjusted anytime during the process temperature control cycle C INSTRUMENT CONTROLS 1 UNIT ON OFF SWITCH this rocker switch engages disengages electrical supply to the pump heater and PVT cooling valve figure 3 3A UP ARROW depress briefly to display the setpoint temperature Depress and hold to increase the setpoint temperature If pressed momentarily the setpoint value is incremented by one degree If held down for more than one second the setpoint will increase slowly at first and then faster after about two seconds The setpoint control range is 32 to 250 F 0 121 C DOWN ARROW depress briefly to display the setpoint temperature Depress and hold to decr
11. The operator should follow this procedure to calibrate the probe 1 Disengage process operations and verify all system pressure is relieved and the unit s pressure gauges read 0 2 Disengage main power supply and verify the Power light on the display is off 3 Remove the To Process temperature probe and insert a 1 2 plug in its place figure 5 4B To complete the calibration procedure the unit will be operated at full flow and pressure The plug is to maintain the mechanical integrity of the unit during the calibration procedure Plug Figure 5 4B 4 Prepare an ice water bath The operator should place an accurate digital thermometer in the ice water bath to read the temperature of the bath The probe will be calibrated to the temperature of the ice water bath 5 Place the probe in the ice water bath 6 Start the unit 7 Reduce the unit s set point via the Down Arrow push button to 32 F ADVANTAGE ENGINEERING INC Page 43 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 8 With the unit in the operations mode the to process temperature on the display should equal the temperature of the ice water bath as indicated by the digital thermometer If not the operator must change the calibration of the probe a To access th
12. Engage the electrical power supply and start the unit Motor name plate Figure 3 2D f The amp meter will display the motor amps Compare the actual motor amps as displayed on the amp meter to the full load amp rating as listed on the motor name plate g If the amp draw is excessive higher than the listed name plate amp rating a throttling valve must be installed in the from process water line The throttling valve can be a gate valve or a ball valve h With the throttling valve installed fully close the valve and then engage the pump motor Slowly open the throttling valve and monitor the motor amps as displayed on the amp meter until the actual motor amps equal the listed full load amp rating of the motor The process flow is now correctly adjusted The valve should remain in this position during operation 6 LOW PROCESS FLOW The minimum recommended process flow rate is 10 GPM Process restrictions may limit the flow to less than 10 GPM We recommend the addition of bypass lines to raise the flow rate to 10 GPM The best place to add bypass lines are on the extra ports on the molding machine manifold If extra ports are not available add a tee in the To Process and From Process lines install a bypass line between the two tees with a throttling valve Adjust the valve for a minimum of 10 GPM ADVANTAGE ENGINEERING INC Page 24 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Depa
13. Remove all seal parts figure 5 11 Note seal component arrangement to facilitate reassembly Clean the motor shaft and lubricate with a mild soap solution Note oil must never be used asa lubricant as it will damage the rubber parts of the seal assembly ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Pump casing bolts Figure 5 1E Impeller Figure 5 1F Motor shaft Figure 5 1G Removing impeller locking screw with ratchet Figure 5 1H Page 37 Temperature Control Units Sentra with VE Series Instrument 13 14 15 16 17 18 19 20 Install new stationary seal member in pump casing cavity figure 5 1J Be certain the stationary seal member is fully squared and seated in cavity Slide the rotating member onto the lubricated pump shaft figure 5 1K Be certain not to damage or tear the rubber bellows assembly Place the spring onto the rotating member Align the tension spring and rotating member before reinstalling the impeller figure 5 1L Be certain the spring and rotating member are aligned before the impeller is fully tightened and the impeller retaining Screw is reinstalled Clean the pump casing cavities impeller and O ring before reassembly Mate the motor and adapter to the pump casing Reinstall the 4 pump casing bolt
14. and will lead to unit overheating Overheating of the unit may lead to unit damage and or serious personal injury 2 5 ELECTRICAL CONNECTION A DVANTAGE MAKING WATER WORK NEMA 1 MODELS 1 Electrical power supply requirements for Nema 1 units are identified on the equipment data tag Verify that available voltage supply is the same as the unit s voltage requirements WARNING DO NOT CONNECT THE UNIT TO A VOLTAGE SUPPLY SOURCE NOT EQUAL TO THE UNIT S VOLTAGE REQUIREMENTS AS SPECIFIED ON THE UNIT S DATA PLATE Use of incorrect voltage will void the unit s warranty and cause a significant hazard that may result in serious personal injury and or unit damage 2 For units with 10 and 16 KW heaters a four conductor cable 10 foot in length has been provided for connection to an operator supplied fused disconnect 3 For units with 24 and 34 KW heaters the operator must provide a four conductor power cable and the fused disconnect 4 The owner supplied fused disconnect must be sized and installed according to the unit s power supply requirements and local electrical codes ADVANTAGE ENGINEERING INC Page 16 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument B NEMA 12 MODELS 1 C CONTR 1 D GENER 1 MAKING WATER WORK
15. service the PVT valve and remove any loose debris Massive debris or scale deposits may necessitate replacement of the ADVANTAGE ENGINEERING INC Page 31 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument internal PVT valve components The procedure for servicing the valve is outlined in Section 5 3 of this manual Drain line obstruction The operator must determine if the drain line is obstructed by the following conditions Section 2 4 outlines the parameters of correct drain line installation a Closed drain line valve An installed but partially or fully closed valve in the drain line prevents full discharge to drain and contributes to an overheating condition The operator should determine the drain line is open b High drain back pressure Pressurized plant drain lines will prevent flow to drain if the differential between the water supply pressure and the drain line pressure is inadequate The factory recommended minimum differential is 20 psi If the differential is less than the factory recommendation plant service personnel should take measures to reduce drain line pressure Instrument defective The instrument is designed and manufactured exclusively by Advantage The instrument is life tested and found to be field reliable However in the case where the
16. supply requirements Make certain all electrical connections are tightly affixed Any loose wiring connections must be tighten before engaging the power supply Make certain no moisture or standing water is present inside the electrical cabinet ADVANTAGE ENGINEERING INC Page 17 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument Transformer Transformer Fuse Power Entry Motor Contactor Instrument Pressure Heater Sensor Probe Connector PDverload Reset Overload Relay Switch Contactor Connector ADVANTAGE ENGINEERING INC Page 18 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 3 0 OPERATIONS 3 1 GENERAL 3 2 MACHINE START UP OPERATIONS PROCEDURE 3 3 INSTRUMENT OPERATION 3 4 SHUT DOWN DISCONNECT PROCEDURE MAKING WATER WORK ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Page 19 Temperature Control Units Sentra with VE Series Instrument 3 1 GENERAL A Failure to follow the factory required operation procedures may
17. the display is off 3 Remove the lift off access panel and set aside 4 Drain machine The machine can be drained by removing the pump casing drain plug 5 Remove heater s junction box cover to located wiring connections The operator should map the wiring connections to ensure correct reinstallation figure 5 2B Heater junction wires Figure 5 2B 6 Disconnect the three power leads from the heater terminals Remove the power cord from the junction box T Remove the 4 heater mounting bolts figure 5 2C 8 Remove heater figure MAKING WATER WORK 5 2D ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Heater mounting bolt Figure 5 2C Page 39 Temperature Control Units Sentra with VE Series Instrument 9 Before the new heater is installed the mating surface of the cast tank should be cleaned Once cleaned place the new heater gasket onto the tank mating surface Coat the mating surface with a high temperature gasket sealant Remove heater Figure 5 2D 10 Set new heater into tank Aligning the bolt pattern of the heater and tank flanges 11 Replace the 4 heater mounting bolts Alternate to the opposite bolt while tightening 12 Reconnect the power cable to the heater terminals Be certain to tighten the power cord junction box connector Replace
18. 200 PSI minimum pressure B Be certain all process piping materials have the equivalent or larger diameter of the particular process connection To process connection connect to water in on process manifold Drain connection connect to one of the following depending on water supply source plant s open drain tower water system return chilled water system return From process connection connect to water out on process manifold Water supply connection connect to one of the following plant s city water source well water source tower water supply chilled water supply 2 2 TO AND FROM PROCESS CONNECTIONS A Connect the unit s To Process port to the Water In port on the process manifold B Connect the unit s From Process port to the Water Out port on the process manifold C Please note process water piping circuitry should be designed to avoid an excessive use of elbows and or lengths of pipe or hose If hose is the material of choice avoid tight twists or curls and excessive lengths D Valves and filters may be installed in the process water piping circuitry to facilitate service and maintenance provided that such devices maintain the full inside diameter of the process connection If installed all such devices must be open and clean during unit operation ADVANTAGE ENGINEERING INC Page 14 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Departme
19. 4400 3444401 4310605 4757865 5486522 5622271 6490000 6491000 6207040 414 771599 3444400 3444401 4310605 4757866 5486522 5622271 6490000 6491000 DVANTAGE MAKING WATER WORK DESCRIPTION MOTOR PUMP ASSEMBLY AS5 1 5HP 2 4 3 60 Adapter iron C2 4551 AS5 Pump case iron D2 1839 AS5 Tank gasket 2 3 8 A 9159 AS5 Tank gasket 4 1 2 A2 8748 AS5 Impeller B2 5264 5 06 AS5 Motor AE5 AS5 A5W 1 1 2HP S 2774R Nut 5 4989 AS5 O ring Case S 5091 55 Shaft seal 101 173 5 8 EPT Shaft seal EPT Ceramic 4949 AE5 AS5 MOTOR PUMP ASSEMBLY 55 2HP 2 4 3 60 Adapter iron C2 4551 AS5 Pump case iron D2 1839 AS5 Tank gasket 2 3 8 A 9159 AS5 Tank gasket 4 1 2 A2 8748 AS5 Impeller B2 5264 5 25 AS5 Motor AE5 AS5 A5W 2HP S 2775R Nut 5 4989 AS5 O ring Case S 5091 55 Shaft seal 101 173 5 8 EPT Shaft seal EPT Ceramic 4949 AE5 AS5 MOTOR PUMP ASSEMBLY 3HP AS5 2 4 3 60 Adapter iron C2 4551 AS5 Pump case iron D2 1839 AS5 Tank gasket 2 3 8 A 9159 AS5 Tank gasket 4 1 2 A2 8748 AS5 Impeller B2 5264 5 25 AS5 Motor AE5 AS5 A5W 4551R Nut 5 4989 AS5 O ring Case S 5091 55 Shaft seal 101 173 5 8 EPT Shaft seal EPT Ceramic 4949 AE5 AS5 ADVANTAGE ENGINEERING INC Page 74 e 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 8 8 SEN
20. 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com DVANTAGE MAKING WATER WORK 7 Temperature Control Units Sentra with VE Series Instrument 6 Pump seal flush The pump seal flush is a flow diverter which serves to cleanse the pump seal assembly of debris which may lodge on the seal and create a leak figure 6 1D HEATER The heater is a dual voltage flange mounted immersion heater set in the pump discharge Seal flush tube Figure 6 1D cylinder The heater elements have a stainless steel sheath Electrical supply to the heater is provided via a mercury contactor figure 6 1E HEATER PUMP DISCHARGE CYLINDER The heater pump discharge cylinder is a custom cast tank The tank is flanged mounted to the pump casing Reinforced machined bosses accept the to process high temperature limit sensor probe and the to process Heater Figure 6 1E connection figure 6 1E ados AVT valve COOLING CYLINDER The cooling cylinder is a custom cast tank The tank is flanged mounted to the pump casing Reinforced machined bosses accept the pressure relief valve the from process pressure gauge and pressure switch capillary connector AVT modulating cooling valve the water supply connection and the from process connection figure 6 1F Figure 6 1F PRESSURE RELIEF VALVE The pressure relief valve is a 150 psi relief valve serving to
21. 7 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Page 21 Temperature Control Units Sentra with VE Series Instrument d Toggle the On Off Switch This will cycle the motor on and then off e Observe the motor shaft as it slows to a stop to identify the rotation Correct rotation is clockwise when Remove shaft cover to view Figure 3 2B viewed from the TESS rear of the motor Incorrect rotation is counter clockwise when viewed from the rear of the motor If the shaft does not rotate when the unit is started the operator must identify the cause as outlined in this manual s troubleshooting and repair section f If the unit is phased correctly continue with the start up procedure at step C If the unit is phased incorrect continue with step 2 2 To correct unit phase a Disengage the electrical power supply to the unit at the unit s disconnect switch Follow proper lockout procedures before proceeding b Once the electrical power supply is disengaged reverse any two power leads of the power cord at the fused disconnect terminals c Note The operator must reverse the te power leads at the gt disconnect only Bil not at the power di entry terminals on the unit s electrical panel figure 3 2C The unit s internal electrical system wiring is phased Do not reverse power leads Figure 3 2C correctly at the at the unit s power entry factory
22. CESS CONNECTION WATER SUPPLY CONNECTION WATER SUPPLY CONNECTION WATER SUPPLY MANIFOLD WATER SUPPLY CONNECTION TO SENTRA 1 WATER SUPPLY MANIFOLD CONNECTION ELECTRICAL CABINET WATER SUPPLY CONNECTION TO SENTRA 2 STRUCTURAL STEEL BASE DRAIN CONNECTION TO SENTRA 1 CASTER DRAIN MANIFOLD CONNECTION WATER SUPPLY MANIFOLD DRAIN CONNECTION TO SENTRA 2 ADVANTAGE ENGINEERING INC Page 64 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 7 6 SENTRA STACKING RACK FRONT VIEW 64 SIDE VIEW BACK VIEW MAKING WATER WORK TO PROCESS DRAIN CONNECTION CONNECTION SENTRA FROM PROCESS o me CONNECTION sui WATER SUPPLY WATER SUPPLY i MANIFOLD 1 CONNECTIONS NE TO PROCESS CONNECTION DRAIN SENTRA G3unnei CONNECTION 2000 FROM PROCESS CONNECTION WATER SUPPLY 5 CONNECTION T
23. EENS d d 5 Ge wl CONNECTION TO CONNECTION TC 21 5 gt 29 gt PLANT WATER SUPPLY PLANT DRAIN ADVANTAGE ENGINEERING INC Page 65 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com THIS PAGE INTENTIONALLY BLANK Page 66 Temperature Control Units Sentra with VE Series Instrument 8 0 APPENDIX 8 1 SPECIFICATIONS 8 2 SENTRA MODEL AND SUFFIX CODING 8 3 INTERPRETATION OF PROCESS PRESSURE GAUGES 8 4 OPERATION OF MOLD PURGE 8 5 CLOSED CIRCUIT OPERATION 8 6 SENTRA 55 PUMP PARTS LIST 1 2 HP TO 1 HP 8 7 SENTRA 55 PUMP PARTS LIST 1 5 HP TO 3 HP 8 8 SENTRA PARTS LIST VE INSTRUMENT ADVANTAGE ENGINEERING INC Page 67 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 8 1 SPECIFICATIONS SENTRA SPECIFICATIONS SK 620 635 645 665 675 680 HEATER KW 6 6 6 6 6 6 PROCESS PUMP HP 12 3 4 1 1 2 3 GPM 20 35 45 62 75 80 PSI 30 30 30 30 30 FULL LOAD AMPERAGE 230 volt 17 0 17 8 18 6 20 2 21 8 246 93o 60hz 460 volt 85 80 93 101 109 123 DIMENSIONS inc
24. EERING INC Page 56 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument heater pump discharge tank figure 6 2C The from process probe is mounted in the suction tank G POWER CORD The supplied power cord is factory installed to the unit The power cord is a 3 conductor with 1 ground wire sized for the unit and 10 in length DVANTAGE MAKING WATER WORK Heater Motor start and Transformer Contactor overload relay Figure 6 2B Instrument service connections Sensor probe and high Figure 6 2C temperature limit ADVANTAGE ENGINEERING INC Page 57 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com THIS PAGE INTENTIONALLY BLANK Page 58 Temperature Control Units Sentra with VE Series Instrument 7 0 RELATED DRAWINGS 7 1 SENTRA PHYSICAL 7 2 SENTRA ELECTRICAL 7 3 SENTRA CIRCUIT SCHEMATIC 7 4 SENTRA REGULATOR BYPASS INSTALLATION 7 5 SENTRA DUAL ZONE DOLLY 7 6 SENTRA STACKING RACK ADVANTAGE ENGINEERING INC Page 59 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sen
25. ER KW 24 24 24 24 24 24 24 PROCESS PUMP HP i 1 2 3 5 71 2 GPM 35 45 65 75 80 90 100 PSI 30 30 30 30 30 34 54 FULL LOAD AMPERAGE 230 volt 63 1 63 9 65 5 67 1 69 9 75 5 82 3 93o 60hz 460 volt 31 6 32 0 32 8 33 6 35 0 37 8 412 DIMENSIONS inches Height 44 44 44 44 44 44 44 Width 16 16 16 16 16 16 16 Depth 24 24 24 24 24 24 24 CONNECTIONS inches 11 4 a 14 14 ha 1 2 172 S D4 1 2 12 12 Ya Ye 12 1 2 WEIGHT pounds Shipping 270 275 280 285 290 295 310 SENTRA SPECIFICATIONS SK 3435 3445 3465 3475 3480 3490 34100 HEATER KW 34 34 34 34 34 34 34 PROCESS PUMP HP 1 1 2 3 5 Th GPM 35 45 65 75 80 90 100 PSI 30 30 30 30 30 34 54 FULL LOAD AMPERAGE 230 volt 88 2 89 0 90 6 92 2 95 0 100 6 107 4 3 60hz 460 volt 44 1 44 5 45 3 46 1 47 5 50 3 53 7 DIMENSIONS inches Height 4 44 44 44 44 44 44 Width 16 16 16 16 16 16 16 Depth 24 24 24 24 24 24 24 CONNECTIONS inches a 174 19 4 1a 1 4 1 2 1 2 S D 2000 h j 7 WEIGHT pounds Shipping 280 285 290 295 300 305 320 Notes 1 Derate heater output by 25 for 208 3 60 operation 2 Consult factory for 5Ohz operations 3 T to process F from process 4 S water supply D drain 5 Approximate unit shipping weight MAKING WATER WORK ADVANTAGE ENGINEERING INC Page 68 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Temperature Control Units
26. NG VALVE eh FROM PROCESS CONNECTION gt Ss TO PROCESS CONNECTION DISCHARGE TANK PRESSURE RELIEF VALVE FROM PROCESS PRESSURE GAUGE WATER SUPPLY CONNECTION gt SUCTION TANK ES 0 ii PUMP PUMP SEAL FLUSH iis O ADVANTAGE ENGINEERING INC Page 62 MAKING WATER WORK 7 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 7 4 SENTRA REGULATOR BYPASS INSTALLATION TO PROCES FROM PROCES DRAIN ei We 3 o 2 WATER PRESSURE REGULATOR VALVE SUPPLY TYPE WATTS U5B 1 2 BYPASS VALVE 25 75psi RANGE TYPE WATTS BP 30 1 2 45 100psi RANGE ADVANTAGE ENGINEERING INC Page 63 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 7 5 SENTRA DUAL ZONE DOLLY SENTRA DRAIN CONNECTION SENTRA 2 FROM PROCESS CONNECTION DRAIN CONNECTION TO PROCESS CONNECTION TO PROCESS CONNECTION FROM PRO
27. Place the coil onto the top bonnet and replace the retaining screw Mesh screen Diaphragm assembly O Ring Figure 5 3D Collar Plate Diaphragm and O Ring Figure 5 3E Top bonnet Enclosure tube Spring Plunge Figure 5 3F Open the water supply to circulate water to the System Check the solenoid valve for leakage Restart the unit as outlined in section 3 ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Page 42 Temperature Control Units Sentra with VE Series Instrument 5 4 PROBE CALIBRATION A The temperature probe figure 5 4A is a temperature transducer The transducer is embedded into a threaded bulb well The transducer converts the temperature of the water into a proportional current output which the microprocessor controller reads displays and bases it controlling functions The gain is automatically calibrated within the microprocessor Typical sensor probe Figure 5 4A electronics The zero adjustment potentiometer is located on the CPU The temperature transducer and instrument circuitry is very stable A small drift may occur over time To ensure correct temperature reading calibrate the probe annually or per your facility calibration standards Operation in high humidity and high vibration environments may require more frequent calibration
28. R PRESSURE RELIEF VALVE E DEFECTIVE HEATER ELEMENT ES REPLACE HEATER E HEAT LOSS ves 4 CHECK FOR EXCESSIVE UNIT RADIATION on dd DETERMINE IF UNIT CAPACITY TOO LOW E DEFECTIVE CONTROL PROBE 5 4 CHECK FOR WATER IN PROBE CONNECTION t REPLACE PROBE E INSTRUMENT DEFECTIVE REPLACE MAKING WATER WORK ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Page 7 THIS PAGE INTENTIONALLY BLANK Page 8 Temperature Control Units Sentra with VE Series Instrument 10 GENERAL 1 1 SAFETY 1 2 EFFICIENCY 1 3 TYPICAL LABEL PLACEMENT 1 4 COMPONENT PLACEMENT ADVANTAGE ENGINEERING INC Page 9 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 1 1 SAFETY A It is important to become thoroughly familiar with this manual and the operating characteristics of the equipment Several important references are made to safety considerations in this manual It is the owner s responsibility to assure proper operator training installation operation and maintenance of the water temperature controller with instrument 1 2 EFFICIENCY A Long te
29. RVICE 5 3 PVT COOLING VALVE SERVICE 5 4 PROBE CALIBRATION 5 5 VOLTAGE CHANGEOVER 5 6 SENSOR PROBE SERVICE 5 7 PRESSURE SWITCH SERVICE 5 8 INSTRUMENT SERVICE 5 9 CELSIUS TEMPERATURE DISPLAY ADVANTAGE ENGINEERING INC Page 35 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 5 1 PUMP SEAL REPLACEMENT A DVANTAGE MAKING WATER WORK The pump seal is a Rotating Member Tension Spring carbon ceramic shaft seal assembly including a stationary member rotating member and tension spring figure 5 14 The life cycle of the pump seal is determined by hours of Stationary member Figure 6 14 use operating temperature and water quality Poor water quality is the primary reason for premature pump seal failure The operator should follow this procedure to replace the pump seal 1 Disengage process operations and relieve all system pressure Remove lift off access panel Figure 5 1B 2 Disengage main power supply Verify the Power light on the display is off 3 Remove the lift off access panel and set aside Figure 5 1B 4 Remove the thermoformed panel It is attached to the stainless steel cabinet by 4 small screws figure 5 1C Thermoformed panel Figure 5 1C removed and electrical 5 Drain machin
30. T POWER LIGHT IS ILLUMINATED A Power supply is ON The operator can determine that electrical power supply to the unit is on by an illuminated Power light on the display Even with the main power supply on the unit is prevented from operating by one of the following conditions 1 Water supply pressure inadequate pressure switch is open The unit is prevented from operation without adequate water supply pressure by the electrical panel mounted pressure switch Sufficient water supply pressure must be present to close the switch 2 Motor overload switch opened The electric motor is protected from overload conditions by a set of thermal overload relays These relays will open trip If the overload relay is open it must be reset before operation can continue An excessive flow condition must be isolated and corrected immediately 3 High temperature limit switch open The unit is prevented from operations at temperatures exceeding 256 F by a high temperature limit switch This switch is installed in the To Process temperature sensor If this switch is open due to a high temperature condition the unit cannot be started and must cool down before the high temperature limit Switch will automatically reset UNIT STOPS A DVANTAGE MAKING WATER WORK The operator should determine the main power supply to the unit is ON by an illuminated Power light on the display With the main power supply on the uni
31. TRA PARTS LIST LE INSTRUMENT Note typical parts list shown Please supply model and serial numbers when order ing parts PART 299082 781000 1835050 1843601 2735358 2746237 2761201 2851112 2877542 3581000 3708505 3775510 3520005 4439900 4713377 6207000 414 771599 3444400 3444401 4310602 4310611 4714466 4757862 5486522 5622271 6490000 6491000 6748201 9118502 7370000 1733456 7541000 7732250 8240000 8764940 8764939 8764949 9060000 DESCRIPTION Bracket home switch SI MD 1642 Caster 2 swivel EY459R Contactor 3030APS 30 AMP Adapter coupling SI MD 1642 Sentra top SS DWG EP 103 Electrical enclosure door SS DWG EP 103 Electrical sub panel DWG EP 103 Gauge panel DWG EP 103 Base DWG EP 103 Pressure gauge 0 160 PSI 2 face Plastic handle P2 41 Heater 10KW 2 4 3 60 square flange Heater flange gasket 4 50 OD Instrument kit SK SI Drip Cover SI MD 1642 Motor pump assembly AS5 3 4HP ODP 230 460 Adapter iron C2 4551 AS5 Pump case iron 137 001 166 AS5 Tank gasket 2 3 8 A 9159 AS5 Gasket tank flange 4 1 2 AS5 Impeller B2 5264 4 5 AS5 Impeller AS5 100345 4 5 mfg after 2 97 Motor 3 4HP 113 000 354T 2 4 3 60 Motor AE5 AS5 A5W 3 4HP S 2772R Nut S 4989 AS5 O ring case 116 000 252 Shaft seal niresist 5 8 Shaft seal ceramic 5 8 Cap screw 102RO3A2 Impeller washer 100301 Motor starter CR354AB3AA1B Auxiliary contact kit 353XAAA Panel mount pressure switch 82681 Heater cylind
32. This occurs when the process requires more heat than the unit is capable of producing The only option in such cases is to install a unit with an adequate heater KW rating for the load 4 Instrument defective The instrument is designed and manufactured exclusively by Advantage The instrument is life tested and found to be field reliable However in the case where the instrument is determined to be defective the operator must remove the assembly according to instructions outlined in this manual and return the assembly to the factory The instrument is not a field serviceable component 4 6 PRESSURE RELIEF VALVE LEAKS A The unit has a 150 psi pressure relief valve mounted in the cooling cylinder If the valve is found to be leaking the operator should check the following 1 Water supply pressure exceeds 75 psi The unit is designed to operate with water supply NOT exceeding 75 psi See section 2 3 paragraph B for specific water supply pressure requirements at corresponding setpoint temperatures If the plant water supply pressure exceeds 75 psi the pressure relief valve may leak Static water supply pressure can be determined at the unit s location by reading the unit s 0 160 PSI pressure gauges when the unit s motor pump is off If the water supply pressure at the unit s location exceeds 75 PSI a pressure reducing valve must be installed in the water supply line The factory recommended regulated pressure out is 55 PSI Refe
33. adversely affect the unit s ability to adequately control process temperature and may create a hazardous operating condition which may result in unit damage or serious operator injury B The Operations segment of this manual is outlined below 3 2 3 3 3 4 Machine start up operations procedure follow this segment to start the unit after the initial installation or to restart the unit after reinstallation to the same or different process This section includes information on system fill electric motor phasing pump rotation and process flow adjustments instrument Operation follow this segment to start up and operate the instrument This section includes information on automatic and manual venting setpoint selection and adjustment and feature explanations Shut down procedure follow this segment to shut down the unit This segment includes information on system cool down shut down electrical power supply precautions and disconnection from the system 3 2 MACHINE START UP OPERATIONS PROCEDURE A SYSTEM FILL 1 DVANTAGE MAKING WATER WORK Engage the water supply source by opening the water supply valve customer installed at the unit s location If a valve is not installed engage the water supply source at the plant s water supply central control point Once the water supply source is open the unit will fill automatically Allow a few moments for the the unit to completely fill The operator can dete
34. and must not be altered in the field 3 To visually verify pump rotation start the unit and observe the pressure gauges The To Process pressure will indicate 35 50 PSI more than the From Process pressure In this state the pump rotation is correct clockwise If this is not evident the unit is not correctly phased and should be corrected as outlined in step 2 MAKING WATER WORK ADVANTAGE ENGINEERING INC Page 22 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument C PROCESS FLOW ADJUSTMENTS 1 The operator must determine and set proper water flow rate for the most efficient and trouble free operation a Water flow rate through the process is determined by the pressure losses in the process loop Generally higher flow rates result in turbulent flow achieving maximum temperature control and lower maintenance b If the flow rate exceeds the motor HP capacity the electric motor will draw excessive amps This is a result of the process loop s ability to flow water at a greater rate than can be provided by the pump This will eventually result in tripping the thermal motor overload relay overload relays open and the unit will shut down and illuminate the Safety and Alarm lights on the display 2 If an excessive flow situation is encountered and the motor overloa
35. d circuit has tripped the operator must manually reset the overload relay before operations can continue This is done by opening the electrical panel cover identifying the reset lever on the overload relay figure 3 2D and pushing Motor overload relays and Figure 3 2D the reset lever in until the overloads are reset evidenced by a clicking sound as the overloads reset 3 If a motor overload situation persists the operator must adjust the flow rate to match the system pressure loss reduce flow rate to prevent continual tripping of the overload relay This procedure is outlined here a Open electrical cabinet panel door The panel cover is hinged and held open by a support cable Note that the electrical power is engaged at this point and caution must be observed while the cabinet panel is open b Identify the motor starter block This block consists of the motor starter contactor and the overload relay Place amp meter on a single power lead coming from the overload relay ADVANTAGE ENGINEERING INC Page 23 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument d Locate the motor name plate on the pump motor housing figure 3 2D The full load amp rating for the motor is listed on the name plate e
36. d pressure out is 55 PSI figure 2 2C 2 4 DRAIN CONNECTION Typical pressure reducing valve Figure 2 2C A Connect the unit s DRAIN port to installation shown on S 925 one of the following determined by the water supply source 1 Open drain for well or city water supply 2 Tower water system return for tower system water supply 3 Chilled water system return for chilled water system supply ADVANTAGE ENGINEERING INC Page 15 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument The factory recommends a minimum of 10 psi pressure differential between the water supply and drain line for proper cooling For most applications the drain line should not be valved However for installations with a pressurized drain system it may be necessary to install a valve in the drain line In such cases the installed valve must be fully opened after installation and the valve handle removed to prevent operating the unit with a closed drain valve The valve handle can be reattached to Typical drain valve installation Figure 2 3A the valve body when it is necessary shown 5 925 to close the valve figure 2 34 CAUTION the unit must never be operated with a closed drain line valve A closed drain line valve prevents adequate system cooling
37. discharge excessive unit pressure to atmosphere The valve can be manually activated by lifting the actuating lever figure 6 1F AVT VALVE The AVT valve is a patented Advantage design using a motor gearbox assembly to open in minute increments from 0 to 100 a custom ball valve assembly The AVT valve is controlled by custom programming of the instrument figure 6 1F PRESSURE GAUGES To and from process pressure gauges display the system pressure To process pressure originates at the heat pump discharge cylinder From process pressure originates at the cooling cylinder The gauges accurately display system pressures from 0 to 160 PSI figure 6 1G ADVANTAGE ENGINEERING INC Page 55 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument H CASTERS The unit is mounted on 4 swivel ball bearing casters The casters allow the unit to be portable and easily move from location to location l STAINLESS STEEL CABINETRY The stainless steel cabinetry prevents unsightly rust and metal decay The electrical cabinet cover is hinged The unit base is made of Figure 6 1G pressed steel with galvanized zinc coating The lift off access panel is secured to the unit base by 5 screws figure 6 1G 6 2 ELECTRICAL SYSTEM A INSTRUMENT The instr
38. e connection shake out the water to clear the service connection and replug If this was the problem the error display should change to Solid Red which can be cleared by pressing the Start push button If not continue with replacement 2 REPLACEMENT Replacement of the sensor probe involves ceasing process operations as outlined in section 3 4 of this manual and removing the defective sensor probe All factory supplied replacement probes are complete with the service connection Unit with HE Series instruments use two sensor probes a to process and a from process The high temperature limit safety switch is a part of the to process sensor probe To replace any sensor probe follow the procedure as outlined below a Stop process operations as described in section 3 4 of this manual b Determine that all process pressure is relieved and the unit s pressure gauges read 0 pressure C Drain the unit by removing the pump casing drain plug The unit can be drained only to below the sensor probe mount if preferred d Disconnect the sensor probe service plug ADVANTAGE ENGINEERING INC Page 47 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument e Using a crescent wrench remove the sensor probe from the cylinder To install a new s
39. e by removing cabinet open the pump casing drain plug 6 Remove the three motor wire leads from the motor wiring terminals The operator should map the wire terminal locations to ensure correct rewiring The power cord should be removed from the motor housing figure 5 1D Motor leads Figure 5 1D ADVANTAGE ENGINEERING INC Page 36 s 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 7 10 11 12 MAKING WATER WORK Locate and remove the 4 pump casing bolts These bolts secure the motor and motor adapter to the pump casing figure 5 1E Separate the motor and adapter from the pump casing to expose the pump impeller figure 5 1F Remove the motor and adapter from the unit and place on a workbench to continue the procedure Locate and remove the dust cap from the motor to expose slotted motor shaft The motor shaft is free to rotate but must be secured to remove the impeller To secure the motor shaft insert a flat bladed screw driver in slot to hold the shaft stationary figure 5 1G Locate and remove impeller locking screw figure 5 1H Using a socket and ratchet the impeller retaining screw can be removed Once removed the impeller can be unthreaded from the motor shaft to expose the pump seal assembly
40. e calibration potentiometer open the electrical cabinet panel door The panel door is secured by a support strap Caution must be employed when the the electrical panel door is open since power is applied to the unit b Locate the instrument CPU The calibration pot is located on the mother board of the instrument assembly figure 5 4C c Use a non conductive device to adjust the potentiometer Adjust the Calibration port Figure 5 4C potentiometer until the to process temperature on the display equals the temperature of the ice bath 9 When the two temperatures to process and ice water bath are equal the calibration procedure is complete 10 Shut down the unit The operator must be certain to remove the 1 2 plug and replace the sensor probe Restart operations ADVANTAGE ENGINEERING INC Page 44 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 5 5 VOLTAGE CHANGEOVER A The unit can undergo a field voltage conversion by qualified technicians Consult factory for 380 volt conversions B For a field voltage changeover the following items will require replacement or rewiring 1 Heater rewiring 2 Motor rewiring 3 Transformer rewiring 4 Motor overloads replacement C The operator should follow th
41. ease the setpoint temperature If pressed momentarily the setpoint value is incremented by one degree If held down for more than one second the setpoint will increase slowly at first and then faster after about two seconds The setpoint control range is 32 to 250 F 0 121 C D STATUS INDICATING LIGHTS 1 2 MAKING WATER WORK POWER ON illuminates when power is applied to the unit PUMP illuminates when the unit s On Off rocker switch is turned on and the motor pump is operating Even with the On Off rocker switch on the Pump light will not illuminate if a safety fault condition exists HEAT illuminates when the heater is on to increase process water temperature ADVANTAGE ENGINEERING INC Page 27 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 4 COOL illuminates when the PVT valve is open Opening the valve will discharge process water to the drain Opening the valve also allows cooling water flow from the water supply source to enter the circulating system and mix with the heated process water to reduce process temperature 3 4 SHUT DOWN DISCONNECT SEQUENCE A PRECAUTIONS WARNINGS 1 The operator must precisely follow all shut down procedures outlined in this manual If the operator fails to do so an unsafe conditi
42. ely 30 seconds to release air pressure T Disconnect power to unit LINE TO DRAIN CHECK VALVE prevents compressed air from purging unit TO PROCESS CONNECTION DRAIN CONNECTION AVT VALVE closed to prevent purge of unit MOLD PURGE SWITCH turns on off mold purge feature Located on electrical cabinet WATER SUPPLY CONNECTION valve must be closed during mold purge operation FROM PROCESS CONNECTION CHECK VALVE prevents water bleed to air line during normal run cycle COMPRESSED AIR CONNECTION SOLENOID VALVE opens to allow compressed air to enter during mold purge operation SOLENOID VALVE opens to purge water to drain ADVANTAGE ENGINEERING INC Page 71 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 8 5 CLOSED CIRCUIT OPERATION A Standard Sentra SK mold temperature controllers are supplied as open circuit units SK units can be used on closed circuit applications with the installation of the SE kit B Factory installed SE kits place a heat exchanger into system to separate the cooling water loop from the process circulation loop Cooling water from plant water supplies circulate only through the tube side of the heat exchanger Process water circulates t
43. ensor probe continue as follows f The new sensor probe threads should be lined with teflon tape and coated with leak preventative sealant Using a crescent wrench thread the new sensor into the machined boss of the cylinder g Reconnect the service connection Restart the unit as outlined in section 3 of this manual ADVANTAGE ENGINEERING INC Page 48 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com DVANTAGE MAKING WATER WORK Temperature Control Units Sentra with VE Series Instrument 5 7 PRESSURE SWITCH SERVICE A The unit is protected from low pressure operations by a pressure switch figure 5 7A This switch is mounted at the bottom of the electrical cabinet B The switch will close and consent the control circuit when sufficient water supply pressure is presented The switch is factory set to 20 psi Pressure switch Figure 5 7A C If insufficient water supply pressure is present the switch will open and prevent operations D In cases where sufficient water supply pressure is present as indicated by the unit s pressure gauges and the pump is off and if the pres sure switch fails to close the pressure switch may be defective To replace the pressure switch follow the steps outlined 1 MAKING WATER WORK Shut down unit operations according to section 3 4 in this man
44. er AS5 D2 1841 Transformer 9T58B42 AVT valve SI Eh 89C 1 2 AVT SI repair kit EH 124 AVT drive kit for 3 8 and 1 2 valves 977700 Pressure relief valve 150 PSI ADVANTAGE ENGINEERING INC Page 75 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com THIS PAGE INTENTIONALLY BLANK Page 76 2009 ADVANTAGE ENGINEERING INC RE 4 5 09
45. ers must be sized for the proper voltage and current draw being used Transformer Figure 5 5C 9 Once a voltage change is complete be certain the unit is properly connected to the new voltage supply as outlined in section 2 5 of this manual Restart unit operations according to section 3 of this manual Motor overloads Figure 5 5D ADVANTAGE ENGINEERING INC Page 46 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com DVANTAGE MAKING WATER WORK Temperature Control Units Sentra with VE Series Instrument 5 6 SENSOR PROBE SERVICE A Each temperature probe figure 5 6A is a temperature transducer The transducer is embedded into a bulb well which is threaded into the tank The transducer converts the temperature of the water into a proportional current output which the microprocessor controller reads displays and bases it controlling functions The gain is automatically calibrated within the Probe controller electronics the zero Service connection Figure 5 6A adjustment potentiometer is located on the CPU B Sensor probe errors are indicated by the Probe light on the instrument with a Flashing Hed display When a sensor probe error is displayed take the following steps to correct 1 RECONNECTION If the service connection of the sensor probe becomes saturated with water Simply unplug th
46. he sum of the water supply pressure and pump generated pressure The from process pressure gauge reads the effect of water supply pressure and pump suction pressure The difference between the to and from process gauges is the pump generated circulating pressure which is also equal to the pressure drop across the process Pressure gauges Figure 7 3A PUMP ROTATION INDICATION If the pump is running and both gauges are close to same value it is likely that the pump is rotating backward or the pump is generating such a high flow that an overload condition will result PUMP MOTOR OVERLOAD CONDITION If the ZP is low with the pump rotating correctly then the flow rate is high which probably will result in a motor overload Refer to the representative pump curve below WATER HAMMER COMPETITIVE SOLENOID VALVE UNITS On competitive mold temperature controllers when gauges supplied the water hammer effect of on off solenoid valves can be seen When the solenoid valve is open both to and from process pressure gauges will fall as the system depressurizes When the valve closes there will be a momentary spike that will be seen on both pressure gauges then they will settle back to normal values This spike is called water hammer Generally centrifugal pumps use HP most efficiently in the center portion of the curve Normally motor overload occurs in this area V FLOW IN GPM
47. hes Height 27 27 27 27 27 27 Width 11 11 11 11 11 11 Depth 16 16 16 16 16 16 CONNECTIONS inches 1 4 34 174 114 S D4 1 2 1 2 12 12 WEIGHT pounds Shipping 195 200 205 205 210 220 SENTRA SPECIFICATIONS SK 1020 1035 1045 1065 1075 1080 1090 10100 HEATER KW 10 10 10 10 10 10 10 10 PROCESS PUMP HP Yo 3 4 1 172 2 3 5 71 GPM 20 35 45 62 75 80 90 100 PSI 30 30 30 30 30 30 34 54 FULLLOAD AMPERAGE 230volt 27 0 27 8 28 6 302 31 8 34 6 40 3 47 1 3 60hz 460 volt 13 5 13 9 14 3 15 1 15 9 17 3 20 2 23 5 DIMENSIONS inches Height 27 27 27 27 27 27 44 44 Width 11 11 11 11 11 11 16 16 Depth 16 16 16 16 16 16 24 24 CONNECTIONS inches 1 4 14 17 1 4 a 12 1 2 5 04 Yo Ya 1 2 1 2 1 2 12 YA 1 2 WEIGHT pounds Shipping 198 200 208 208 213 223 275 290 SENTRA SPECIFICATIONS SK 1620 1635 1645 1665 1675 1680 1690 16100 HEATER KW 16 16 16 16 16 16 16 16 PROCESS PUMP HP Ya 1 1 2 2 3 5 71 2 GPM 20 35 45 62 75 80 90 100 PSI 30 30 30 30 30 30 34 54 FULL LOAD AMPERAGE 230 volt 42 0 42 8 43 6 45 2 46 8 496 554 62 2 3 60hz 460 volt 21 0 21 4 21 8 226 23 4 248 277 314 DIMENSIONS inches Height 27 27 27 27 27 27 44 44 Width 11 11 11 11 11 11 16 16 Depth 16 16 16 16 16 16 24 24 CONNECTIONS inches 1 4 1 4 a 1 4 12 1 2 S D 12 1 2 1 2 1 2 1 2 12 12 WEIGHT pounds Shipping 200 205 210 210 220 225 285 300 SENTRA SPECIFICATIONS SK 2435 2445 2465 2475 2480 2490 24100 HEAT
48. hrough the shell side of the heat exchanger C To control process water temperature a microprocessor controlled AVT modulating valve is ei installed on the heat exchanger drain line TO PROCESS D The closed circuit kit will add 10 to the overall height of the unit The width and depth do not change although the length of connection hose extending from the back of the unit must be accounted for BYPASS T sn nT PROCESS TO PROCESS TON SUPPLY DRAIN L3 EXCHANGER AVT VALVE BYPASS VALVE HEAT EXCHANGEF FROM PROCESS WA a YA WATER SUPPLY wa w DRAIN ADVANTAGE ENGINEERING INC Page 72 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 8 6 SENTRA AS5 PUMP PARTS LIST 1 2 HP TO 1 HP PART 6206995 414 771599 3444400 3444401 4310601 4757861 5486522 5622271 6490000 6491000 6207000 414 771599 3444400 3444401 4310602 4757862 5486522 5622271 6490000 6491000 6207010 414 771599 3444400 3444401 4310603 4757863 5486522 5622271 6490000 6491000
49. ine continuity at each fuse If continuity is not determined replace the fuse Then determine cause of blown fuse Control circuit transformer fuse is open blown Determine continuity at the control circuit transformer fuse If continuity is not determined replace the fuse 4 4 UNIT OVERHEATS A MAKING WATER WORK This is evidenced by To Process temperatures consistently above the selected setpoint temperature Overheating is also evidenced by a To Process temperature that continues to escalate above the setpoint temperature with no apparent cooling action even though the Cool light is on Extreme overheating is evidenced by To Process temperatures over 256 F The operator should check for the following conditions 1 Inadequate water supply pressure The unit must be supplied with adequate water flow to provide cooling when required The minimum pressure differential between the water supply and drain to achieve full cooling capacity is 10 PSI The minimum water supply pressure is 20 PSI A drop in water supply pressure operation will cause the pump to stop and a safety fault to be displayed PVT valve defective The instrument opens and closes the PVT cooling valve as prescribed by the current process load If the valve becomes clogged with process water debris or scaled with mineral deposits its operation is hindered or fully prevented and adequate process water discharge to drain is prevented The operator must
50. ing cooling valve to maintain process temperature at setpoint figure 5 8A The instrument is not a field serviceable component If the instrument is determined to be in need of repair the operator must Sentra HE instrument Figure 5 8A remove the assembly and return it to the factory for repair To service the instrument take the following steps 1 Disengage process operations according to the procedure outlined in section 3 4 The operator must be certain all System pressure is relieved and the unit s pressure gauges read 0 Disengage main power supply and verify the Power light on the display is off Remove the thermoformed front panel and set aside The panel is attached to the stainless steel cabinet by 4 small Screws Open the hinged electrical cabinet panel cover The panel is opened by removing four small screws The instrument is mounted on the electrical cabinet panel cover The instrument is secured by four mounting bolts A series of electrical connections link the instrument to the mechanical components of the unit Figure 5 8B Connections Figure 5 8B Remove the large molex connector Remove the ground terminals Remove the sensor plug ADVANTAGE ENGINEERING INC Page 50 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra wi
51. instrument is determined to be defective the operator must remove the assembly according to instructions outlined in this manual and return the assembly to the factory The instrument is not a field serviceable component 4 5 UNIT UNDERHEATS A This is evidence by operations with To Process temperatures consistently below the selected setpoint temperature 1 DVANTAGE MAKING WATER WORK Process water leakage When the instrument engages the heater to elevate process temperature the input of heat into the process can be offset by a defective PVT valve If the PVT valve is defective it may pass a larger than required stream to drain thus providing unwanted cooling A defective PVT valve should be repaired immediately Heater element failure A failed heater element will not input adequate heat into the process to elevate the process water temperature The operator must check the amps at the heater contactor with the contactor energized Zero amps at the contactor indicate a failed heater or burnt wire connections The operator should remove the failed heater and replace with a new heater according to the procedure outlined in section 5 2 ADVANTAGE ENGINEERING INC Page 32 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com D Temperature Control Units Sentra with VE Series Instrument 3 Unit capacity too low
52. ion the control circuit is not consented and the unit cannot be started If a high temperature condition exists the unit must first cool down reduce water temperature before the high temperature limit switch will automatically reset to allow operation d Temperature sensor Failure of the To Process temperature sensor will be indicated in the Temperature window by a Check the sensor cable and connector for loose wires or moisture If no problems are found replace the sensor B INSTRUMENT OPERATION 1 DVANTAGE MAKING WATER WORK Process temperature control operation is started by toggling the unit s On Off rocker switch to the on position When the On Off rocker switch is toggled the instrument will immediately display the process temperature as indicated by the temperature sensor If the indicated temperature is less than 100 F the instrument will automatically open the PVT cooling valve for 45 seconds This automatic system vent cycle will purge entrained air from the process system unit hoses piping circuitry and tooling to the drain Automatic venting is indicated by a Air Prg display in the Temperature window If the automatic vent cycle does not result in the ADVANTAGE ENGINEERING INC Page 26 e 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Temperature Control Units
53. is procedure to complete a field voltage changeover 1 Disengage process operations and verify all system pressure is relieved and the unit s pressure gauges read 0 2 Disengage main power supply Follow proper lock out procedures The operator must verify the Power light on the display is off 3 Remove the lift off access panel and set aside 4 Rewire the heater to the new voltage Figure 5 5A shows the wiring for 230 and 460 volt heaters 240 VOLT WIRING 480 VOLT WIRING Wiring schematics for 230 and 460 volt heaters Revised 9 98 Figure 5 5A 5 Remove the thermoformed front panel and open the electrical cabinet panel door Unplug the instrument connectors to fully extend the hinged panel ADVANTAGE ENGINEERING INC Page 45 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 6 Rewire the pump motor for the new voltage Most Sentra pump motors are dual voltage Figure 5 5B shows the wiring schematic for 230 and 460 voltages 208 230 460 480 Wiring schematics for 230 and 460 volt pump motors Figure 5 5B T Rewire the transformer to the proper voltages a shown by the schematic on the transformer figure 5 5C 8 Replace the motor overloads with a set sized for the proper current draw figure 5 5D The motor overload heat
54. nstrument Cooling Valve Temperature Sensor Heating Cylinder Electrical Panel Inside stainless steel cabinet Cooling Cylinder Pump Pump Motor Thermoformed Cover Panel Vented Stainless Steel Cabinet ADVANTAGE ENGINEERING INC Page 11 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument anual amp Quick Start Guide Electrical Panel Lift Off Cover Panel ADVANTAGE ENGINEERING INC Page 12 gt 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com DVANTAGE MAKING WATER WORK Temperature Control Units Sentra with VE Series Instrument 2 0 INSTALLATION 2 1 GENERAL 2 2 TO AND FROM PROCESS CONNECTIONS 2 3 WATER SUPPLY CONNECTION 2 4 DRAIN CONNECTION 2 5 ELECTRICAL CONNECTION ADVANTAGE ENGINEERING INC Page 13 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 2 1 GENERAL A All process piping materials such as hose rigid piping valves or filters used in process water piping circuitry must be rated for 350 F minimum temperature and
55. nt Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 2 3 WATER SUPPLY CONNECTION A Connect the unit s Water Supply port to the plant s city water well water tower water or chilled water supply B Water supply pressure requirements vary with operating temperatures Figure 2 2A shows the required operating water supply pressures for various operating process temperatures The required water supply pressure retains process water in a liquid state at temperatures over 180 F Failure to maintain the required water supply pressure will cause premature failure of and increase maintenance in susceptible areas such as the shaft seal and heater OPERATING TEMPERATURE 180 F 1909 20095 21005 220 2305 240 F 250 F 20PSI 25PSI 30PSI 35 5 40PSI 45PSI 50PSI 55PSI WATER SUPPLY PRESSURE Figure 2 2A C The factory recommended minimum operating water supply pressure requirement is identified on the unit s data tag figure 2 2B D Static water supply pressure can be determined at the unit s location by reading the unit s 0 160 PSI pressure gauges when the unit s pump motor is OFF Figure 2 2B E If water supply pressure as read on the unit s pressure gauges exceeds 75 PSI a pressure reducing valve must be installed in the water supply line refer to section 7 4 of this manual for installation information The factory recommended regulate
56. on can develop resulting in damage to the unit or injury and or death to operating personnel When disconnecting the unit from the process system the operator must determine the unit s process temperature is at ambient or below 85 F and all system pressure is relieved and the unit s pressure gauges read 0 Injury or death to operating personnel and damage to the unit could result if a hot and pressurized unit is disconnected from the system B UNIT SHUT DOWN without system disconnect 1 DVANTAGE MAKING WATER WORK Adjust the setpoint temperature to 32 F The instrument will disengage the heater contactor if engaged and open the PVT valve Operate the unit until process temperature as indicated on the Temperature display is at the ambient water supply temperature or below 85 F Stop operations by switching off the On Off rocker switch Disengage the water supply to the unit by closing the water supply valve if installed or by turning off the water supply source at the central control point If any residual pressure is evident open the pressure relief valve to dissipate Disengage the power at the fused disconnect Determine the Power light on the display is OFF Before disconnecting and removing the process circuitry be certain all system pressure is vented and the pressure gauges read 0 When the process circuitry is disconnected and removed from the unit a small amount of water will be discharged f
57. r to section 7 4 for regulator installation drawing Back flow prevention device in water supply line If a back flow prevention device check valve pressure regulator closed valve is installed in the water supply line increased pressures from thermal expansion are unable to move into the water supply line This will increase the unit s internal pressure causing the pressure relief valve to leak Refer to section 7 4 for regulator installation drawing Valve contamination The pressure relief valve may become contaminated with water debris causing the valve not to close properly If this is the case flushing the valve for a moment will cleanse the seat and allow it to work properly If flushing the valve does not remedy the leaking the valve must be replaced Extreme internal system pressure If the internal pressure in the Sentra unit is elevated the pressure relief valve will leak as a safety measure to dissipate excessive pressure If this is the case the operator must determine why the system internal pressure is excessive and correct the condition ADVANTAGE ENGINEERING INC Page 33 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com THIS PAGE INTENTIONALLY BLANK Page 34 Temperature Control Units Sentra with VE Series Instrument 5 0 SERVICE MAINTENANCE 5 1 PUMP SEAL REPLACEMENT 5 2 HEATING CYLINDER SE
58. rench to separate the bonnet assembly from the valve body The plunger is loose inside the enclosing tube Be certain it is retained in the enclosure tube as the bonnet is removed figure 5 30 Plunger Diaphragm assembly 6 Identify the diaphragm assembly Gently remove the assembly from the valve body figure 5 3D Top bonnet Enclosure tube Figure 5 3C ADVANTAGE ENGINEERING INC Page 41 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument T 10 11 12 13 14 DVANTAGE MAKING WATER WORK Identify the mesh screen Gently remove the mesh Screen and clean or replace as necessary Clean the valve body Reset the mesh screen into the valve body If a new diaphragm assembly was obtained continue with step 12 If not disassemble the diaphragm assembly and note component order figure 5 3E Clean the valve port plate collar and O ring Once cleaned reassemble the diaphragm Set the reassembled diaphragm assembly or the new assembly back into the valve body The stem should be facing out of the valve body Insert the plunger with spring first into the enclosing tube of the top bonnet figure 5 3F Holding the plunger in the enclosure tube set the top bonnet onto the valve body and tighten
59. rm efficiency of operation is largely determined by proper maintenance of the mechanical parts of the unit and water quality We recommend filtering where required to prevent solids from plugging critical parts such as pumps heaters and seals The services of a competent water treatment specialist must be obtained and his recommendations followed Advantage accepts no responsibility for inefficient operation damage caused by foreign materials or failure to use adequate water treatment 1 3 TYPICAL LABEL PLACEMENT Warning Label Summarizes the safety precautions when unit is in use Process Connection Label Details process connections hook up Unit Data Tag Details unit Serial Number voltage and other important unit information ADVANTAGE ENGINEERING INC Page 10 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 1 4 COMPONENT PLACEMENT A The temperature controller is designed to circulate temperature stabilized water through the process system to result in process temperature control B Please note that the ability of the equipment to achieve this objective is significantly affected by the method of installation C If the operator has any questions contact the Sales or Service Department at 317 887 0729 Pressure Gauges Heater I
60. rmine the unit is properly filled when the To Process pressure gauge and the From Process pressure gauge stabilize at equal or closely similar pressure The operator must check for any water leakage in the unit s mechanical system the process and throughout the plant s water supply system If a water leak is observed the operator must disengage the water supply system relieve all pressure and repair the leak The operator must verify the leak is repaired by refilling the system as outlined in this procedure ADVANTAGE ENGINEERING INC Page 20 e 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 4 During system fill air is trapped at various places in the water system Air is purged automatically the AVT valve during initial pump start up outlined below All air must be purged before the unit is engaged for process temperature control Entrained air in the system will adversely affect the unit s ability to control process temperature The operator can determine all entrained air is purged when no pressure spikes are evident via the unit s pressure gauges 5 Adequate water fill and pressure must be supplied to the unit for efficient and safe operation To ensure sufficient water fill an electrical panel mounted pressure switch figure 3 2A is supplied wi
61. rom the unit Please note that this water should not be warm or pressurized if all shut down and disconnecting procedures were followed Remaining process water can be discharged by removing the pump casing drain plug ADVANTAGE ENGINEERING INC Page 28 e 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 4 0 TROUBLESHOOTING 4 1 UNIT WILL NOT START POWER LIGHT IS NOT ILLUMINATED 4 2 UNIT WILL NOT START POWER LIGHT IS ILLUMINATED 4 3 UNIT STOPS 4 4 UNIT OVERHEATS 4 5 UNIT UNDERHEATS 4 6 PRESSURE RELIEF VALVE LEAKS 4 7 COOLING VALVE FAULT ULU ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Page 29 Temperature Control Units Sentra with VE Series Instrument 4 1 4 2 4 3 UNIT WILL NOT START POWER LIGHT IS NOT ILLUMINATED A One or more fuses at the main disconnect device are open blown Determine continuity at each fuse If continuity is not determined replace the fuse Then determine cause of blown fuse Control circuit transformer fuse is open blown Determine continuity at the control circuit transformer fuse If continuity is not determined replace the fuse UNIT WILL NOT STAR
62. rtment Fax 317 885 8683 www AdvantageEngineering com D DVANTAGE MAKING WATER WORK Temperature Control Units Sentra with VE Series Instrument Setpoint Adjustment Buttons Machine Status Lights n SENTRA TEMPERATURE CONTROLLER VE Series Fot Service 317 487 0729 email service o For Information om ADVANTAGE water system products viet www Advantage ngimeenng com Figure 3 3A Unit On Off Switch 3 3 INSTRUMENT OPERATION Note Standard temperature range for VE Series mold temperature control units is approximately 30 F above the cooling water supply temperature to 250 F A INSTRUMENT START UP 1 When the correct electrical power and adequate water supply pressure are supplied to the unit it is possible to start the unit for temperature control duty 2 When the power is engaged to the unit the instrument figure 3 3A will momentarily illuminate all indicating lights and digits on the display After a short delay the controller software version number is displayed At this time the operator can verify that all lights and digits are functioning properly If the operator determines an indicating light or digit does not illuminate the controller must be removed and sent to the factory for repair 3 Also the instrument will immediately check the status of the sensor probe the high temperature safety switch and the water supply pressure switch for acceptable opera
63. s Reconnect the motor power cord and leads Replace the thermoformed front panel and the lift off cover E When this procedure is complete the operator may restart the unit In many cases a new pump seal will experience a small amount of leakage for a short time This is normal After a few moments the new seal will take seat and the leak will stop MAKING WATER WORK ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Figure 5 11 Figure 5 1J Figure 5 1K Aligning impeller and spring Figure 5 1L Page 38 Temperature Control Units Sentra with VE Series Instrument 5 2 HEATING CYLINDER REPLACEMENT A The heater is a flange mounted assembly and inserted into the cast cylinder tank and secured by 4 bolts figure 5 2A B The operator can determine if the heater requires replacement when the heater draws 0 amps or when a continuity check of each heater element is negative Heater Figure 5 2A C Generally heaters fail due to low water flow low water pressure air in the system or defective heating elements D The operator should follow this procedure to replace the heater 1 Disengage operations and be certain all system pressure is relieved and the unit s pressure gauges read 0 2 Disengage main power supply Verify the Power light on
64. ss system The pump will increase the system pressure between 35 50 PSI over the plant water supply pressure The pump is driven by an electrical motor ump Casing 1 Pump casing The pump casing is an exclusive design The casing is cast of iron and flanged to accept the heater discharge and cooling tanks The casing is the support element in the pump motor assembly and is secured to the unit base figure 6 14 Electric Pump Figure 6 1A 2 Pump adapter The pump Motor Adapter adapter is the mating element between the pump casing the electric motor The adapter is machined to accept the pump seal flush line The stationary pump seal member is set in the seal cavity of the pump adapter figure 6 14 3 Electrical motor The electric motor is a dual voltage 3 phase ODP motor The motor serves to turn the pump impeller creating process flow figure 6 14 4 Impeller The impeller is custom designed for the unit and creates the higher flow gpm from standard HP ratings figure 6 1B Impeller Figure 6 1B 5 Pump Seal The pump seal prevents water leakage from the pump adapter The seal is made up of three items the stationary member seated in the seal cavity the rotating member placed on the motor shaft and the tension spring figure 6 1C shows the stationary member only Stationary member Figure 6 1C ADVANTAGE ENGINEERING INC Page 54 525 East Stop 18 Road Greenwood Indiana
65. t panel and set aside The panel is attached to the stainless steel cabinet by 4 small screws Open the hinged electrical cabinet panel cover The panel is opened by removing four small screws Locate the instrument A jumper bar controls the Temperature display The jumper bar is located on the larger circuit board figure 5 94 Using non conductive pliers remove the jumper from the Fahrenheit position standard Figure 5 9B to the Celsius position Figure 5 9C After securing the electrical Jumper position for Celsius Figure 5 9C panel cover and replacing epo cn AL the thermoformed front panel resume operations The change will take effect once power is resupplied to the unit ADVANTAGE ENGINEERING INC Page 52 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 6 0 SENTRA COMPONENTS 6 1 MECHANICAL SYSTEM 6 2 ELECTRICAL SYSTEM ADVANTAGE ENGINEERING INC Page 53 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com DVANTAGE MAKING WATER WORK Temperature Control Units Sentra with VE Series Instrument 6 1 MECHANICAL SYSTEM A MOTOR PUMP ASSEMBLY The unit pump is a multi component assembly serving to circulate water through the proce
66. t will be prevented from starting by the following conditions 1 Water supply pressure inadequate pressure switch is open The unit is prevented from operation without adequate water supply pressure by the electrical panel mounted pressure switch Sufficient water supply pressure must be present to close the switch 2 Motor overload switch opened The electric motor is protected from overload conditions by a set of thermal ADVANTAGE ENGINEERING INC Page 30 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com D Temperature Control Units Sentra with VE Series Instrument overload relays These relays will open trip If the overload relay is open it must be reset before operation can continue An excessive flow condition must be isolated and corrected immediately High temperature limit switch open The unit is prevented from operations at temperatures exceeding 256 F by a high temperature limit switch This switch is installed in the To Process temperature sensor If this switch is open due to a high temperature condition the unit cannot be started and must cool down before the high temperature limit Switch will automatically reset The operator should check the Power light on the display The operator should check the following conditions 1 One or more fuses at the main disconnect device are open blown Determ
67. th VE Series Instrument 8 Remove the four mounting nuts The instrument is now loose and can be removed To reinstall a factory issued instrument continue with step 9 9 Place the instrument into the panel mount aligning the four mounting stems Once the instrument is aligned tighten the nuts to secure the instrument 10 Connect the sensor plug 11 Connect the ground terminals 12 Connect the large molex connector 13 The operator can now start the unit as outlined in section 3 of this manual The operator must reconfigure if necessary the instrument to restore the preferred operating parameters ADVANTAGE ENGINEERING INC Page 51 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 5 8 CELSIUS TEMPERATURE DISPLAY A The following procedure changes the Temperature display units from Fahrenheit to Celsius Fahrenheit display is standard B Note that there is no indication for Fahrenheit or Celsius temperature display C To change to Celsius temperature display do the following 1 DVANTAGE MAKING WATER WORK Disengage process operations and relieve all system pressure Disengage main power supply Verify the Power light on the display is off Follow standard lock out procedures Remove the thermoformed fron
68. th the unit A capillary line feeds the pressure switch If the water supply pressure is Panel mounted pressure switch Figure 3 2A not adequate the unit can not be operated This prevents operation with inadequate water fill and pressure If the unit is operated without adequate water fill and pressure the unit may be susceptible to overheating and could result in unit damage and or serious injury to operating personnel B ELECTRIC MOTOR PHASING PUMP ROTATION 1 The operator must determine the electric motor is phased MAKING WATER WORK correctly This is done by visually inspecting the rotation of the motor shaft as outlined below Incorrect phasing of the unit results in poor operation and eventual damage a Supply electrical power to the unit by engaging the unit s disconnect switch Once the correct voltage is supplied to the unit the Power light on the display will illuminate b Remove the thermoformed cover panel and open the hinged electrical cabinet panel cover Note that the electrical power is engaged at this point and caution must be observed while the electrical supply is engaged and the cabinet panel is open Locate the electric motor figure 3 2B and identify the motor shaft inside the electric motor housing The motor shaft can be seen through the vent slots in the motor housing or by removing the shaft cover ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood Indiana 46142 317 88
69. the junction box cover and the lift off cover panel D When complete restart the unit ADVANTAGE ENGINEERING INC Page 40 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 5 3 PVT VALVE SERVICE A The unit uses the Pulsed Valved Technology solenoid valve figure 5 3A as the cooling valve The solenoid valve is controlled by the instrument B Generally the PVT valve may fail due to poor water quality low water flow or defective valve components Typical PVT valve Figure 5 3A C The operator should follow this procedure to service the PVT valve 1 Disengage process operations according to the procedure outlined in section 3 4 The operator must be certain process fluid temperature is under 100 F and pressure is relieved pressure gauge reads 0 2 Disengage main power supply The operator must verify the Power light on the display is off 3 Remove or open any access cover panel and set aside to gain access to the solenoid valve Retaining screw 4 Identify the retaining screw figure 5 3B on the solenoid valve coil Remove the screw Keeping all electrical connections intact lift the coil off of the enclosure tube and set aside 5 Use a pair of channel lock C il Figure 5 38 pliers or a pipe w
70. ting conditions If all systems are found to be ok the unit will begin operations If a system is not found to be ok the instrument will not start and will illuminate no FLO in the temperature display window ADVANTAGE ENGINEERING INC Page 25 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 4 Conditions that will prevent the unit from starting process temperature control operations are a Water supply pressure inadequate pressure switch is open The unit is prevented from operating without adequate water supply pressure by an electrical panel mounted pressure switch Sufficient water supply pressure must be present to close the switch and consent the safety circuit b Motor overload switch opened The electric motor is protected from excessive flow by a set of thermal overload relays These relays will open trip and prevent operation If open the overload relay must be reset before operations can continue An excessive flow condition must be corrected immediately High temperature limit switch open The unit is prevented from operations with temperatures exceeding 256 F by a high temperature limit switch This switch is installed in the To Process temperature sensor If this switch is open due to a high temperature condit
71. tra with VE Series Instrument 7 1 SENTRA PHYSICAL Left Side View 19 1 2 Left Side View To Process Instrument 1 fX Drain Pressure Gauges From Process 26 5 8 Water Supply 000000000000000 000 000000000000 M00 800000008020 Rear View Right Side View 12 1 2 ADVANTAGE ENGINEERING INC Page 60 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 MAKING WATER WORK www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument SENTRA ELECTRICAL 7 2 waviv 105 9NI7009 7109 5 HOLOW YNOLLdO QION31OS CYNOLLdO aloNarios LIWA dW31 HSIH 38OHd SS390Hd OL OAS QVAOLL H3WHOJSNVHI gt mic CEAg H ur 4g o 9 4 E QW id wavy WA IHM 6 05 a GION3108 TVNOLLdO 05 7109 uaivaH l 05 05
72. ual Be certain proper lock out procedures are followed Also be certain system pressure is eliminated and the unit s pressure gauges read 0 pressure Drain unit by removing the pump casing drain plug A capillary runs from the cooling cylinder to the pressure switch Remove the capillary connection The brass elbow mounted on the pressure switch must be removed Remove the electrical connections to the pressure switch The pressure switch is mounted onto the electrical cabinet with two 1 2 nuts in series Remove the nuts to remove the pressure switch A new pressure switch from the factory should be installed by continuing with step 7 Thread one 1 2 nut onto the pressure switch and then place the pressure switch through the panel in the original mounting hole Thread the second 1 2 nut from the bottom of the pressure switch Tighten to lock the pressure switch in place Install the brass elbow fitting Teflon tape and leak preventative paste should be used to prevent water leakage Install the capillary tube and resume operations ADVANTAGE ENGINEERING INC Page 49 525 East Stop 18 Road Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Department Fax 317 885 8683 www AdvantageEngineering com Temperature Control Units Sentra with VE Series Instrument 5 8 INSTRUMENT SERVICE A The instrument controller is a microprocessor based instrument designed to cycle the heater and AVT modulat
73. ument is a custom designed and assembled microprocessor controller The instrument is mounted to the electrical panel cover The instrument controls the cycling of the heater motor pump and AVT valve System and setpoint temperatures are displayed continually System parameters are programmable figure 6 24 Typical instrument with service connections removed Figure 6 2A B TRANSFORMER The transformer supplies 110 volts to the controlling instrument figure 6 2B C MOTOR STARTER OVERLOAD RELAY The electrical motor is engaged when the motor starter contacts close on command by the instrument The electric motor is protected from excessive amperage by a set of thermal overload relays which open when excessive amperage heats the overloads and the relay opens figure 6 2B D HEATER CONTACTOR The heater contactor is a mercury contactor On command from the instrument the mercury contactor will close and voltage will be supplied to the heater figure 6 2B E PRESSURE SWITCH The electric panel mounted pressure switch will close when sufficient pressure is supplied to the unit 20 psi A closed pressure switch will consent the control circuit to the instrument controller to allow process operations figure 6 2B F SENSOR PROBES The unit uses two sensor probes The to process temperature sensor and the high temperature limit safety Switch are housed in the same assembly and mounted in the ADVANTAGE ENGIN

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