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Thermolator heaTrac User Guide

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1. Shut off the cooling water in feed Drain the Thermolator using the drain plugs located at the rear of the unit Remove the four bolts that hold the heater ele ment in place Use a 15 16 inch socket with 1 2 inch drive Lift the heating element out of the heater tube Lift the element straight up Replace the heater gasket Use a high temperature Teflon paste to ensure a good seal Reverse these steps to install the new heater element and reassemble the unit lt Heater element Heater fe TS Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 n gt amp UGH002 0514 hot surface hazards 100 38 WARNING Electrical shock Before attempting maintenance of any kind on the Thermolator you must stop the unit disconnect and lockout the main power supply and allow the unit to cool to less than Disconnect and lockout the main power Shut off the cooling water in feed Remove the top and side panels of the Thermolator Drain the unit of all fluid Remove the drain plugs at the rear of the heater casting Remove the seal flush line Use a 1 2 inch open end wrench to remove the vent line from the connection on the pump adapter Remove the pump assembly bolts Use a 9 16 inch open end bo
2. COOLING SOLENOID VALVES Part No Description 09002969 1 2 inch solenoid valve 4 0 CV 09004510V 3 4 inch solenoid valve 5 0 CV UGH002 0514 RECOMMENDED SPARE PARTS PD 3 RECOMMENDED SPARE PARTS TH 1 and TH 2 Thermolators 208 230 460V 6kW 12kW amp 18kW units 1 HP through 3 HP HEATER CONTACTORS PD 4 Part No Description 20004401 20004401 Heater contactor for 6kW 208 230 460V Heater contactor for 12kW 230 460V 09000417 REPLACEMENT BOARDS for TH 1 TH 2 Part No Heater contactor for 12kW 208V Description 09003732 TH1 operator board 09003731 TH1 motherboard 09003735 TH1 flat ribbon cable 09003734 TH2 operator board 09003733 TH2 motherboard 09003737 15 feet coiled control cable TH 2 02001186PH 30 feet coiled control cable TH 2 02001187 50 feet coiled control cable TH 2 PUMP OVERLOADS Part No Description Pump overload for 1 HP 460V Pump overload for 1 HP 230V and 2 460V Pump overtoad for 1 HP 208 230V Pump overload for 3 HP 460V Pump overload for 2 HP 208 230V 20003914 Pump overload for 3 HP 208 230V PUMP CONTACTORS Part No Description Part No Description 11001213 Thermolator transformer 11000400 Thermocouple standard temp unit
3. Is the unit connected to a host machine SPI communica tion link has failed 6 10 TROUBLESHOOTING Are the network address and baud rate correct Is something wrong with the cable Thermolator heaTrac TH 1 and TH 2 Solution If the Thermolator is not con nected to a host device set the SPI address to OFF using the Setpoint adjustment buttons on the control panel O Check the network address The address may be set to any number from 32 to 254 a hexadecimal integer between 20 and FE as long as that number has not been assigned to another machine connected to the same net work O Make sure the baud rate 9600 4800 2400 or 1200 matches the host machine Check the communication cable condition and connec tions The cable must conform to SPI standards Check for loose connections on the motherboard UGH002 0514 Thermolator has detected non recoverable error involv ing he microprocessor control The Alarm LED lights and the STOP RUN LED flashes red The Thermolator shuts down or will not start The control displays an error code indicating the source of the problem Alarm RAM hardware failure ROM checksum failure COP failures Illegal Opcode through Software cannot write to CPU non volatile memory UGH002 0514 Cause Electrical noise or failed CPU on the motherboard caused system write tests do fail during p
4. 6 15 Replacing the Heater Contactor 6 16 Checking and Replacing Thermocouples 6 17 Repairing Solenoid Valves 6 18 Replacing Heater Elements 6 20 Removing the PUMP C so Eq 6 21 APPENDIX Customer Service A 1 Warranty Guarantee Information A 2 MP Pumps HTO Series Operation and Maintenance B 1 Technical Information C 1 Thermolator SPI commands D 1 Material Safety Data E 1 PaARTS DIAGRAMS Spare Parts Lists 222222255558 RE ARES S RR ED ENS PD 1 Te Cubes uda Oe Renee he pd E d PD 5 TH 1 Circuit Board PD 6 WINDOS sausra d x dc e RUP Ren YS Ron PD 7 2 Circuit Boatd bes PD 8 ii Thermolator heaTrac 1 and TH 2 UGH002 0514 INTRODUCTION 0 Purpose of the User Guide 1 2 How the guide is organized 1 2 0 Your responsibilities as a user 1 2 ATTENTION Read this so no one gets hurt 1 3 UGHO002 0514 Thermolator heaTrac TH 1 and TH 2 PURPOSE THE UsER GUIDE How THE GUIDE 15 ORGANIZED YOUR RESPONSIBILITY As A USER 1 2 INTRODUCTION This User Guide describes the Conair Thermolator TH 1 and TH 2 oil temperature controllers and explains step by step how to install operate maintain and
5. Sight glass O oro o a E PEN To process From process Cooling water in Cooling water out Pressure for optional relief valve t heat exchanger E 08 9 7 6 B B HTR1 500 single zone 2 500 dual zone HTR1 500 rear view and connections MODELS HTR1 500 Performance Characteristics Minimum setpoint F Maximum setpoint F Pump Performance Pump Size Hp kW Nominal flow gpm l min Pressure nominal flow psi bar Dimensions inches mm HTR2 500 70 21 500 260 70 21 500 260 1 0 75 55 208 16 1 1 1 5 1 12 211 49 65 246 21 1 5 3 2 24 75 284 85 322 32 2 2 1 0 75 1 5 1 12 2 1 49 55 208 16 1 1 3 2 24 65 246 75 284 85 322 21 1 5 32 2 2 A Height B Width 43 1090 14 355 31 5 800 43 1090 28 710 31 5 800 Weight Ib kg Operating Shipping 300 136 305 138 310 141 320 145 600 272 610 277 620 281 640 290 To From Process Cooling Water Inlet Outlet FULL LOAD AMPS HTR1 500 HTR2 500 Heater 6 kW 12 kW 18 kW 6 kW 12 kW 18 kW Voltage 208 230 460 575V 208V 230V 460V 575 208 230 460 575V 208V 230V 460 575 208V 230V 460V 575V 208V 230 460V 575V Pump 1Hp 0 75 kW 21 2 19 2 9 6 1 5 1 12 kW 21 9 19 8 9 9 2Hp 149KkWj 23 6 2
6. anos PD 5 TH 1 230 460V WIRING DIAGRAM UGH002 0514 46 SAP S S d 3 PHASE INPUT F1 HPS LPS HPS LPS LLS WPS AUTOSTART AUTOSTART e lt 2 AC OUT 1 TH 1 CIRCUIT BOARD UNLDR 2 VENT 2 SOL UNLDR 2 VENT 2 SOL UNLDR 1 COOL 1 SOL UNLDR 1 COOL 1 SOL WARNING IT IS VERY IMPORTANT THAT SWITCHES 7 AND 8 BE SET TO THE PROPER UNIT TYPE BEFORE OPERATING THIS UNIT sw Hot Oil Unit AUX OFF PMP AUX 1FS COMP AUX 1FS COMP AUX PUMPDOWN PUMPDOWN HEAT COMP HEAT COMP HTS COMP OL HTS COMP OL CONFIGURATION DIP SWITCH N NO 110V NOT USED NOT USED NOT USED NOT USED TCPL S F6 SUP RET ALARM 2 CONTROL OPER PNL CABLE 0 6 HEATRAC CiRCUIT BOARD 10 VENT SOL 2 VENT SOL 2 COOL SOL 9 COOL SOL 2 PUMP 6 PUMP 6 PUMP OL 5 PUMP OL 4 PUMP AUX 7 PUMP AUX 11 1 5 or JUMPER 4 UGH002 0514 TBNvd 4 2 24 avoa MN3HLON P gt 7821 1133 318v V OLESOVE
7. gt gt 4 3 PHASE INPUT UNLDR 2 VENT 2 SOL UNLDR 2 VENT 2 SOL UNLDR 1 COOL 1 SOL UNLDR 1 COOL 1 SOL I pt PMP AUX PMP AUX 1FS COMP AUX 1FS COMP AUX PUMPDOWN PUMPDOWN HEAT COMP HEAT COMP HTS COMP OL HTS COMP OL LLS PURGE 3SOL LLS PURGE 3SOL PURGE 4SOL PURGE 4SOL TCPL S F6 SUP RET 10 VENT SOL 2 VENT SOL 2 COOL SOL 9 COOL SOL 2 PUMP 6 PUMP 6 PUMP OL 5 PUMP OL 4 PUMP AUX 7 PUMP AUX 11 411FS or JUMPER 4 2 HEAT HEAT 12 5 8 HTS 2 ALARM 22 ALARM UGH002 0514
8. DO NOT install or use near water where the pumping system may come into contact with water or is splashed by water PUMPS INC TECUMSEH PRODUCTS COMPANY 34800 BENNETT DRIVE FRASER MI 48026 1686 DO NOT operate beyond the pressure or temperature limits stated in the product literature see form 9001 DO NOT allow severe temperature changes to occur in a short time period within the pumping system DO NOT mix different types or grades of oil within the oil system DO NOT use an oil that is not a recommended heat transfer oil by the manufacturer DO NOT exceed the maximum oil temperature rated by the oil manufacturer at the hottest point in the pumping system DO NOT mount the pump in conditions that high piping loads exist on the pump flanges FORM 3043 PRINTED IN U S A 810 293 8240 FAX 810 293 8469 MP PUMPS HTO SERIES APPLICATION AND INSTALLATION INSTRUCTIONS Application assistance and technical information can be obtained by calling MP PUMPS at 810 293 8240 The HTO pump is designed for pumping high temperature fluids that are non corrosive non volatile and have good lubricating qualities The primary application for use is with heat transfer oils It is the users responsibility to determine the pump and product compatibility with the materials of construction INSTALLATION AND START UP INSTALLATION 1 The pump must be installed in a horizontal
9. High Deviation Return Temp Low Deviation Average Temp Address Baud Rate Cool Down Pump Heater Cooling Valve Venting Valve Test Mode SPI Communication Auto Start Low Oil Alarm Low Water Flow Alarm High Temp Safety Sil Alarm 4 Repeatedly press and release any key to test With each key press and release the left display will indi cate the number of the input being tested v1 v2 v3 etc The right display indicates either 1 for voltage present or for an absence of voltage Only inputs that are actually used by the particular model will be tested 5 Exit the test and enter the next test Press and hold the Setpoint 9 key for 3 seconds to exit and index to the next test UGH002 0514 Thermolator heaTrac TH 1 and TH 2 control INPUT TEST MAINTENANCE 5 7 The Output Test verifies the function of outputs available OUTPUT TEST the various models of TH 1 TH 2 Not all outputs are used on all models The performance evaluation of the inputs is based on the output monitors OM 5 6 1 Connect all outputs to the system IMPORTANT Testing each output requires the fir ing of the associated solid state relay Make sure an output device is connected to the controller other wise the test result will be erroneous 2 Enable Test Mode Press any key to display the first t
10. ewe 4 5 Starting the Thermolator 4 6 Stopping Thermolator 4 7 Performing an Auto Tune 4 10 5 1 Preventative maintenance 5 2 To access the Thermolator enclosure 5 3 Checking fluid level in the reservoir 5 4 UGH002 0514 Thermolator heaTrac TH 1 and TH 2 MAINTENANCE continued Performing System Tests 5 5 CONTENTS The Key Display OR 5 6 Input Tesh cbe vod 5 7 Output 168b 2220542030484 s8Sh8665 6 44deo8eu5 Rae 5 8 Disabling and Enabling 5 9 Calibrating Temperature Sensors 5 10 Logging Operating Hours 5 12 TROUBLESHOOTING 0 1 6 2 Few Words of Caution 6 2 How to Identify the Cause of a Problem 6 3 DIAGNOSTICS Shut Down Alarms 6 4 Warning Alarms is erm RR EUER ES Ex Rd 6 8 System Alarms aud oz ce ee hue doe brc oomen e vns 6 11 Thermolator Will Not Power Up 6 12 REPAIR Checking and Replacing 6 13 Resetting and Replacing Overloads 6 14 Replacing the Motherboard
11. If you do have a problem please complete the following checklist before calling Conair 1 Make sure you have all model serial and parts list numbers for your particular equipment Service personnel will need this information to assist you Make sure power is supplied to the equipment CJ Make sure that all connectors and wires within and between control systems and related components have been installed correctly O Check the troubleshooting guide of this manual for a solution O Thoroughly examine the instruction manual s for associated equipment especially controls Each manual may have its own troubleshooting guide to help you CJ Check that the equipment has been operated as described in this manual O Check accompanying schematic drawings for information on special considerations SERVICE INFORMATION WE RE HERE TO HELP How TO CONTACT CUSTOMER SERVICE BEFORE YOu CALL Additional manuals and prints for your Conair equipment may be ordered through the Customer Service or Parts Departments for a nominal fee APPENDIX A 1 Conair guarantees the machinery and equipment on this order for a period as defined in the quotation from date of shipment against defects in material and workmanship under the normal GUARANTEE use and service for which it was recommended except for parts that are typically replaced after normal usage such as filters liner plates etc
12. Press and hold the Select 9 key for 3 seconds to exit and index to the next test You can now proceed to another menu in Test Mode or disable Test Mode and resume normal operation TO DISABLE TEST MODE complete steps 2 through 5 in Performing System Tests setting dip switch 6 to OFF instead of ON Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 TROUBLESHOOTING 0 Before beginning few words of caution How to identify the cause of a problem DIAGNOSTICS Shut down alarms e Warning alarms 0 System alarms 0 Thermolator will not power REPAIR Checking and replacing fuses Resetting overloads Replacing the pump overload Replacing the motherboard Replacing the heater Ccontactol irre Checking and replacing thermocouples 0 Repairing solenoid valves Replacing heater elements Removing the pump UGHO002 0514 Thermolator heaTrac TH 1 and TH 2 BEGINNING Few WonRbps OF CAUTION 6 2 TROUBLESHOOTING You can avoid most problems by following the recommended installation operation and maintenance procedures outlined in this User Guide If you do have a problem this section will help you determine what caused it and tell you how to fix it Before you begin troubleshooting Find the wiring plumbing and other diagrams that were ship
13. The RUN STOP light changes from flashing red to steady red 2 Note any indicator lights or error messages to help determine the cause of the problem 13 Find the alarm or error code in the diagnostics tables in the TROUBLESHOOTING section of this manual 4 Press EJ to clear the alarm and shut down the Thermolator to correct the problem Press EZ to resume normal operation after the problem is corrected UGH002 0514 Thermolator heaTrac TH 1 and TH 2 control Alarm WARNING Disconnect and lockout the main power source before opening the Thermolator or its electri cal enclosure for servic ing Disconnect oil and water lines as needed TROUBLESHOOTING 6 3 The Thermolator has detected a problem that could lead to equip SHUT DOWN ment damage or personal injury if it is not corrected AL ARMS Alarm LED lights and the STOP RUN LED flashes red Thermolator automatically shuts down control displays a red LED or alarm code indicating the source of the problem Alarm The pump motor overload has tripped The contact is open N WARNING Only qualified electrical service per sonnel should examine and correct problems that require opening the unit s electrical enclosure or checking electrical current to diagnose the cause of a problem 6 4 TROUBLESHOOTING Possible cause Is the correct voltage supplied to the pump motor Is the required water flow greate
14. Venting Valve Test Mode v SPI Communication Start Display Low Oil Alarm Temperature elect Supply Temp Low Water Flow Alarm High Deviation Return Temp High Temp Safety Low Deviation Average Temp Address ilence Baud Rate Down Alarm TH 1 and TH 2 models have security feature that pre vents accidental or unauthorized changes to the setpoint tem perature high and low deviation limits SPI address and baud rate If passcode protection is enabled you must enter the correct passcode to change these parameters To enter the passcode 1 Press and hold the Setpoint Select button for 5 seconds The control will display 1 PaS to indi cate a passcode is needed 2 Press the Select button until the correct passcode appears in the display 3 Press again to enter the passcode If the passcode is correct the control displays ACC PAS for 3 seconds If the passcode is incorrect the control dis plays rEJ PAS rejected passcode Press Setpoint to select the parameter you want to change You will have access to the system parameters until The power is cycled off and on The RUN or STOP button is pressed Q No key has been pressed for 30 seconds NOTE Pressing the STOP or RUN key while you are entering a passcode will abort the passcode entry sequence UGHO002 0514 Thermolator he
15. shutoff safety Sight glass for visual inspec tion of oil level Venting sole TEFC Pump noid valve prevents Totally trapped air in enclosed fan q pp system cooled pump motor Shell and tube heat exchanger cooling circuit a optional cools iz the unit before powering it down Air cooled seal cavity Cooling check valve no cooling water required vents coolant back flow into the exchanger TH 1 CONTROL Standard features include Actual temperature display shows the actual temperature of the fluid entering the to process line 6 Setpoint temperature display shows the fluid tem perature setpoint during normal operation Both of these window will display alarms error codes modes and parameters if there is a prob lem with the temperature controller Status lights indicate the operating status of the device Green when the device is on and red when there is a problem RS485 communications utilizing SPI protocol with baud rates and addresses programmable right on the operator panel Visual and optional audible alarms alerts you to alarm conditions such as high low deviation low water pressure pump overload or high temperature safety switch Setpoint adjustment buttons Press the up or down arrows to change temperature and SPI parameters TH 2 coNTROL the features of the TH 1 plus Autostart capability for convenient preheating of molds Works with external timers
16. Cooling water in Cooling water out Pressure for optional relief valve heat exchanger UGH002 0514 Thermolator heaTrac TH 1 and TH 2 control CONNECTING PROCESS OIL AND COOLING WATER SUPPLY LINES Tools for installation O Pipe wrench large enough for a 2 inch pipe O Premium quality Teflon thread sealant rated for 500P F oil NOTE We recommend that you install an external ball valve on the cooling water inlet of the Thermolator This valve is useful for ser vice when cooling option is installed INSTALLATION 3 5 CONNECTING THE MAIN PowER SUPPLY IMPORTANT Always refer to the wiring diagrams that came with your temperature control unit before making electrical connections The diagrams show the most accurate electrical compo nent information 3 6 INSTALLATION WARNING Electrical shock hazard This equipment is powered by three phase main voltage Always disconnect and lock out the main power source before performing any work involving electrical connections All wiring disconnects and fusing should conform to your region s electrical codes and should be installed only by qualified personnel Before beginning note the electrical specifications on the nameplate mounted to the side of the unit The electrical hookup must match these specifications with 10 maxi mum voltage variance An improper power supply could damage the unit as well as seriously injure an ope
17. or m arrow until the address you want appears in A V the setpoint display The address may be set EPIS to any number from 32 to 254 a hexadeci mal integer between 20 FE as long as S that number has not been assigned to another Baud Rate machine connected to the same network Setpoint Set the baud rate to 12 24 48 or 96 The Thermolator must be set to send and receive data at the same baud rate as the host machine Press the setpoint V arrow until the baud rate you want appears in the setpoint display window 12 2 1200 bps 48 4800 bps 24 2400 bps 96 9600 bps The green SPI status light on the control panel should flash when the unit is communicating The LED will turn red indi cating an alarm if SPI communication is not properly set up UGH002 0514 Thermolator heaTrac TH 1 and TH 2 control INSTALLATION 3 15 INSTALLING THE AUTO START FEATURE TH 2 ONLY IMPORTANT Always refer to the wiring diagrams that came with your tempera ture control unit before mak ing electrical connections The diagrams show the most accurate electrical component information 3 16 INSTALLATION AN WARNING Electric shock hazard This equipment is powered by high voltage Always disconnect and lock out the main power source before opening the unit or the electrical enclosure to modify factory settings Failure to disconnect and lock out the main power source c
18. 1 TYPICAL SPECIFIC GRAVITY Approx 0 8734 25 25 C MOLECULAR WEIGHT Average Molecular Weight 350 for each specific application We warrant that the heat transfer fluid con forms to the specifications in this bulletin but make no further warranty expressed or implied including the warranties of merchantability or fitness for a particular purpose NF MSDS 496 PARTS DIAGRAMS 0 Spare Parts Lists PD 1 5 TH 2 PD 7 UGH002 0514 Thermolator TH 1 and TH 1 Plus PD 1 RECOMMENDED TH 1 andTH 2 Thermolators SPARE PARTS 208 230 460V 9kW amp 12kW units 1 HP through 3 HP PUMP ASSEMBLIES Air cooled mechanical seal Totally enclosed fan cooled motor Part No Description 09003669 1 HP pump model 09003670 1 1 2 HP pump model 1 09003671 2 HP pump model 09003672 3 HP pump model PD 2 RECOMMENDED SPARE PARTS UGHO02 0514 1 2 Thermolators RECOMMENDED 208 230 460V 6kW 12kW amp 18kW units 1HP through 3HP SPARE PARTS REPLACEMENT HEATERS Part No Description 09002018 6 KW 208V 3 60 MS 09001579 6 KW 230 460V 3 60 MS 09002019 12 KW 208V 3 60 MS 09002017 12 KW 230 460V 3 60 MS 25917401 Heater flange gasket COOLING SOLENOID OVERHAUL KITS Description 09004614 1 2 inch solenoid overhaul kit 4 0 CV 09004554 3 4 inch solenoid overhaul kit 5 0 CV
19. from process thermocouples TH 2 models allow you to select how the unit will measure and control the process temperature The control point can be selected as the supply the return or the average of the the two temperatures To select the control point source on TH 2 models 1 Disconnect and lockout power to the unit 2 Open the electrical enclosure 3 Set dip switches 3 and 6 to the OFF position Set dip switch 5 to the ON position Close the electrical enclosure and restore power to the unit Press any button when the control displays Cnt Pt TH 2 Microprocessor Setpoint 57 Actual controller will display Sel CnP and flashes the LED for the current con NOTE All dip switch illustra trol point tions in this manual show switches 7 and 8 set to ON 7 If you have an Isolated Select a new control point using the Display 5 Circuit model these switch button f cis dravid ba eai to OAZ Stop pressing the select button until the indicator light next to the control point you want illuminates 3 1 2 INSTALLATION Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 2 Microprocessor CONAIR SELECTING TH E 10 11 12 Setpoint aie Heater RATU R E Cooling Valve P ve CONTRO
20. internally during start up OMP PUMPS Nc TECUMSEH PRODUCTS COMPANY 34800 BENNETT DRIVE FRASER MI 48026 1686 810 293 8240 FAX 810 293 8469 8 Assemble the seal housing 12 29162 to the adaptor 9 29160 with three 5 16 18 screws 5 29178 As steady pressure is applied to the seal housing to hold it in place thread the three 5 16 18 screws in and torque them to 25 inch Ibs each Working around the bolt circle tighten the screws in 25 inch Ibs increments until each screw is tightened to 150 inch Ibs 9 Assemble fan clamp 4 29164 to drive sleeve 10 Assemble the pump to the motor Slide the motor onto the pump Install and tighten the four mounting screws Push the impeller towards the motor until it stops contact with the impeller and isolater Tighten the drive clamp screw to 70 90 inch lbs and install piping FORM 3043 PRINTED IN U S A PUMPS SERIES Thermal vapors leaking from a system can be highly flammable Any system leak should be repaired immediately Do not insulate the pump or system piping with porous flammable insulation Fluid may wick decompose and spontaneously ignite Ideal mechanical seal life is 20 000 hours Reduced seal life may be experienced from extreme conditions Recommended spare parts and service parts to rebuild the HTO 80 are 29166 DRIVE SLEEVE 1 25662 GASKET 1 29158 ISOLATOR 2 291
21. o HACE 3 T HA EEA ATTA LIL e ERN EHE H 1 10 100 e Pit 5 1 S S 2 Q 9 1333 avaH 1 101 UGH002 0514 TECHNICAL INFORMATION C N 5103 1 GALLONS PER MINUTE PUMP CURVES APPENDIX 1 Technical Data Fluid Fouling Problems in Closed Loop Paratherm Corporation Heat Transfer Fluids Rev 296 Temperature Control Systems Thermal liquid temperature control systems provide major advantages over other methods of heating and cooling Among them are efficiency low main tenance lack of hot or cool spots and the absolute control of temperature One problem system fouling can reduce equipment performance and product output and lead to increased down time and unacceptable product quality Fouling can occur when the heat trans fer fluid is degraded And the bruised fluid can no longer transfer the same amount of heat or flow as quickly Fluid Damage There are three ways the fluid can be bruised contamination oxidation or overheating Contamination results from foreign matter in the system In new systems incomplete cleaning can leave weld slag spatter and flux dust and dirt and quench oils and protective lacquers to mix with the
22. 6 feet Process pressure gauge 0 60PSI Water pressure relief valve Caster Handle namie T Part No Level Switch 500 Deg F rated Description QCH003 1197 User Guide Thermolator TH 1 Series Quick Card Thermolator TH 1 QCH004 1197 RECOMMENDED SPARE PARTS Quick Card Thermolator TH 2 UGH002 0514 606 lt 0766 ONIYIM L H L ZX vX SX 9X 109 09 7 ZX vX SX 9X 2 109 c ocz 19 43ASOJSNVMI 1041409 GYVOEYSHLOW Ol 6 8X LX D E 2 x 13 9 ML WNOILdO NSA 1009 318 2 WWOO ayog YSHLOW EE 1421 1133 gt gt 7491 14405 AK IWNOILdO 1054 D 0 T b OVA OLL INVHO onim 33S LOGS VAM LC gt gt ARRRRRR zi tf ONnONO HLAVA 12 Fi e HZ SYSHLO AG 193NNOOSIGQ 03504 penec TIT j 21 zi zo od eo 10 WL au asid SYJH10 A8 LdNYYSLNI 2 IMOHS
23. MON ITORS were disabled and give fuse failures 1 Enable Test Mode 2 Press any key to display the first test menus TH 2 Microprocessor Pump Heater md EIS F Cooling Ls 1 J e Venting Test Mode v SPI Communication Auto Start Setpoint Displa Play Low Oil Alarm Temperature elect Supply Temp Low Water Flow Alarm High Deviation Return Temp High Temp Safety Low Deviation Average Temp Address Baud Rate Cool Down 3 Select the Enable Disable menu Press and hold the Setpoint key for 3 seconds to index to each test menu until the controller indicates 0517 in the actual display and the status of the selected output in the Select display 4 Press the Setpoint A or key to change the Status Each press of the key changes the output status from ON to OFF or OFF to ON OUTPUT Monitor SELECTION GUIDE 1 2 Heat OM4 Vent 5 Press the Setpoint to select the next output Repeat Step 4 to change the status of the output or press any key to continue indexing through the outputs 6 Save changes and exit the output menu Press and hold the Select 5 key for 3 seconds to save the changes and exit UGH002 0514 Thermolator heaTrac TH 1 and TH 2 control MAINTENANCE 5 9 TH 1 2 Therm
24. as the setpoint is not being saved or if this error persists andTH 2 TROUBLESHOOTING 6 11 THERM OLATOR If you apply power to the Thermolator and the control panel does not light you have a problem with the main power circuit or the WILL unit s microprocessor board WARNING Electrical Shock Hazard Disconnect and lockout the main power supply PowER UP Symptom Applying power does not turn on the Thermolator or light the control panel The control panel is lit but the Thermolator will not operate when RUN is pressed 6 12 TROUBLESHOOTING before proceeding Possible cause Is power reaching the Thermolator Has the unit blown a fuse Is the correct voltage reaching the Thermolator Is the unit in Test Mode Solution O Verify that the main power supply and any customer installed electrical discon nect or emergency stop devices are in the ON posi tion O Verify correct electrical con nections between the unit and the control and between the unit and the power supply Replace any damaged wires or cables Check Fuse 1 on the mother board and any fuses or breakers associated with customer installed disconnect devices Replace or reset as required Identify the cause of the ground fault and correct it See Check ing and Replacing Fuses Check the electrical require ments on the unit nameplate Verify correct main supply voltage to the unit and the sec ondary voltage supply
25. following mainte MAINTENANCE nance schedule SCHEDULE Whenever process variables change O Perform an Auto Tune The Auto Tune ensures that the control continues to obtain good approximations of the PID constants used to compensate for the thermal lag of the system You should perform an Auto Tune after the first two hours of operation and whenever the process changes such as after a mold change installation of different pipe sizes or change in process setpoint See the Performing Auto Tune the OPERATION section Daily CJ Check for leaks in cooling and process lines Before and during operation you should inspect the unit and all plumbing lines for leaks If a leak develops stop the Thermolator and repair it CJ Keep the unit and the area around it clean Check for and remove lint dust or other obstructions on the unit especially around air intake areas Keep the floor around the unit dry CJ Check the process fluid level HTR1 500 s have an internal reservoir that contains the process fluid Check the level indicator on the back of the unit to make sure the reservoir contains an adequate amount of process fluid Refill as needed with the specified heat transfer fluid Monthly or as often as needed O Inspect the fluid in the fluid reservoir For at least the first three months of operation check the sight glass in the process fluid reservoir for debris or discoloration that could indicate fluid co
26. or switches Choice of temperature control points allows you to monitor and con trol from the process supply temperature or the process return temper atures or from an average of the two Remote control with 15 foot cables optional to 50 feet and magnetic backs allow you to place the control where you want it Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 The Thermolator process inlets and outlets must connected to the plumbing that will circulate the temperature controlled water or fluid through the process Optional cooling water inlets and outlets are connected to the cooling water supply 1 Remove the shipping pipe plug from the female connections on the back of the Thermolator 2 Install pipe to the rear of the Thermolator Use male 1 jinch NPT piping for process oil connec tions and male 3 inch NPT piping for water connections Pipe and pipe threads must be clean and new Clean threads with solvent removing all oil grease and dirt Allow the threads to dry before proceeding 3 Coat the pipe threads with thread sealant Follow the sealant manufacturer s directions 4 Connect the male pipe to the appropriate female connection on the back of the unit Start by hand until the threads engage then use a pipe wrench to tighten the connection only enough to prevent leaks Do not over tighten Sight glass O To process From process
27. repair this equipment Before installing this product please take a few moments to read the User Guide and review the diagrams and safety infor mation in the instruction packet You also should review man uals covering associated equipment in your system This review won t take long and it could save you valuable instal lation and operating time later Symbols have been used to help organize the User Guide and call your attention to important information regarding safe installation and operation N Symbols within triangles warn of conditions that could be hazardous to users or could damage equipment Read and take precautions before proceeding Numbers within shaded squares indicate tasks or steps to be performed by the user A diamond indicates the equipment s response to an action performed by the user An open box marks items in a checklist eo A shaded circle marks items in a list You must be familiar with all safety procedures concerning installation operation and maintenance of this equipment Responsible safety procedures include Thorough review of this User Guide paying particular attention to hazard warnings appendices and related dia grams Thorough review of the equipment itself with careful attention to voltage requirements intended uses and warning labels Thorough review of instruction manuals for associated equipment Step by step adherence to instructions outlined in
28. to overheat degrade and foul Flows may decrease for a variety of reasons contaminants lodged in valves lines or strainers bypass valves hanging up pump problems out of spec components or the wrong valves mistakenly closed Solutions Never exceed the maximum film or bulk temperature of any heat transfer fluid This is possible but in practice not very easy or inexpensive power failures alone can victimize even the most fail safe system not to mention operator error or worn components And system contamination is difficult to totally prevent Specify a heat transfer fluid that does not foul when severely overheated Paratherm The Paratherm NF won carbon coat a system s internal surfaces when severely overheated Formulated for service to 600 F the odorless crystal clear NF fluid provides excellent heat transfer and is low in viscosity It is exceedingly reliable cost effective and totally non toxic The NF fluid can be safely combined with used lube oils and recycled locally or burned for BTU value If severely overheated the Paratherm NF evolves carbon granules Remaining in suspension they cannot adhere to the system s internal surfaces and can be easily filtered out fossil fired systems the circulating pump should be allowed to run until the excess heat stored in the heater s refractory and structural members has safely exited the firebox Note The information and recommendations i
29. 1 4 10 7 3Hp 224kWj 26 5 24 0 12 SPECIFICATIONS NOTES For units equipped with optional heat exchanger and cooling circuits Tal voltages are 3 phase 60 Hz Specifications can change without notice Check with a Conair representative for the most current information 2 4 DESCRIPTION Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 INSTALLATION Unpacking the boxes 3 2 Preparing for installation 3 3 Connecting the water supply 3 4 Optional purge valve hookups 3 5 Connecting the main power 3 6 Testing the installation 3 7 Initial setup 3 8 Changing temperature units 3 9 Enabling and disabling passcode protection 3 10 Selecting the temperature control point 2 3 12 0 Entering setpoint deviation parameters 3 14 0 Activating SPI communication 3 15 Installing the Auto Start feature 23s was Pes er 3 16 UGHO002 0514 Thermolator heaTrac TH 1 and TH 2 U NPACKING THE Thermolator heaTrac models come fully assembled If they were specified at the time of the order the optional cooling BOXES exchanger and valve is factory installed Remote control cord TH 2 only Thermolator heaTrac 1 Carefully remove Thermolator and compo nents from their shipping containers and set upright 2 Remove all packing material protective paper tape and plastic Check
30. 67 LIP SEAL 1 29168 SEAL ASSEMBLY 1 29165 GASKET 3 29230 O RING 1 At disassembly check the impeller and other wear items for unusual wear Replace if necessary When servicing the pump care should be taken that the pump has cooled to a sufficient temperature to permit disassembly The product should be drained from the pump housing and disposed in accordance with the fluid manufacturer s recommendations Operating personnel should be warned to exercise care and utilize eye and skin protection when servicing the pump HTO PUMP CROSS SECTION AND DETAIL UE lt SE 2 Yy 2 7 2 SS 22277 EX XX 2 472 lt DESCRIPTION IMPELLER CAST IRON SEAL ASSEMBLY HEX JAM NUT S S COOLING FAN CLAMP ALUMINUM CAPSCREW GASKET CAPSCREW O RING VITON ADAPTOR DUCTILE IRON ISOLATOR CARBON GRAPHITE 11 DRIVE SLEEVE STAINLESS STEEL SEAL HOUSING DUCTILE IRON LIP SEAL VITON HOUSING DUCTILE IRON GASKET PIPE PLUG S S LOCKWASHER S S CAPSCREW CPS OMANODAAWND CUBIC METERS PER HOUR 15 SH3l3W QV3H 7 101 e e e e N r st 3450 RPM 85 II EEE Smee 9 1 5 1 25 TTI Tig teri tii LN iw e LLL LII 5
31. CONAIR www conairgroup com USERGUIDE UGH002 0514 Thermolator heaTrac Series Oil Temperature Controller HTR1 500 with TH 1 or TH 2 controls Corporate Office 724 584 5500 Instant Access 24 7 Parts and Service 800 458 1960 Parts and Service 814 437 6861 Please record your _ It s a good idea to record the model and serial number s of equipment s model and your equipment and the date you received it in the User serial number s Guide Our service department uses this information along the date you received it with the manual number to provide help for the specific in the spaces provided equipment you installed Please keep this User Guide and all manuals engineering prints and parts lists together for documentation of your equipment Manual Number UGH002 0514 Serial number s Model number s DISCLAIMER Conair shall not be liable for errors contained in this User Guide or for incidental consequential dam ages in connection with the furnishing performance or use of this information Conair makes no warranty of any kind with regard to this information including but not limited to the implied warranties of merchantability and fitness for a particular purpose Copyright 2014 Conair All rights reserved INTRODUCTION 1 1 TABLE OF Purpose of the User Guide 1 2 How the guide is organized 1 2 CONTENTS Your responsib
32. Conair s guarantee is limited to replacing at our option the part or parts determined by us to be defective after examination The customer assumes the cost of transportation of the part or parts to and from the factory Conair warrants that this equipment will perform at or above the ratings stated in specific quotations covering the equip ment or as detailed in engineering specifications provided the WARR ANTY equipment is applied installed operated and maintained in the recommended manner as outlined in our quotation or specifi cations Should performance not meet warranted levels Conair at its discretion will exercise one of the following options Inspect the equipment and perform alterations or adjustments to satisfy performance claims Charges for such inspections and corrections will be waived unless failure to meet warranty is due to misapplica tion improper installation poor maintenance practices or improper operation Replace the original equipment with other Conair equipment that will meet original performance claims at no extra cost to the customer Refund the invoiced cost to the customer Credit is subject to prior notice by the customer at which time a Return Goods Authorization Number RGA will be issued by Conair s Service Department Returned equipment must be well crated and in proper operating condition including all parts Returns must be prepaid Purchaser must n
33. E gt Alddns ONIYIM c H L Wavy ST NYOH 3 zz IX 7X X GX X 5goxis U z ZL 09 09 M 62 4 1 3 2 AL anna z D ion 7052 f og c ocz 1N3A 1 ABVMWIMd 3 035 1 10 41 09 Tost 7 1002 5 GYVOBUBHLON OL gt _ J Li Gn z Y dii lBvisoinv 8i 5 ae i anna p IXCIXZIXLIXOLX 6X 8X X 0t LN LUN UIN LUN IX ZX SX 9X KW Y S YOLINON 3SWHd OVA OLL LNVHO ONIIM 336 MAC A AA A Wi ral TT TIZ A HLAVA 212 ES T i Qn Hz M TT FEN 193NNOOSIO 35043 22 22290550 03 1 ar 1 1 A8 1dNYYIINI WL zii Xs if zt wap EE a 7 n eq one Ep WL 25101 PD 7 2 230 460 WiRING DIAGRAM UGH002 0514 A A 1 LLS WPS LLS WPS AUTOSTART AUTOSTART HPS LPS HPS LPS e lt ACOUT 2 AC OUT 1 TH 2 CIRCUIT BOARD WARNING IT IS VERY IMPORTANT THAT SWITCHES 7 AND 48 BE SET TO THE PROPER UNIT TYPE BEFORE OPERATING THIS UNIT rHERMOLATOR Hot Oil Unit CONFIGURATION DIP SWITCH 2 CONTROL OPER PNL CABLE D O O MOOOD 2 PD 8 TH 2 BOARD
34. ENANCE section 5 Fuse 1 Control power Fuse 5 UNLDR 1 VENT2SOL Vi t UNLDR 1 VENT2SOL UNLDR2 COOL1SOL n va e UNLDR2 COOL1SOL 2292 Soe Fuse 4 Cooling valve 2092 TN OR Fuse 2 Pump CONFIGURATION HTS COMP OL DIP SWITCH HTS COMP OL Fuse 3 Heater LLS PURGE 3501 LLS PURGE 3SOL PURGE 4501 PURGE4SOL le 5 4 2 1 2 1 6 5 4 2 1 4 2 1 2 E S 9 S 2 iz S S 1200hm 2 CONTROL OPER PNL CABLE TCPL S SUP RET cc 12345678 1234 UGH002 0514 Thermolator heaTrac TH 1 and TH 2 CHECKING AND REPLACING FUSES WARNING Shock Hazard Only qualified service personnel familiar with electrical testing and industrial equipment should examine and correct problems that require opening the unit with power on to diagnose the cause of a problem IMPORTANT Always refer to the wiring dia grams that came with your Thermolator to locate specific electrical components Illustrations in the User Guide are intended to be represen tative only TROUBLESHOOTING 6 13 RESETTING OVERLOADS REPLACING THE Pump OVERLOAD The pump motor overload is located inside the unit s electri cal enclosure 1 2 3 Disconnect lockout the main
35. ESHOOTING 6 15 REPLACING THE WARNING Electrical Shock Hazard Only qualified service personnel who have been H EATER trained on electrical testing and the procedures for avoiding the hazards should diagnose or correct prob CONTACTOR lems that require opening the unit with power on Thermolators use mercury displacement heater contactors IMPORTANT Always The heater contactors should be replaced if refer to the wiring dia You have checked the amp draw on each of the three phase grams that came with legs and discovered a voltage imbalance greater than 10 your Thermolator to You have checked the continuity and found that ohms at locate specific electrical the coil equal zero components Illustrations in the User Guide are To replace the heater contactor intended to be represen tative only 1 Disconnect and lockout the main power 2 Open the electrical enclosure door Turn the screw on the front panel counterclockwise to open 3 Disconnect the wires from the heater contactor contactor Make sure you label the wires to ensure you can connect them correctly to the new contactor Remove the contactor by removing the screws that hold it in place 5 Discard the old contac tor using the proper disposal procedure See Material Safety Data Sheet 7439 97 the APPENDIX Reverse this procedure to install the new con tactor Make sure the wires are connec
36. INT ACTUAL CALIBRATION DISPLAY DISPLAY Zero Calibrate Supply Sensor 32 F 0 C Zero Calibrate Return Sensor 32 F 0 C Span Calibrate Supply Sensor 510 F 266 C Span Calibrate Return Sensor 510 F 266 5 Using the thermocouple calibrator apply the appropriate temperature to the control input 5 1 0 MAINTENANCE Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 6 Press the up A key to begin calibrating The controller displays the name of the current calibration examples 32 SC L 32 rC L 510 SC H or 510 rC H TH 2 Microprocessor Pump Setpoint 73 Actual Aree E 1 Cooling Valve p p 9c Venting Valve Test Mode SPI Communication Auto Start Low Oil Alarm Low Water Flow Alarm High Temp Safety Display Select Supply Temp Return Temp Average Temp Cool Down 7 Wait until the control displays don or bad A don message in the Setpoint display indicates the cali bration was successful A bad message in the Setpoint display indicates a bad calibration NOTE The original calibration value stored in EEProm can be restored for the current calibration by pressing the STOP key at any time 8 Press Select to start the next calibration Pressing and releasing the Select 5 key at the end of a calibration tel
37. L POINT Test Mode SPI Communication A v Auto Start TH 2 ONLY Low Oil Alarm Select Temperature elect Supply Temp Low Water Flow Alarm High Deviation Return Temp High Temp Safety Low Deviation Average Temp Address On Off Baud Rate Cool Down Alarm Press the RUN button to save the control point The control will display Pr OFF to prompt you to remove power to the unit IMPORTANT If RUN is not pressed the new control point source will not be saved Turn off power to the unit Disconnect and lock out the main power supply Open the electrical enclosure Set dip switch 5 to OFF Close the electrical enclosure and restore power to the unit The TH 2 will now control the process temperature based on actual temperatures recorded at the new control point source UGH002 0514 Thermolator heaTrac TH 1 and TH 2 control INSTALLATION 3 1 3 ENTERI NG You can establish a normal operating range around the process temperature setpoint using the high and low deviation parame SETPOI NT ters If the process temperature exceeds the high deviation limit or falls below the low deviation limit for longer than 15 DEVI ATION minutes the Thermolator will alert you to the unacceptable temperature variation with an alarm light PARAMETERS These temperature deviation limits will adjust automatically relative to the process temperature setpoint The factory default setting is th
38. NG POINT Not applicable APPEARANCE Clear liquid ODOR Odorless VAPOR PRESSURE 1 mm Hg 70 F SOLUBILITY Negligible in water Soluble in hydrocarbons Not regulated by D O T no placarding required NOTE We present the information and recommendations in this bulletin in good faith and believe them to be correct however Paratherm Corporation makes no representations as to accuracy or completeness We supply this information on the condition that the user determine suitability of product E 4 1996 Paratherm Corporation WASTE DISPOSAL METHOD All disposals must comply with federal state and local regulations The fluid if spilled or discarded may be a regulated waste Refer to state and local regulations Caution If regulated solvents are used to clean up spilled fluid the resulting waste mixture may be regulated Department of Transportation DOT regulations may apply for transport ing this material when spilled Waste material may be landfilled or incin erated at an approved facility Materials should be recycled if possible This material as supplied is not regulated by RCRA as hazardous waste ADDITIONAL INFORMATION SARA Title Paratherm NF is not subject to the reporting require ments of section 313 of Title of the Superfund Amendment amp Reauthorization Act of 1986 and 40 C F R part 372 Nil Ambient Temperature PERCENT VOLATILE VAPOR DENSITY AIR 1 gt 1 EVAPORATION RATE EE 1
39. You should perform an Auto Tune after the first two hours of operation and whenever process variables change changes in cooling water pressure piping or molds large ambient swings new setpoint temperature to ensure that the control continues to obtain good approximations of the PID constants used to compensate for the thermal lag of the system To ensure a successful Auto Tune verify that O The Auto Tune feature has been enabled Auto Tune is enabled or disabled via dip switch 2 on the motherboard O The process value is stable A fluctuating process value will fool the software into making inaccurate tuning deci sions The software waits 5 minutes for the process value to stabilize before it starts the Auto Tune process If the process value still fluctuates after 5 minutes the Auto Tune terminates and the control displays the At ti error The control is in STOP mode and the process value is in ambient temperature This allows the software to obtain good approximations of process parameters which are crit ical for performing an accurate tune If this requirement is not met then a good tune cannot be guaranteed The setpoint process deviation is at least 25 F If the absolute value of setpoint process temperature is not greater than or equal to 25 F the Auto Tune will terminate The control will display an At dEV error 1 Press Stop to shut down the Thermolator 2 Disconnect and lock out main
40. aTrac TH 1 and TH 2 control OPERATION 4 5 STARTING THE THERMOLATOR IMPORTANT If you are operating the Thermolator for the first time since installation you should perform an Auto Tune after two hours of normal opera tion You should perform the Auto Tune periodically to ensure that the control cor rectly calculates how much heat and cooling should be applied to maintain the process setpoint See Performing an Auto Tune 4 6 OPERATION Before starting the Thermolator verify that the system has been installed correctly for your application See the INSTALLATION section If Passcode Protection has been enabled you must enter the correct passcode before you can change or enter any of the operating parameters including the temperature setpoint 1 Turn on the optional water supply to the lThermolator The supply must be at least 15 psi Check for leaks in the cooling water and process fluid lines before continuing 2 Turn on main power to the Thermolator The control initiates a brief self test Indicator lights blink green then red Setpoint and actual windows will display FER for three seconds followed by the software version The windows then display the factory default setpoint of 100 F and the actual temperature Enter the passcode Setpoint if necessary Hold the SSS Setpoint Select button for 5 l l 1 seconds When the control displays 1 5 use the setpoint ad
41. alve fuse Output Monitors in the MAINTENANCE section Has the motherboard Replace the motherboard See output channel at the Checking and Replacing the designated fuse failed Motherboard UGH002 0514 Thermolator heaTrac TH 1 and TH 2 TROUBLESHOOTING 6 7 The Thermolator has detected problem that could lead to a shut WARNING down condition if it is not corrected ALARMS The Alarm LED lights The Thermolator continues operating The control displays a red LED or alarm code indicating the source of the problem Alarm Possible cause Solution Is the cooling valve stuck Disassemble the cooling valve open or leaking water and check for particles block The Thermolator ing the valve seat Check the will not heat to the valve seat for excessive wear setpoint temperature Replace as required using a or takes too long to valve repair kit See Repairing reach the setpoint Solenoid Valves temperature The actual temperature of Did a heater element fail With the unit powered down fluid supplied to the Check for loose connections process is lower than Check resistance between the the setpoint devia phase legs on the output side tion allows of the heater contactor Readings should be within WARNING 0 25 ohms of each other The Thermolator should Replace the heater if neces be tested and repaired sary See Replacing Heater only by qualified techni Elements cians equipped with the correct tools andtrai
42. an result in severe personal injury If you have a TH 2 model you can automatically start and stop the Thermolator from a remote switching or timing device that has power contacts rated 110VAC such as the process machine control Wiring the device to the Thermolator is accomplished through a dry contact to the appropriate terminals on the motherboard After wiring the device to the unit Auto Start must be enabled by configuring a dip switch on the motherboard 1 2 3 Disconnect and lockout power to the unit Open the electrical enclosure Punch a small hole in the left side of the electrical enclosure The hole must be large enough to accommodate conduit for the power contact wires from your switching or timing device 4 Insert the two power leads from the device through the conduit into the electrical enclosure Device contacts DODD M PODDSD 5 Q oort sees ORE 330029 2000 1 22002 amp lt lt lt lt lt lt 5 Connect the 110VAC device contact wires to Thermolator heaTrac TH 1 and TH 2 control the Auto Start terminals Make sure terminals are screwed tight UGH002 0514 INSTALLING THE AuTO START FEATURE TH 2 ONLY 6 Set dip switch 4 to the ON position Close the electrical enclosure and restore power to the unit TH 2 Microprocessor CONAIR Setpo
43. anels of the Thermolator Lift the top panel straight up then lift the side panels up 6 Remove the solenoid valve from the cooling water inlet line 7 Disassemble the solenoid valve see exploded views on next page 8 Inspect and clean or repair the valve body assembly Remove foreign particles and replace damaged parts as necessary 9 Reassemble the valve and other components Reassemble in reverse order Seal all pipe fittings with pipe sealant Check that all flows are in the correct direction Check for leaks before resuming operation 6 1 8 TROUBLESHOOTING Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 Indicates Parts Supplied in Solenoid Enclosure Kit Housing 7 8 Dia Hole for 1 2 Conduit Solenoid Base Sub Assembly 0 9375 26 UNS 2A Thread Core REPAIRING SOLENOID VALVES Retaining Retaining Cap M ay Sleeve TU Grounding Wire Not present on all constructions Insulating Washer Coil Insulating Washer Sleeve Tapped Hole in Core 0 250 28 UNF 2B 0 38 Minimum Full Thread Alternate Construction with Nameplate on Housing Indicates Parts Supplied in Solenoid Enclosure Kit Housing Retaining yr Cover Spring Washer Sleeve Grounding Wire Not present on a
44. ative maintenance See an alarm condition that requires troubleshooting Relocate ship or store the unit To shut down the unit for purging the process lines diagnos tic testing routine maintenance or troubleshooting press the Stop button Then refer to the appropriate topic or section in this User Guide To shut down the unit to change fluid hookups 1 Press cool and drain the unit of all oil or fluid Drain the unit using the drain plugs on the back of the heater casting 2 Once the unit is cool remove the cooling water hookups v VU Drain plug To shut down the unit for relocation or storage 1 Press Stop and drain the unit of all fluid Drain the unit using the two drain plugs 2 Disconnect the power supply and all water feeds 3 Position the control panel to rest flush with the unit In shipment or storage the Thermolator can withstand an environment between 40 F 40 C and 150 F 65 C with 95 relative humidity non condensing UGHO002 0514 Thermolator heaTrac TH 1 and TH 2 control OPERATION 4 7 PERFORMING AN AuTO TUNE 4 8 OPERATION AN WARNING Electric shock hazard This equipment is powered by high voltage Always disconnect and lock out the main power source before opening the unit or the electrical enclosure to modify factory settings Failure to disconnect and lock out the main power source can result in severe personal injury
45. ccessible sites Keep collected mercury in a tightly closed bottle for recovery or disposal Disposal procedure Dispose in accordance with all applicable federal state and local environmental regulations 7 Storage and Handling Precautions Mercury should be stored in a secure poison area inside a tightly closed container 8 Exposure Control and Protective Equipment Ventilation Use general or local exhaust ventilation to meet TLV requirements Respiratory protection None required where appropriate ventilation conditions exist If the TLV is exceeded a self breathing apparatus is advised Eye skin protection Safety goggles and face shield uniform protective suit and rubber gloves are recommended 9 Physical and Chemical Properties Appearance and odor Silver white heavy mobile liquid metal odorless Boiling point 675 F 357 C Melting point 38 F 39 C Specific gravity 13 5 Vapor pressure 0 002 mm HG Vapor density 1 01 Solubility in H 0 negligible less than 0 1 Solubility in solvents Sulfuric acid nitric acid lipids 10 Stability and Reactivity Data Stability Stable Hazardous polymerization Will not occur Conditions to avoid Heat Incompatibles Strong acids IMPORTANT Users of this equipment should study this MSDS carefully to become aware of and understand the hazards associated with the product If necessary or appropr
46. controllers are listed in the following tables The standard required commands and three optional com SU PPORTED BY mands are listed in the SPI Command Pairs table along with the Select and Poll command pairs in hexadecimal format THE R Select commands set or change Thermolator functions Poll TH ERMOLATO R9 commands retrieve information from the Thermolator SPI Command Pairs Mold temperature controllers Device ID hex 20 Commands Select Poll Echo 0x20 0x20 Select stores 4 bytes of information at the Thermolator Poll retrieves it 0x21 0x20 Setpoint Process Temperature 0 20 0 20 Sets and retrieves the process temperature setpoint 0x31 0x30 Alarm High Temperature Deviation 0x20 0x20 Sets the alarm band temperature retrieves setpoint alarm band value 0x33 0x32 Alarm Low Temperature Deviation 0x20 0x20 Sets the alarm band temperature retrieves setpoint alarm band value 0x35 0x34 Mode Machine 0 20 0x20 Start stops the Thermolator acknowledges alarms retrieves run status 0x49 0x48 Version 0x20 Retrieves 4 bytes of SPI version information 0x22 Process Status 0x20 Retrieves run status and alarm conditions 0x40 Status Machine 1 0x20 Retrieves run status and alarm conditions 0x42 Status Machine 2 0x20 Retrieves run status and alarm conditions 0x44 Temperature from Process 0x20 Retrieves the actual temperature of fluid returning to the Ther
47. d 3 1 4 INSTALLATION Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 series Thermolators provide SPI compatible sup port for RS 485 serial communications with a host machine You can use SPI communication to change or monitor the Process temperature setpoint High and low temperature deviation alarms Process status run and alarm conditions Machine 1 status Machine 2 status Actual temperature to process Actual temperature from process To use the SPI communication option you must connect the Thermolator to the host machine and set the communication baud rate and node address using the setpoint select and adjustment buttons on the control panel 1 Connect the host machine to the Thermolator Plug the male DB9 connector into the serial communica tions port on the Thermolator 2 Apply power to the Thermolator 3 Enter the passcode if necessary Hold the Setpoint Select button for 5 seconds When the control displays 1 use the setpoint adjustment but tons to enter the passcode ACTIVATING SPI COMMUNICATION NOTE To disable SPI use the setpoint or W arrow to select Address Press the W arrow until OFF is displayed in the setpoint window See the APPENDIX for additional SPI programming information 4 Enter the node address Press the Setpoint Select button to choose jc Address Then press the setpoint
48. e absorbed by the skin or through the eyes It may be fatal if swallowed or inhaled It emits toxic vapors especially when heated Do not get mercury in your eyes on your skin or on your clothing Do not breathe mercury dust Keep mercury in a tightly closed container Use with adequate ventilation Wash thoroughly after handling Effects of overexposure Mercury causes skin digestive tract and severe respiratory tract irritation It may affect the central nervous system and cause severe eye irritation Inhalation of vapors may cause coughing chest pains nausea and vomiting Chronic effects of overexposure may include kidney and or liver damage and central nervous system depression Chronic effects of mercury poisoning include a buildup of the metal in the brain liver and kidneys Symptoms include headache tremors loose teeth loss of appetite blisters on the skin and impaired memory This substance has caused adverse reproductive and fetal effects in animals Target organs Eyes skin respiratory system central nervous system kidneys and liver Routes of entry Inhalation absorption eye contact skin contact 4 Emergency and First Aid Measures Call a physician immediately If swallowed Immediately induce vomiting if person is conscious If inhaled Immediately remove exposed person to fresh air If the person is not breathing give artificial respiration If breathing is difficult give
49. e optional manual mold purge the control button is located on the side of the Thermolator electrical enclosure 1 CONTROL Run Stop Press the RUN button to start normal operation Press STOP to stop the temperature control unit Actual values display The green window displays the temperature at the middle of the mold This temperature Setpoint display The window displays the setpoints entered for the fluid temperature the high is calculated as an average of the tempera and low e Running tures of the supply oil and return oil tion alarms the SPI baud Stopped The lights indicate whether the temperature is in degrees Fahrenheit or Celsius rate and the SPI address W Alarm flashing Status lights The lights indicate the operating status of the listed components Except in Test Mode and Auto Start the lights indicate Off or inactive On or active Alarm condition TH 1 Microprocessor Actual ao LI CCL co Setpoint mE ci Cooling Venting Valve Test Mode SPI Communication Low Oil Alarm Low Water Flow Alar Temperature High Temp Safety High Deviati gon n Test Mode is used for initial programming When test mode is enabled nor mal operation is disabled Test Mode off Low Deviation Address Baud Rate Alarm Setpoint Select button Press repeated
50. e process temperature setpoint x 25 F 4 C This parameter is adjustable to establish a nar rower or wider acceptable temperature range for normal oper ation The Low Deviation cannot be set to fall below the facto ry set Low Safety temperature The High Deviation cannot be set to exceed the factory set High Safety temperature Model riso Process Setpoint 100 F 38 C High Safety 510 F 266 C Low Safety 60 F 16 C To change the temperature deviation settings 1 Press the Setpoint Select button to select the deviation m ri parameter you want to change 2 Use the and V setpoint buttons to enter the deviation T temperature The setting is High Deviation Low Deviation stored in memory even when the e power is turned off The recom Baud Rate mended setting is 2 10 NOTE If you enabled passcode protection you must enter the passcode to change this parameter Too enter the passcode Hold down the Setpoint Select button for 5 seconds When the control displays 1 PaS use the setpoint adjustment buttons to enter the passcode Press the Setpoint Select button again If the correct passcode was entered the controller will display ACC PAS for 3 seconds If the passcode was incorrect the controller will display rEJ PAS rejected passcode Access to system parameters remain until power is cycled or the RUN or STOP button is presse
51. eing cleared if the unit is not processing otherwise it is SET Elsewhere on the chart e If a bit is not shown to be SET it is cleared e The System Alarm bit is SET if an alarm is present It is the logical OR of Process alarm and Machine alarm e Processing System Alarm Process Alarm and Machine Alarm bits are repeated for Process Status Machine 1 Status and Machine 2 Status 001 0499 THERMOLATOR SPI COMMANDS APPENDIX D 3 SPI SrATUS WoRDS Status Machine 2 0 20 0 44 SPI STATUS WORD Alarm Process Reserved Reserved Reserved Reserved c c o o EU Alarm System R23 Fault Sensor Alarm Machine VH Reserved CE Reserved mE Reserved 9 Processing Reserved Fault CAL 15 14 2 Eprom error SET SET A D converter error CJC Error RAM hardware ROM checksum robe Failure safet Prog Hi temp safety Output monitor failure Low water pressure High deviation alarm ow deviation alarm rog Lo temp safet c E lt gt m 2 mE z w 3 E a et UN NE EE i 5 ump overload ow water level est Mode hase error 49 m NOTES The SPI list defines the Processing bit as being cleared if the unit is not processing otherwise it is SET Elsewhere on the chart e If a bit is not shown to be SET it is cleared e The System Alarm bit is SET if an alarm i
52. est menus 4 Select the Output Test menu TH 2 Microprocessor Pump Setpoint m Actual Aimee pt Cooling Valve pz 5 Venting Valve Test Mode v SPI Communication Auto Start Display Low Oil Alarm Temperature Select Supply Temp Low Water Flow Alarm High Deviation Return Temp High Temp Safety Low Deviation Average Temp Address Baud Rate Cool Down Alarm Press and hold the Setpoint key for 3 seconds to index to each test menu until the controller displays oUt Repeatedly press and release any key to test With each key press and release the left display will indi cate the number of the output being tested 051 052 2 etc The right display indicates either 1 for a good output or for a failed output Only outputs that are actually used by the particular model will be tested Exit the test and enter the next test Press and hold the Setpoint key for 3 seconds to exit and index to the next test 5 8 MAINTENANCE Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 output monitors the Thermolator be enabled or dis abled permanently through the OM Enable Disable Menu in DISAB LING OR Test Mode ENABLING You need to use this feature if you have replaced the mother board or if dip switches 7 and 8 have been changed erro OUTPUT neously This will enable any required output monitors that
53. fluid In existing sys tems dirty bruised fluid may remain or a non compatible fluid may have been added Oxidation occurs when hot fluid comes in contact with the oxygen found in air The fluid will start to smoke like over heated cooking oil and will become acidic and corrosive And as the fluid oxidizes it becomes less efficient and less resistant to heat Note We strongly recommend that copper or copper bearing materials not be used in hot oil systems Copper when in contact with hot fluid and air will act as a catalyst causing the fluid to oxidize much more quickly Overheating occurs as the fluid s film temperature rises above its recom mended maximum The fluid will first start to distill with the smaller molecules beginning to boil and vapor ize Viscosity thickness increases causing flows to decrease This allows the fluid to linger in contact with the heated surface and pick up too much heat As temperatures continue to rise chemical bonds begin to break and the fluid releases sooty carbon Allowed to continue unchecked the process repeats itself until all the fluid has been carbonized System Problems Overheating the most serious type of bruising is caused by loss of input heat control or a decrease in fluid velocity Input Heat Control Problems with the equipment include improper flame propagation in fossil fired heaters and controller glitches or human failure in electrically
54. from the transformer to unit compo nents Replace the transformer if necessary If the Test Mode LED is lit you must disable Test Mode on the motherboard before resum ing operation See Performing System Tests in the MAINTENANCE section Thermolator heaTrac TH 1 and TH 2 UGHO002 0514 This procedure covers the factory installed fuses on the unit s motherboard If you have installed an electrical disconnect or emergency stop switch additional fuses and or breakers may have been used elsewhere in the in the main power circuit To replace a blown fuse 1 Disconnect and lockout the main power 2 Open the electrical enclosure door Turn the screw on the front panel counterclockwise to open 3 Replace the fuse The fuses are located on the mother board and are labeled and identified on the orange shield 4 Close the electrical enclosure and restart the unit If fuses continue to fail O Verify that the unit is receiving the correct voltage Check the voltage phasing and amperage ratings on the unit s nameplate O Verify that the unit s transformer is operating correctly Check for proper voltage 120V 10 to the voltage sensing device for the fuse location O Check all wiring referencing the fusing location for loose connections damage or improper grounding Verify that the correct device is being used for this fuse location See Disabling or Enabling Output Monitors in the MAINT
55. fy Auto Start disabled Auto Start enabled Control point protect Control point source select Test Mode disabled Test mode enabled Controller type selection Controller type selection Controller type selection Controller type selection Available only on TH 2 models T Switch 7 must be off and 8 must be ON for oil units not change these settings To change the dip switch settings see the appropriate topic on the following pages Thermolator TH 1 and TH 2 UGHO002 0514 WARNING Electric shock hazard This equipment is powered by high voltage Always disconnect and lock out the main power source before opening the unit or the electrical enclosure to modify factory settings Failure to disconnect and lock out the main power source can result in severe personal injury The temperature units are factory set as degrees Celsius or degrees Fahrenheit as specified when the unit was ordered When the Thermolator is on the indicator lights to the right of the Actual temperature display on the control panel will show which temperature unit has been set TH 2 Microprocessor CONAIR Heater mmm 21 21771 F Os E G LI 5 Venting Vaive Test Mode yv SPI Communication Auto Start Setpoint Display Low Oil Alarm Temperature elect Supply Temp Low Water Flow Alarm High Deviation Return Temp High Temp Safety Low Deviati
56. he Alarm LED lights and the STOP RUN LED flashes red Thermolator automatically shuts down control displays a red LED or alarm code indicating the source of the problem Alarm Possible cause Is the cooling valve stuck open Actual temperature of oil supplied to the process is below the programmed 50 F safety limit Has the heater failed Is the th 1 thermocouple the process Has the thermocouple return line failed failed Is the th 1 thermocouple the process Has the thermocouple supply line failed failed Solution Disassemble the cooling valve and check for particles block ing the valve seat Check the valve seat for excessive wear Replace parts as required using a valve repair kit See Repairing Solenoid Valves Check for a bad heating element or a heater contactor that failed in the open position See Replacing the Heater Contactor and Replacing Heater Elements Check for a loose thermocou ple or loose wire connections to the thermocouple Check the thermocouple and replace if necessary See Checking and Replacing Thermocouples Check for a loose thermocou ple or loose wire connections to the thermocouple Check the thermocouple and replace if necessary See Checking and Replacing Thermocouples 6 6 TROUBLESHOOTING Thermolator heaTrac TH 1 and TH 2 UGH002 0514 The Thermolator has detected a problem that could lead to equip ment damage or
57. he supply oil and return oil The lights indicate whether the temperature is in degrees Fahrenheit or Celsius TH 2 Microprocessor Setpoint mE LL Select Temperature High Deviation Low Deviation Address Baud Rate Setpoint Select button Press repeatedly until a green light appears next to the parame ter you want to program or view NOTE Default settings for the devia tion setpoints are High setpoint 10P F Low setpoint 10P F A warning alarm occurs indicator light turns red whenever the actual temperature is outside this setpoint range Recommend setting 2 10P Setpoint adjustment buttons Press A or V to enter tempera ture and SPI parameters Press A to increase a value Press V to decrease a value TIP Press and hold the button for faster scrolling speed UGH002 0514 CONAIR Actual Heuer i LI cO Cooling Valve Venting Valve Test Mode SPI Communication Auto Start Low Oil Alarm Low Water Flow Alar High Temp Safety Display Select Supply Temp Return Temp Average Temp Silence Alarm Cool Down Alarm Press to acknowledge the alarm light and silence the optional audible alarm The alarm light will flash until the cause of the alarm condition is fixed Cool Down On Off The Cool Down feature resets the setpoint temperature to 100P F to cool the system before stopping P
58. heated systems Power failures and bumps can drop the pump motor out The fluid standing stagnant in the tubing of fossil fired heaters absorbs heat radiating and convecting from the refractory and starts to boil Flow A reduction in or loss of flow is the most common cause of overheating As flows decrease fluid velocity and turbu lence also decrease and the heat trans fer fluid remains in prolonged contact with the heated surface Even though the system s bulk fluid temperature may not change much the film temper ature can rise dramatically and quickly This extra heat is no longer transferred as rapidly to the bulk of the fluid and the fluid distills and then cracks at the heated surface As molecules at the film layer crack carbon can be formed This carbon adheres to the heated surface and much of it bakes on thickening as the process repeats itself and successive layers are added Difficult to remove the carbon coating acts as an insulator both in heater tubing and on electrical heater elements and can severely affect flows The carbon that escapes or breaks away from the heated surface is carried throughout the system and can lodge in restrictions clog small channels and hang up control valves further con tributing to the problem In addition the fluid is now more vis cous Not flowing as well it remains in contact with the heated surface longer picking up even more heat and contin uing
59. his type of equipment should per form this test procedure 1 Turn on the cooling water supply and check for leaks If any leaks appear stop the test and fix the prob lem before continuing The cooling water must be at least 15 PSI or the unit will function slowly during cooling 2 Apply power to the unit Indicator lights on the control panel blink green then red to test operation of the LEDs Setpoint and actual windows will display for three seconds followed by the software version The windows then display the factory default setpoint of 100 F and the actual temperature 3 Check the rotation of the pump Remove the top access panel Verify that the pump rotation matches the direction indicated on the rotation sticker on top of the pump NOTE If the rotation is incorrect stop the test and disconnect power to the unit Open the electrical enclosure and switch any two of the three power source wires on the terminal block Return to Step 2 and check rotation again 4 Replace the top access panel Press the RUN key to start the unit If everything is working correctly The RUN STOP light turns green The unit initiates a 60 second venting sequence Cooling and venting valves are active for 60 seconds The pump is active for the final 30 seconds Indicator lights will energize when the device is active Normal operation begins The heater turn
60. how to use this precision electronic equipment and who understand the hazards involved Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 Most Thermolator malfunctions are indicated by illuminat ed alarm light and error codes displayed on the control panel A problem can trigger three types of alarms Shut Down Alarms The Thermolator detected a problem that caused it to shut down automatically to prevent equip ment damage or personal injury Warning Alarms The Thermolator continues to operate but warns of a problem that could lead to a condition that will shut down the unit System Errors The system error codes indicate a non recoverable problem with the microprocessor control When the Thermolator control detects a problem the red Alarm light is activated and the RUN STOP light changes from green to flashing red TH 2 Microprocessor E Setpoint CIS How TO IDENTIFY THE CAUSE OF A PROBLEM ri UR e Cooling Valve A status light Fuog E o Venting Valve that turns from Test Mode green to red v SPI Communication indicates an Oy autostart alarm condition Display Low Oil Alarm Temperature elec Supply Temp Low Water Flow Alarm High Deviation Return Temp High Temp Safety Low Deviation Average Temp Address Baud Rate Cool Down Silence When an Alarm condition occurs 1 Press to silence any optional audible alarm
61. iate the reader should consider consulting reference works or individuals who are experts in ventilation toxicology and fire prevention to use and understand the data in this MSDS To promote safe handling the reader should furnish this information to anyone whom he or she knows or believes will use this equipment E 2 Material Safety Data Sheets UGH002 1199 Material Safety Data Sheet Manufacturer s Name Paratherm Corporation Paratherm Corporation NF Heat Transfer Fluid Address 1050 Colwell Road CAS Number 6042 47 65 Conshocken PA 19428 TSCA Inventory Status Included Emergency Telephone No 610 941 4900 NFPA Hazard Identification Trade Name Paratherm NF Revision Date April 3 1996 DegreeofHazard Hazard Ratings 0 Least dec Health 0 1 Slight Tm v 1 1 2 Moderate Reactivity 0 3 High COMPONENT CAS HAZARDOUS PERCENTAGE COMPONENT 4 Extreme NAME NUMBER IN BLEND Min Max EXPOSURE LIMITS UNITS Hydrotreated OSHA PEL None established see item below Natural Hydrocarbon 8042475 No 10000 ACGIH TLV None established see item below HEALTH EFFECT ACUTE EFFECTS CHRONIC EFFECTS EYE CONTACT On rare occasions prolonged and repeated exposure to oil mist poses a Paratherm NF is non irritating to the eyes upon direct contact SKIN CONTACT Paratherm NF is not expected to cause any skin irritation upon direct single or repeated and prolonged co
62. ility as a user 1 2 ATTENTION Read this so no one gets hurt 1 3 DESCRIPTION 2 1 What is the Thermolator heaTrac 2 2 Typical applications 2 2 How it Saeed Sed UE IRR NES es 2 3 iri Noni eive ER ES 2 6 Features and options 2 8 INSTALLATION 3 1 Unpacking the 22 2 52245955 3 2 Preparing for installation 3 3 Connecting the cooling water supply 3 4 Connecting the power 3 6 Testing the installation 3 7 25225 5 3 8 Changing temperature units 3 9 Enabling and disabling passcode protection 3 10 Selecting the temperature control point TH 2 3 12 Entering setpoint deviation parameters 3 14 Activating SPI communication 3 15 Enabling the Auto Start feature TH 2 3 16 4 1 TH 1 control feat res inco Oo ed 4 2 2 control features 4 3 Positioning control panel 4 4 Ent ring DasscOUBS
63. inside the electrical enclosure and behind the side panels for accessories or hardware that may have been placed there for shipping 3 Carefully inspect all components to make sure no damage occurred during shipping and that you have all the necessary hardware If damage is found notify the freight company immediately 4 Take a moment to record serial numbers and specifications in the blanks provided on the back of the User Guide s title page The information will be helpful if you ever need service or parts 5 You are now ready to begin installation Complete the preparation steps on the next page 3 2 INSTALLATION Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 The Thermolator heaTrac is easy to install if you plan the location and prepare the area properly Position the Thermolator as close to the process machine as possible Thermolator Process e Alternate locations 2 Make sure the installation area provides three phase power source supplying the correct current for your Thermolator model Check the serial tag on the side of the electrical enclosure for the required volt age phase frequency full load amps disconnect fuse size and minimum wire connection size Field wiring should be completed by qualified personnel to the planned location for the Thermolator All electrical w
64. int Actual Sicil Aen a NOTE All dip switch illus 11111 trations in this manual show UN ES L LI ce Venting Valve A Test Mode switches 7 and 8 set to ON v SPI Communication If you have an Isolated Display Q Auto start Circuit model these switch es should be set to OFF Temperature Supply Temp Low Water Flow Alarm High Deviation Return Temp High Temp Safety Low Deviation Average Temp Address Silence Baud Rate Cool Down Alarm When Auto Start is enabled The Auto Start indicator light flashes to indicate that the Thermolator can start at any time The Thermolator will start whenever the remote switching or timing device sends a signal to start processing The Auto Start indicator light is on whenever the Thermolator is under the control of the remote device To disable Auto Start Repeat steps 1 2 and 7 setting dip switch 4 to the OFF instead of the ON position UGH002 0514 Thermolator heaTrac TH 1 and TH 2 control INSTALLATION 3 1 7 OPERATION 0 TH 1 control 4 2 eo TH 2 control we ee eee e 4 3 Positioning the control panel 4 4 0 Entering a passcode 4 5 Starting the Thermolator 4 6 0 Stopping the Thermolator 4 7 Performing an Auto Tune 4 8 UGHO002 0514 Thermolator heaTrac TH 1 and TH 2 normal operating functions can be controlled from the TH 1 control panel If you have th
65. iring should comply with your region s electrical codes A clean well ventilated environment The room temperature should not exceed 120 F 48 C with 95 non condensing humidity and should not fall below 32 F 0 C Minimum clearance for safe operation and maintenance The diagram at right shows minimum clearance for operation You also need enough clearance in the rear for water hookups For maintenance you should move the Thermolator to provide at least 36 inches on any side City tower or chiller water may be used as long as the supply pressure is at least 15 psi and not more than 85 psi 3 Install plumbing for process and cooling lines You will need two 1 4 inch NPT male fittings for the process oil inlet and outlet and two 3 4 inch NPT male fittings for the cooling water inlet and outlet Larger line sizes are acceptable as long as they are reduced at the Thermolator connections Smaller line sizes are not recom mended UGH002 0514 Thermolator heaTrac TH 1 and TH 2 control PREPARING FOR INSTALLATION Dv 254 mm 10 inches ars E 04 12 inches ra of the Thermolator EU i s A 0 inches source of water for cooling 42429299 6 508 mm INSTALLATION 3 3 FEATURES OF THE HEATRAC 3 4 INSTALLATION Expansion Fluid Low watt reservoir tank density electric immersion heater Low level pump
66. justment buttons to enter the passcode Press the Setpoint v Select button again Enter the temperature ew Temperature setpoint Press the Setpoint High Deviation Select button until the green Low Deviation light appears next to Address Temperature Press to increase or W to decrease the temperature setting Baud Rate 5 Press to start normal operation The RUN STOP light turns green The unit initiates a 60 second venting sequence Cooling and venting valves are active for 60 seconds The pump is active for the final 30 seconds Normal operation begins The heater turns on when the actual temperature is below setpoint The cooling valve turns on if the actual temperature is above the setpoint If the Alarm light turns on press to silence the option al audible alarm Then see the TROUBLESHOOTING section Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 WARNING Electrical shock and AN hot surface hazards STOPPING THE Before attempting maintenance of any kind on the Thermolator you must stop the unit THERMOLATOR disconnect and lockout the main power supply and allow the unit to cool to less than 100 38 You must shut down Thermolator whenever you Change the water hookups Shut down the process machine Purge the process circuit of the oil Run the unit s diagnostic tests Perform routine or prevent
67. lectrical sys tems and industrial appliances UGH002 0514 Possible cause Has oil stopped flowing between supply outlet and return inlet Did the cooling valve fail Is the temperature differ ence between the cooling water supply and the set point too small Did a heater contactor fail Is the high deviation tem perature set too low Thermolator heaTrac TH 1 and TH 2 WARNING ALARMS Solution Check for a plugged pipe or closed valve Check the cooling valve See Repairing Solenoid Valves The temperature difference should be at least 25 F to achieve proper cooling Increase the process setpoint decrease the cooling water supply tem perature or increase cooling water supply pressure With power on and the Heater LED lit Check the amp draw on each of the three phase legs to the heater All should match the FLA listed for the heater on the unit nameplate Replace the heater contactor if there is a voltage imbalance greater than 10 See Replacing the Heater Contactor Increase the high deviation set point The recommended setting is the setpoint 2 F to 10 F TROUBLESHOOTING 6 9 WARNING ALARMS Alarm The Thermolator has detected a problem that could lead to a shut down condition if it is not corrected Alarm LED lights Thermolator continues operating control displays a red LED or alarm code indicating the source of the problem Possible cause
68. led and drain the unit Drain all oil using the drain plugs locat ed the bottom of the unit Remove the unit s top panel and open the electrical enclo sure Remove the thermocouple Loosen the compression nut to slide the thermocouple out of the casing Disconnect the thermocouple wires at the motherboard Install the new thermocouple Insert the tip of the new thermocou ple at least 1 inch into the tank tighten the compression nut Thread the leads through the raceway lead ing to the electrical enclosure Attach the thermocouple leads to the moth erboard UGH002 0514 Thermolator heaTrac TH 1 and TH 2 control CHECKING THERMOCOUPLES REPLACING THERMOCOUPLES WARNING Hot surfaces Allow the Thermolator to cool to below 100 F 38 C before servicing the unit TROUBLESHOOTING 6 17 E EPAIRING Every Thermolator has a solenoid valve assembly that controls the cooling water out flow SOLENOID VALVES hot surface hazards Before attempting maintenance of any kind on the Thermolator you must stop the unit AN disconnect and lockout the main power supply and allow the unit to cool to 100 F 38 C 0 WARNING Electrical shock and 1 Shut off the cooling water infeed 2 Drain the unit of all water through the manual lever on the pressure relief valve Remove the cooling water inlet feed 3 4 Disconnect and lockout main power 5 Remove the top and side p
69. ll constructions with Nameplate 7 8 Dia Hole for 1 2 Conduit Solenoid Base Sub Assembly 0 9375 26 UNS 2A Thread Core AC UGH002 0514 Coil Sleeve uu Thermolator heaTrac TH 1 and TH 2 control Tapped Hole in Core 0 250 28 UNF 2B 0 38 Minimum Full Thread TROUBLESHOOTING 6 19 REPLACING gt HEATER ELEMENTS 1 3 4 IMPORTANT Always refer to the wiring dia grams that came with your Thermolator to locate specific electrical components Illustrations in the User Guide are 5 intended to be represen tative only 6 10 6 20 TROUBLESHOOTING hot surface hazards WARNING Electrical shock and Before attempting maintenance of any kind on the Thermolator you must stop the unit disconnect and lockout the main power i Supply and allow the unit to cool to less than 100 F 38 C Disconnect and lockout the main power Remove the top panel of the Thermolator Remove the heater cap Use a 1 4 inch open end wrench to remove the three bolts that hold the cap to the heater tank Remove the heater wiring harness Label the wiring layout of the heater terminals wires are labeled 2T1 2T2 2T3 and GND Then unscrew the lock ing screws on the wiring harness and remove the wires Heat al PS
70. ls the controller to perform the next calibra tion 9 Exit Calibration Mode Press and hold the Select 9 key for 3 seconds to exit the Calibration Mode You can now proceed to the next test in Test Mode or disable Test Mode and resume normal operation TO DISABLE TEST MODE complete steps 2 through 5 in Performing System Tests setting dip switch 6 to OFF instead of ON UGH002 0514 Thermolator heaTrac TH 1 and TH 2 control CALIBRATING TEMPERATURE SENSORS 5 11 MAINTENANCE LOGGING OPERATING Houns 5 12 MAINTENANCE You can see the total numbers of operation by accessing the Total Operating Hours Log in Test Mode 1 2 Enable Test Mode Press any key to display the first test menus Thermolator TW 2 Microprocessor CONAIR Pump Setpoint Actual Run Heater L 2 Venting Valve Test Mode A V SPI Communication Auto Start Display Low Water Pressure Temperature was Supply Temp High Temp Safety High Deviation Return Temp Low Deviation Average Temp Address Silence Baud Rate Purge Valve E Alarm 3 Index through test menus to the operating log Press and hold the Setpoint key for 3 seconds to index to each test menu until the Actual display indicates Log The Setpoint display indicates the total number of operat ing hours in 100 hour units Exit the Operating Hours Log
71. ly qualified personnel should perform procedures that require access to the electrical enclosure while power is on 2 CAUTION Hot surfaces Surface temperatures inside the Thermolator can exceed 500 F 260 C Always allow the unit to cool to below 100 F 38 C before opening servicing or disassembling the unit UGH002 0514 Thermolator heaTrac TH 1 and TH 2 control ATTENTION READ THIS SO NO ONE GETS HURT INTRODUCTION 1 3 READ THIS SO ONE GETS HURT 1 4 INTRODUCTION WARNING Hazardous substance The electrical contactors in the Thermolator have mercury contactors Mercury is considered a hazardous sub stance and must be dealt with accord ingly Material Safety Data Sheet 7439 97 has been included in the instruction packet This sheet explains the potential hazards how to avoid them and how to clean up and dispose of the mercury if it spills Thermolator TH 1 and TH 2 UGH001 0514 DESCRIPTION What is the Thermolator healrac 2 2 Typical applications 2 2 0 How it works 2 5 Specifications heaTrac 2 6 Features and options 2 8 UGHO002 0514 Thermolator heaTrac TH 1 and TH 2 WHAT IS THE THERMOLATOR HEATRAC TYPICAL APPLICATIONS 2 2 DESCRIPTION The Thermolator heaTrac circulates oil at a temperature to add or remove heat as needed to maintain a uniform temperature setpoint in the p
72. ly until a green light appears next to the parame ter you want to program or view NOTE Default settings for the devia tion setpoints are High setpoint 10P F Low setpoint 10P F A warning alarm occurs indicator light turns red whenever the actual temperature is outside this setpoint range Recommend setting 2 10P OPERATION Setpoint adjustment buttons Press A or V to enter tempera ture and SPI parameters Press A to increase a value Press V to decrease a value TIP Press and hold the button for faster scrolling speed Thermolator heaTrac TH 1 and TH 2 control Test Mode on unit disabled Alarm Press to acknowledge the alarm light and silence the optional audible alarm The alarm light will flash until the cause of the alarm condition is fixed UGH002 0514 normal operating functions can be controlled from the TH 2 CoNTROL TH 2 control panel including the optional mold purge Setpoint display The window displays the setpoints entered for the fluid temperature the high and low temperature devia tion alarms the SPI baud rate and the SPI address Run Stop Press the RUN button to start normal operation Press STOP to stop the temperature control unit Running Stopped Alarm flashing Actual values display The green window displays the temperature at the middle of the mold This temperature is calculated as an average of the tempera tures of t
73. molator 0x72 NOTE Both High and Low Temperature Deviation commands set the same variable Use only one of these commands to avoid problems See the tables on the following pages for the SPI status words and BIT positions for Process Status Machine 1 Status and Machine 2 status For more information on the SPI protocol you can obtain the SPI Communication Protocol Manual by contacting The Society of the Plastics Industry Inc 1801 K Street NW Suite 600K Washington DC 20006 202 974 5200 Fax 202 296 7005 www plasticsindustry org IMH001 0300 THERMOLATOR SPI CoMMANDS APPENDIX D 1 SPI Status WoRDS Status Process Poll 0 20 0x40 SPI STATUS WORD Reserved Reserved Alarm Process Alarm System Reserved Reserved w Alarm High temperature deviation mE Alarm Low pressure condition Alarm Low temperature deviation Alarm Low flow 7 Alarm High pressure condition Alarm Machine Reserved 34 Processing Word BIT position 2 1 SET SET C E ROM checksum E M Hi temp safet Prog Hi temp safety Output monitor failure E Low water pressure SET High deviation alarm SET SET SET Low deviation alarm SEI SET SET Prog Lo temp safet Pump overload Low water level Test Mode Phase error wn m o m NOTES The SPI list defines the Processing bit as being cleared if the unit is not processi
74. n this literature are made in good faith and are believed to be correct as of the below date You the user or specifier should indepen dently determine the suitability and fitness of Paratherm heat transfer fluids for use in your specific application We warrant that the fluids conform to the specifications in Paratherm literature Because our assistance is furnished without charge and because we have no control over the fluid s end use or the conditions under which it will be used we make no other warranties expressed or implied including the warranties of mer 1996 Paratherm Corporation 1050 Colwell Road Conshohocken 19428 USA E mail techinfo paratherm com Website http www paratherm com 610 941 4900 800 222 3611 chantability or fitness for a particular use or purpose recommendations in this bulletin are not intended nor should be construed as approval to infringe on any existing patent The user s exclusive remedy and Paratherm s sole liability is limited to refund of the purchase price or replacement of any product proven to be otherwise than as warranted Paratherm Corporation will not be liable for incidental or consequential damages of any kind Some product names of companies found in Paratherm literature are registered trademarks This statement is in lieu of individually noting each Fax 610 941 9191 The SPI commands supported by Conair Thermolator mold S MANDS temperature
75. nd 5 to OFF Set dip switch 6 to ON Close the electrical enclosure and restore power to the unit The control displays tSt The Test Mode LED lights TH 2 Microprocessor CONAIR Pump Heater Cooling Venting Valve C 4 Setpoint F Actual SPI Communication Auto Start Low Oil Alarm Supply Temp Low Water Flow Alarm High Temp Safety Display Alarm 6 Press any button to display the first test menu Test mode provides the following menus Key Display Test Input Test Output Test Calibration Total Operating Hours Output Monitor Enable Disable After performing each test hold the Setpoint for 3 seconds to index to the next test menu The procedure for each test is described on the following PERFORMING SYSTEM TESTS IMPORTANT All normal operating functions are disabled while Test Mode is enabled To return to normal operation you must disable Test Mode To disable Test Mode repeat steps 2 through 5 setting dip switch 6 to OFF instead of ON pages UGH002 0514 Thermolator heaTrac TH 1 and TH 2 control MAINTENANCE 5 5 Key Display Test the function of displays LEDs KEv DisPLAY and buttons on the control panel TEST 1i Enable Test Mode 2 Press any key If necessary index to the Key Display menu TH 2 Microprocessor CONAIR Pump Setpoint un Hea
76. ned Did a heater contactor With power on and the in the maintenance and fail Heater LED lit Check the repair of electrical sys amp draw on each of the three tems and industrial phase legs to the heater appliances should match the FLA listed for the heater on the unit nameplate Replace the heater contactor if there is a voltage imbalance greater than 10 See Replacing the Heater Contactor Is the low deviation tem Increase the low deviation set perature set too low ting The recommended setting is 2 F to 10 F below the process setpoint Is the Thermolator cor Review specifications and rectly sized for the appli selection guidelines that apply cation to heater and pump sizes in temperature control units 6 8 TROUBLESHOOTING Thermolator heaTrac TH 1 and TH 2 UGH002 0514 The Thermolator has detected a problem that could lead to a shut down condition if it is not corrected Alarm LED lights Thermolator continues operating control displays a red LED or alarm code indicating the source of the problem Alarm High Deviation The Thermolator will not cool down or takes too long to cool down The actu al temperature of fluid supplied to the process is higher than the setpoint deviation allows N wARNING The Thermolator should be tested and repaired only by qualified techni cians equipped with the correct tools and trained in the maintenance and repair of e
77. ng otherwise it is SET Elsewhere on the chart e If a bit is not shown to be SET it is cleared e The System Alarm bit is SET if an alarm is present It is the logical OR of Process alarm and Machine alarm e Processing System Alarm Process Alarm and Machine Alarm bits are repeated for Process Status Machine 1 Status and Machine 2 Status APPENDIX D 2 THERMOLATOR SPI COMMANDS IMH001 0499 SPI STATUS 5 Status Machine 1 Poll 0x20 0x42 SPI STATUS WORD Alarm Phase Alarm Low current Alarm High current Alarm Low volts Alarm High volts Alarm Low temperature safety limit Alarm Process mE Alarm Low pressure safety limit RUE Alarm High temperature safety limit 224 Alarm High pressure safety limit 24 Alarm Machine EU Alarm System Reserved C Reserved 9 Processing E 45 cis cis lt gt Word BIT position 2 SET SET A D converter error SET SET CJC Error SET SET RAM hardware ROM checksum Probe Failure E M Hi temp safet SET SET SET Prog Hi temp safety SET SET SET Output monitor failure SET 5 Low water pressure SET High deviation alarm Low deviation alarm Prog Lo temp safet E ET SET SET Phase error SET 02 ITI 92 90 m 142 42 The SPI I O list defines the Processing bit as b
78. not be started until the temperature difference is at least 25 F Auto Tune timed out Auto Tune will time out if a stable process value cannot be obtained 5 minutes into the tune or if the tuning process takes longer than 30 minutes If this error occurs verify that you followed every requirement under To ensure a successful Auto Tune and perform a second tune Invalid PID constants were generated The most likely causes of this error is a tune started inappropriately or an external ele ment i e loose thermocouple that upset the process while tuning was in progress Verify that you followed every requirement under To ensure a successful Auto Tune and perform a second tune UGHO002 0514 Thermolator heaTrac TH 1 and TH 2 control OPERATION 4 9 MAINTENANCE Maintenance schedule 5 2 Accessing the Thermolator enclosure 2 5 3 Checking fluid level in the rIeservolr 5 4 Performing system tests 5 5 Key Display Test 5 6 e input Testo 5 7 5 8 0 Disabling or enabling output monitors 5 9 Calibrating temperature SENSOIS nc DIDI 5 10 Logging operating hours 5 12 UGHO002 0514 Thermolator heaTrac TH 1 and TH 2 Thermolator heaTrac TH 1 and TH 2 oil temperature con P REVENTATIVE trollers are essentially maintenance free However to maintain the best performance we recommend the
79. ntact however similar chemical composition products applied to the skin of laboratory animals resulted in minimal to slight dermal irritation INHALATION Paratherm NF has a low vapor pressure and is not expected to present an inhalation hazard at ambient conditions Caution should be taken to prevent aerosolization or misting The permissible exposure limit PEL and threshold limit value TLV for the fluid as oil mist is 5 mg m3 Exposures below 5 mg m3 appear to be without significant health risk INGESTION Ingestion is relatively non toxic unless aspiration occurs Paratherm NF has laxative properties and may result in abdominal cramps and diar thea See Personal Health Protection section below EYE CONTACT Immediately flush eyes with large amounts of water and continue flush ing for 15 minutes If fluid is hot treat for thermal bums and take victim to hospital immediately SKIN CONTACT Remove contaminated clothing If fluid is hot submerge injured area in cold water If victim is severely burned take to a hospital immediately INHALATION Paratherm NF has a low vapor pressure and is not expected to present EYE PROTECTION Eye protection is not required under conditions of normal use If the fluid is handled such that it could be splashed into eyes wear plastic face shield or splash proof safety goggles SKIN PROTECTION No skin protection is required for single short duration exposures For prolonged or repea
80. ntamination or degradation Replace as required Quarterly every 3 months O Inspect power cords wires and electrical connections Check for loose or frayed wires burned contacts and signs of overheated wires Check exterior power cords to the main power source and from the electrical box to the pump and heating elements Check the ground wire and thermocouple connections Replace any wire that appears damaged or has worn or cracked insulation 5 2 MAINTENANCE Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 PREVENTATIVE Annually every 12 months Test and calibrate the unit s control systems Thermolator s Test Mode checks the operation of displays control buttons inputs and outputs You Sc HEDULE can also calibrate the supply and return thermocouples See Performing System Tests in this section WARNING Electrical shock and ACCESSING THE hot surface hazards Before attempting maintenance of any kind TH on the Thermolator you must stop the unit disconnect and lockout the main power ENCLOSURE A supply and allow the unit to cool to less than 100 F 38 C To access the Thermolator enclosure Remove the top access panel by lifting straight up Remove the side panels by lifting straight up UGH002 0514 Thermolator heaTrac TH 1 and TH 2 control MAINTENANCE 5 3 The heaTrac TH 1 and 2 models separa
81. ntation of the control panel Do not mount the detached TH 2 control panel to a hot surface The control panel on the TH 1 series Thermolators can be swiveled raised and lowered to provide easy viewing and access The TH 2 control panel also can be mounted up to 50 feet from the unit using a remote control cable and the mag netic back on the back of the panel To raise and swivel the control panel Grasp the black control panel handles and pull upward Use the handles to rotate the control panel Do not rotate the panel 360 degrees To lower the control panel Grasp the black control panel handles and rotate the control until it is aligned with the unit Do not rotate the panel 360 degrees Gently push down on the handles until the control panel is flush with the unit To detach the TH 2 control panel The TH 2 control panel may be removed and mounted up to 50 feet from the unit Do not stretch the cable The cable is available in various lengths so that you can order the appro priate cable for your installation Grasp the black control panel handles and pull upward Use the magnetic back to mount the control panel in the remote location Connect the remote mounted control to the unit with the cable provided 4 4 OPERATION Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 TH 2 Microprocessor E NTERIN G A Pump Setpoint Actual Heater PASSCO D E 0 m F Cooling Valve l
82. o prompt you to remove power to the unit IMPORTANT If RUN is not pressed the new passcode will not be saved 8 Turn off power the unit Disconnect and lock the main power supply 0 Open the electrical enclosure 0 1 11 Close the electrical enclosure and restore power to the unit A passcode now is required to change system parameters Disabling Passcode Protection To disable passcode TH 2 Microprocessor protection and allow Setpoint Actual universal access to Mo o utu system parameters Aay 1 Follow Steps 1 through 5 in the previous section US on enabling pass code protection 2 Hold down the setpoint adjustment button to select OFF as the new passcode 3 Follow steps 7 through 11 in the previous section UGH002 0514 Thermolator heaTrac TH 1 and TH 2 control INSTALLATION 3 1 1 SELECTING THE A WARNING Electric shock hazard This equipment is powered by high voltage Always TEM PERATURE disconnect and lock out the main power source CONTROL POINT before opening the unit or the electrical enclosure to modify factory settings Failure to disconnect and lock out the main power source can result in severe TH 2 personal injury models control the process temperature based upon the average of the temperatures recorded at the supply to process and return
83. olators use type thermocou CALI BRATI NG ples to sense the temperature in the return and supply process TE MPERATURE lines These thermocouples should be calibrated annually or when a new thermocouple is installed to ensure correct opera SENSORS im The Thermolator s Calibration Mode provides zero and span calibration of both the supply and return line thermocouples Special Tools Needed You access the Calibration Mode while in Test Mode type thermocouple calibrator 1 Enable Test Mode See Performing System Tests 2 Press any button to display the first test menu 3 Select the Calibration Mode menu Press and hold the Setpoint 5 key for 3 seconds to index to each test menu until the controller indicates SC L in the Actual display TH 2 Microprocessor Pump Heater m Cooling Valve 5 d kd Venting Valve Test Mode SPI Communication Auto Start Low Oil Alarm Temperature Supply Temp Low Water Flow Alarm Setpoint T Actual Display High Deviation Return Temp High Temp Safety Low Deviation Average Temp Address ni Baud Rate Cool Down Alarm 4 Release the Setpoint key You are now in calibration mode Each press and release of this key will exit the current calibration and start the next calibration The table below lists the calibrations that will be performed SETPO
84. on Average Temp Address Silence Baud Rate Coo Down To change this setting move Dip Switch 1 on the control circuit board 1 Disconnect and lock out main power to the Thermolator 2 Open the electrical enclosure 3 Change Dip Switch 1 to OFF for 4 Close the electrical enclosure and restore main power to begin operating UGH002 0514 Thermolator TH 1 and TH 2 CHANGING TEMPERATURE UNITS NOTE All dip switch illustra tions in this manual show switches 7 OFF and 8 set to ON Do Not Change these settings INSTALLATION 3 9 ENABLING AND WARNING Electric shock hazard DISABLING This equipment is powered by high voltage Always disconnect and lock out the main power source PASSCODE before opening the unit or the electrical enclosure to modify factory settings Failure to disconnect and PROTECTION lock out the main power source can result in severe personal injury The TH 1 and TH 2 provide the ability to protect system parameters from unauthorized changes during normal operat ing mode When system passcode protection is enabled the following parameters cannot be changed unless you enter the correct passcode The Process Setpoint High Deviation Alarm Setpoint Low Deviation Alarm Setpoint Baud Rate selection for serial communications Address selection for serial communications When the unit is turned on for the firs
85. otify Conair in writing of any claim and pro vide a customer receipt and other evidence that a claim is being made Except for the Equipment Guarantee and Performance Warranty stated above Conair disclaims all other war ranties with respect to the equipment express or LIMITATIONS implied arising by operation of law course of dealing usage of trade or otherwise including but not limited to the implied warranties of merchantability and fitness for a particular purpose APPENDIX 2 WARRANTY INFORMATION 1MS0003 0796 PUMPS SERIES INSTALLATION AND SERVICE INSTRUCTIONS This bulletin must be read completely before installing operating or servicing the pump WARNING A If any of the items listed below are violated serious injury or death from burns caused by hot oil may occur DO NOT perform service or maintenance when the pumping system is pressurized or hot serious injury or death from burns caused by hot oil may occur DO NOT operate the pump in a manner that it was not intended to be used DO NOT install for use in an open environment where people are present DO NOT install in a rigid piping system that does not allow the pipe to expand and cause the pump to be strained DO NOT continue to operate the pumping system when a known leak exists or the system continues to smoke DO NOT continue to operate the pump when unusual noise or vibration occurs
86. ower up The CPU and or PROM chip U1 or U2 is not making good contact with its socket or the PROM chip has failed A failed CPU failed moth erboard software bug or electrical noise caused an internal software error The CPU tried to execute an illegal software instruc tion due to electrical noise or a failed motherboard A failed CPU failed moth erboard software bug or electrical noise caused an internal software error The memory has exceeded its usable life or there is a software bug This error occurs only after changes have been made to non volatile memory either through the operator panel or SPI Thermolator heaTrac TH 1 SYSTEM ALARMS Solution Make sure all connections on the motherboard are solid Operate unit in a noise free environment If error persists contact Conair service Make sure the CPU and PROM chips are seated correctly in the sockets If error persists contact Conair service Cycle power to the unit If the problem persists contact Conair service technicians You may need to replace the mother board Make sure all connections to the motherboard are solid and that the unit is operating in a noise free environment If error persists contact Conair service Cycle power to the unit If the problem persists contact Conair service technicians You may need to replace the mother board Cycle power to the unit Contact Conair service if an operating parameter such
87. oxygen In case of contact Immediately flush eyes or skin with plenty of water for at least 15 minutes while removing contaminated clothing and shoes Wash clothing before using again MSDS 7439 97 6 MERCURY UGH002 199 Material Safety Data Sheets 5 DS 5 Fire and Explosion Data Fire and explosion Mercury presents a slight fire and explosion hazard when 7439 97 6 hazards exposed to heat or flame Mercury vapors are heavier than air may travel a considerable distance to source of ignition and flash back M E RC U RY Firefighting media Dry chemical carbon dioxide water spray or foam For larger fires use water spray fog or alcohol foam 1984 Emergency Response Guidebook DOT P 5800 3 Firefighting Use agents suitable for type of fire Use water in flooding procedures amounts as a fog Avoid breathing corrosive and poisonous vapors Keep upwind Move containers from the fire area if possible Cool containers exposed to flames with water from side until well after fire is out 1984 Emergency Response Guidebook DOT P 5800 3 6 Spill and Disposal Procedures EPA Hazardous Waste Number U151 Toxic Waste If spilled or discharged Wear self contained breathing apparatus and full protective clothing Clean up the spill immediately Collect and store using a suction pump with a capillary tube Calcium polysulfide with excess sulfur should be sprinkled into cracks or ina
88. ped with your equipment These diagrams are the best reference for correcting a problem The diagrams also will note any custom features such as special wiring control or plumbing options not covered in this User Guide Verify that you have manuals for other equip ment in the process line Solving problems may require troubleshooting malfunctions or incorrect operating procedures on other pieces of equipment 1 If an alarm is present note any indicator lights and messages shown on the control panel These indicators will help you discover the cause of the problem more quickly The Thermolator is equipped with many safety devices Do not remove or defeat them Improper corrective action can lead to hazardous conditions and should never be attempted to sustain production WARNING This machines should be adjusted and serviced only by qualified techni cal personnel who are familiar with construc tion and operation of this type of equipment WARNING Hot surfaces and liquids Allow the Thermolator to cool to below 100 F 38 C before servicing the unit DANGER Voltage hazard Troubleshooting the electrical system of this equipment requires use of precision electronic measuring equipment and may require access to the electrical enclosure while power is on Exposure to potentially fatal voltage levels may be unavoidable These troubleshooting proce dures should be performed only by qualified electrical technicians who know
89. personal injury if it is not corrected SHUT DOWN The Alarm LED lights and the STOP RUN LED flashes red ALARMS The Thermolator automatically shuts down The control displays red LED or alarm code indicating the source of the problem Alarm Possible cause Solution Is the pump rotating Check pump rotation against the wrong direction the arrow stamped on the pump If the pump is rotating in the wrong direction discon nect and lockout the main power source Open the electri cal enclosure and reverse any two leads on the power connection The incoming power is out of phase A leg may have failed or is disconnected NOTE This alarm is available only on Has one of the main sup Disconnect power and open TH 2 models ply wire leads become the electrical enclosure Check disconnected for loose connections in main supply and on motherboard Has the indicated device Disconnect and lockout the blown a fuse main power Open the electri cal enclosure Check for loose wires and incorrectly installed jumpers or terminal blocks associated with the fuse error Replace the fuse if necessary See Checking and Replacing Cooling valve fuse Is the correct device Replace the fuse then enter being used for this fuse Test Mode Turn off the Output location Monitor associated with the fuse location and test outputs See Performing System Tests and Disabling or Enabling Pump fuse Heater fuse Vent v
90. power Open the electrical enclosure door Turn the screw on the front panel counterclockwise to open Check the overload If the yellow button is out the overload has tripped Press the blue button to reset the overload Verify that the overload trip point does not exceed the FLA for the pump Disconnect and lockout the main power Open the electrical enclosure door Turn the screw on the front panel counterclockwise to open Locate the pump overload module attached to the pump motor starter Disconnect the three power leads from the over load module to the pump motor Note the placement of each lead and label as needed 5 Disconnect auxiliary wiring on the overload module 6 Remove the overload module Loosen the three screws that connect the overload module to the motor con tactor Pull the overload module down to release it from the starter bs 7 Reverse these steps to install the new overload module 8 Set the module reset mode to 9 M for manual Motor contactor 27716 9 Set the proper FLA trip point 6 14 TROUBLESHOOTING Do not exceed the FLA for the pump motor Thermolator heaTrac TH 1 and TH 2 UGH002 0514 10 11 UGH002 0514 Disconnect and lockout the main power supply Open the electrical enclosure door Turn
91. power to the unit 3 Enable Auto Tune Open the electrical enclosure Set dip switch 2 to ON Close the electrical enclosure and restore power to the unit 4 Restore power to the unit Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 TH 2 Microprocessor PERFORMING AN Setpoint pe iE Actual rd AUTO Tu N Cooling Venting Valve Test Mode v SPI Communication Auto Start Displa Play Low Oil Alarm Select Temperature Select Supply Temp Low Water Flow Ala 6 High Deviation Return Temp High Temp Safety Low Deviation Average Temp Address F Silence Baud Rate Cool Down Alarm 5 Press the Setpoint Select button simultaneously to begin the Auto Tune The Actual display will flash and the current process temperature to indicate that an Auto Tune is underway If Auto Tune is successful the controller automatically starts controlling using the new PID parameters If you press the STOP button or a fault occurs during the Auto Tune the control enters stop mode and Auto Tuning immediately terminates The actual display stops flashing At If a fault occurred the control will display the appro priate error message ERROR MESSAGE ERROR DESCRIPTION Insufficient setpoint process deviation If the absolute value of setpoint process value is less than 25 The Auto Tune can
92. quid UNUSUAL FIRE AND EXPLOSIVE CONDITIONS Dense smoke may be generated while burning Carbon monoxide carbon dioxide and other oxides may be generated as products of combustion STABILITY THERMAL LIGHT ETC Stable CONDITIONS TO AVOID None HAZARDOUS POLYMERIZATION Will not occur INCOMPATIBILITY MATERIALS TO AVOID May react with strong oxidizing agents HAZARDOUS DECOMPOSITION PRODUCTS If burned will produce carbon dioxide and carbon monoxide STEPS TO BE TAKEN IF FLUID IS RELEASED OR SPILLED Consult health effect information in Section III Personal Health Protection Information in Section V Fire Protection Information in Section VI and Reactivity Data in Section VII Notify appropriate authorities of spill Contain spill immediately Do not allow spill to enter sewers or watercourses remove all sources of ignition Absorb with appropriate inert materials such as sand clay etc Large spills may be picked up using vacuum pumps shovels buckets or other means and placed in drums or other suitable containers HANDLING AND STORAGE REQUIREMENTS Do not transfer to unmarked containers Store in closed containers away from heat sparks open flame or oxidizing materials Paratherm NF is not classified as hazardous under DOT regulations Fire extin guishers should be kept readily available See NFPA 30 and OSHA 1910 106 Flammable and combustible liquids 646 F 347 C 10 fraction BOILING POINT MELTI
93. r than the pump s capacity Is the motor overload faulty or set incorrectly Is the pump working properly Solution Supply voltage should match the rating on the pump name plate If voltage is correct check wiring connections Review pump sizing for the application 0 Decrease the water flow from the process Disconnect the power and open the electrical enclosure Verify that the overload is set to trip at the proper amperage which should not exceed the FLA Manually trip and reset the overload If the problem contin ues replace the overload See Resetting and Replacing Overloads Replace the pump if supply voltage wiring and overload settings are correct but the pump continues to draw exces sive current Thermolator heaTrac TH 1 and TH 2 control UGHO002 0514 The Thermolator has detected problem that could lead to equip ment damage or personal injury if it is not corrected Alarm LED lights and the STOP RUN LED flashes red Thermolator automatically shuts down control displays a red LED or alarm code indicating the source of the problem Alarm e High Temp Safety The actual tempera ture of oil supplied to the process exceeds the 510 F safety switch limit WARNING Only qualified electri cal service personnel should examine and correct problems that require opening the unit s electrical enclosure or checking electrical current to diagnose the ca
94. rator The electrical hookup also should run through a fused dis connect sized for the nameplate amperage and conforming to Article 250 of the National Electrical Code 1 Open the unit s electrical enclosure 2 Insert the main power wire through the knockout A hole in the right side of the enclosure 3 Secure the power wire with a rubber compres sion fitting or strain relief 4 Connect the power wires to the terminals Connect the three hot wires to L1 L2 and L3 on the terminal block 5 Connect the ground wire to the copper grounding mount If you have installed a disconnect device follow the manufacturer s wiring instructions IMPORTANT Before initiating power to the unit O Check the system for leaks O Verify that the disconnect fuse b minimum wire size meet the voltage phase frequency and amperage specifications stated on the name plate mounted on the side of the unit O Verify that resistance to ground on each phase is at least 1 meg ohm Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 WARNING Only qualified personnel TESTING THE should perform this procedure INSTALLATION Parts of this test require opening the unit while it is energized Only qualified personnel who have been trained in the use of electrical testing devices and in avoiding the safety hazards involved in safely troubleshooting t
95. ress to turn the feature on Press again to turn it off Display Select button Press repeatedly until a green light appears next to the parameter you want to program or view in the Actual values window See the User Guide for pro gramming information Thermolator heaTrac TH 1 and TH 2 control Status lights The lights indicate the operating status of the listed components Except in Test Mode and Auto Start the lights indicate Off or inactive or active Alarm condition Test Mode is used for initial pro gramming When test mode is enabled normal operation is disabled Test Mode off Test Mode on unit disabled Auto Start allows you to start and stop the Thermolator from a remote switching or timing device such as the processing machine control This feature can only be enabled by configur ing a dip switch on the control motherboard Disabled Auto Start not available xti flashing Enabled unit can start at any time On and under control of the remote device OPERATION POSITIONING CAUTION Improper use of the swiveling THE CONTROL control panel can damage the unit Do not rotate the control panel 360 PANEL degrees This will twist and possibly damage the control wiring and connections to the motherboard in the electrical enclosure Do not use the control panel handles control cables to move the Thermolator The handles are designed only for orie
96. rocess The heaTrac offers an enhanced TH 2 control with additional diagnostic features and autostart capa bilities Both the TH 1 and TH 2 models are available in single or multiple zone configurations Multiple zone models can con trol up to two temperatures at different locations in the process Two zone models have common cooling water mani folds and electrical connections The best model for your application depends on the process temperature you need to maintain and the quality of the cool ing water supply TH 1 and TH 2 models separate the cooling water from the process fluid which is held in a reservoir All heaTrac models are recommended for Process temperatures up to 500 F 260 C Use with chiller water or with properly treated and filtered tower or city water Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 Thermolator heaTrac models maintain the process tempera ture by heating and cooling fluid for the process circuit The process fluid heat transfer oil which is stored in a reservoir is isolated from the optional cooling water supplied by a chiller tower or other source The temperature of the process fluid is measured as it leaves the unit s heater tank The fluid then flows through the To Process line to the mold or process The fluid returns to the unit through the From Process line for reheating or cooling If the process temperature is below the se
97. s on if the actual temperature is below setpoint The optional cool ing valve is active if the actual temperature is above set point The test is over Proceed to initial setup if the unit operated normally refer to the TROUBLESHOOTING section if it did not UGH002 0514 Thermolator heaTrac TH 1 and TH 2 control INSTALLATION 3 7 INITIAL SETUP 3 8 INSTALLATION AN WARNING Electric shock hazard This equipment is powered by high voltage Always disconnect and lock out the main power source before opening the unit or the electrical enclosure to modify factory settings Failure to disconnect and lock out the main power source can result in severe personal injury The factory set parameters and operating modes will satisfy most applications But you can change some settings and enable or disable features as needed You can modify the parameters for high and low process tem perature deviation warnings from the control panel See SETTING SETPOINT DEVIATION PARAMETERS Dip switches on the motherboard inside the TH 1 and TH 2 electrical enclosure allow you to O Select the units of measure for tem perature displays O Enable password protection O Enable the Auto Tune O Enable the Auto Start feature O Enable the Test Mode O J Select the source point of tempera ture control Display units in F Display units Auto Tune disabled Auto Tune enabled Passcode protect Password reset modi
98. s present It is the logical OR of Process alarm and Machine alarm e Processing System Alarm Process Alarm and Machine Alarm bits are repeated for Process Status Machine 1 Status and Machine 2 Status APPENDIX D 4 THERMOLATOR SPI COMMANDS 001 0499 Material Safety Data Sheet An explanation of the terms used in this document may be found in OSHA 29 CFR 1910 1200 which is available from OSHA regional or area offices 1 Chemical Identification Substance Mercury CAS Number 7439 97 6 Chemical name Mercury Synonyms Quicksilver Liquid silver Formula HG Molecular weight 200 59 Trade name Not applicable Chemical family Metal The Conair Group Inc One Conair Drive Pittsburgh PA 15202 412 312 6000 Material Weight Supplier of MSDS information Emergency contact For CHEMTREC assistance call 800 424 9300 in the U S 703 527 3887 international 2 Composition and Exposure Limits Exposure Limits Mercury 100 0 05 mg m Threshold Limit Value skin TWA 0 1 mg m Permissible Exposure Limit PEL 3 Hazards Identification Hazard Ratings 0 no hazard 4 extreme hazard Health 4 Extreme Poison Carcinogenic NTP No Flammability 0 None IARC No Reactivity 1 Slight Z List No Contact 3 Severe Life OSHA Reg No Personal Health Effects WARNING Mercury is a dangerous poison and an extreme contact hazard Mercury may b
99. shaft position 2 The housing may be rotated to a horizontal or vertical discharge to fit the particular piping installation 3 Rigid and supported piping must be used that will not strain the pump housing when temperature changes are made during the use of the pump 4 The piping system must be free of foreign material and moisture before start up 5 Pipe thread sealing compound must be used on the NPT flanges that is compatible with the fluid being pumped and is rated for the temperature requirements 6 The installation should permit adequate circulation of air to provide proper cooling of the motor and pump seal housing 7 Do not install in a sealed enclosure or insulate the pump adapter and motor The motor and or pump seal may fail from excessive heat 8 A good installation will have an enclosure that provides adequate air flow of ambient air to the motor of the pump B 2 START UP 1 Follow all requirements and recommendations from the heat transfer fluid manufacturer for fill start up and use 2 Check for leaks before insulating the piping system 3 Check for proper shaft rotation by jogging the power and observing the fan clamp Rotation arrows are provided on pump housing 4 The seal cavity inside the pump will internally vent during fill and start up 5 A small amount of oil may leak from the seal cavity at the shaft this is normal for a new installation and will stop after approxima
100. t point the heater elements inside the heater tank are energized TO PROCESS VENT OVERFLOW PIPE TO AN APPROPRIATE COVERED VENTED METAL RECEPTACLE COOLING WATER OUTLET FROM PROCESS UGH002 0514 COOLING WATER NLET HTX OPTIONAL If the temperature is above the setpoint value the cooling valve opens Cool water enters the cooling piping and circulates through a tube heat exchanger to cool the process fluid 3 Note cooling is optional FILL Thermolator heaTrac TH 1 and TH 2 control How Ir 5 GALLON RESERVOIR HTR OPTIONAL The vent line allows warm process fluid to expand to the reservoir The reservoir supplies process fluid through a make up line as needed The pump moves process fluid from the mixing tank to the heater tank Pressure is mea sured after the pump The temperature of the process fluid is measured as it flows into the suction tank through the From Process line DESCRIPTION 2 3 Dimensions and performance characteristics vary according to the model voltage and components selected See the cabinet style reference chart to determine dimensional information for your specific model Additional technical information can be found in the Appendix of this User Guide SPECIFICATIONS
101. t time passcode protec tion is disabled To enable passcode protection 1 Disconnect and lock out main power to the unit 2 Open the electrical enclosure 3 Set dip switch 3 to ON and switches 5 and 6 to OFF Close the electrical enclosure and restore power to the unit 5 Press any TH 2 Microprocessor button when Setpoint x Actual the control dis Pas St 6 plays Pas rSt AY gt EH Passcode Reset Display The control will 2 NOTE All dip switch illustra display the last tions in this manual show passcode used switches 7 OFF and 8 set to ON Do Not Change 6 these settings Select a new passcode using the and V setpoint adjustment buttons Stop pressing the setpoint buttons when the passcode you want appears in the setpoint display window Selecting OFF as the passcode will disable the passcode feature 3 1 0 INSTALLATION Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 TH 2 Microprocessor E NAB LI N G AN D Pump Setpoint Pn Actual Heater D lt LI N G I f I7 47 9 zm ud PASSCODE PROTECTION Low Oil Alarm Temperature eleci Supply Temp Low Water Flow Alarm High Deviation Return Temp High Temp Safety Low Deviation J Average Temp Address Baud Rate Cool Down Alarm 7 Press the RUN button to save the passcode The control will display OFF t
102. te the cooling water from the process FLUID LEVEL IN fluid which is held ina sg A reservoir inside the unit TH E R ES E RVO This reservoir should be m kept at least three quar ters full of the process fluid From process e You can check the fluid level in the reservoir Cooling water in using the sight glass ON Cooling water out ORS Pressure for optional relief valve the back of the heat exchanger 0 Thermolator To fill the reservoir 1 2 3 4 Disconnect and lockout power and remove the top panel of the Thermolator Locate the reservoir near the top of the unit Locate the fill port at the top of the reservoir Refill the reservoir Monitor the level using the sight glass on the back of the unit Replace the top panel of the Thermolator 5 4 MAINTENANCE Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 The TH 1 TH 2 Thermolators provide a Test Mode that tests displays and keys on the control panel as well as inputs and outputs The Test Mode also allows calibration of the sup ply and return line thermocouples System tests and calibration should be performed annually To 1 2 3 4 5 enable Test Mode Press to shut down the Thermolator Disconnect and lock out main power to the unit then open the electrical enclosure Set dip switches 3 a
103. ted correctly A WARNING Hazardous Substance Thermolators use mercury displacement contac tors Mercury is considered a hazardous substance and must be dealt with accordingly See Material Safety Data Sheet 7439 97 6 for information on the how to avoid the potential hazards and how to clean up and dispose of mercury if it spills 6 1 6 TROUBLESHOOTING Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 The Thermolator uses two type thermocouples to monitor supply and return process temperatures One ther mocouple is installed in the wall of the heater tank at the to process outlet The other thermocouple is installed in the wall of the cooling tank at the from process inlet To check a thermocouple after a probe error 1 2 Disconnect and lockout the main power Open the electrical enclosure door Turn the screw on the front panel counterclockwise to open Unplug the appropriate thermocouple from the motherboard and install a jumper on the leads Refer to the wiring diagrams that came with your unit Restart the Thermolator If error message disappears replace the thermocouple If error message does not disappear replace the mother board See Replacing the Motherboard To replace a thermocouple 1 2 3 Disconnect lockout the main power Shut off the process valves if instal
104. ted exposures use impervious synthetic rubber clothing boots gloves aprons etc over parts of the body subject to exposure If handling hot fluid use insulated protective clothing boots gloves aprons etc RESPIRATORY PROTECTION Respiratory protection is not required under conditions of normal use If vapor or mist is generated when the fluid is heated or handled use an risk of pulmonary disease such as chronic lung inflammation This con dition is usually asymptomatic as a result of repeated small aspirations Shortness of breath and cough are the most common symptoms Aspiration may lead to chemical pneumonitis which is characterized by pulmonary edema and hemorrhage and may be fatal Signs of lung involvement include increased respiration rate increased heart rate and a bluish discoloration of the skin Coughing choking and gagging are often noted at the time of aspiration Gastrointestinal discomfort may develop followed by vomiting with a further risk of aspiration CARCINOGENICITY NTP No IARC No OSHA No an inhalation hazard at ambient conditions If vapor or mist is generat ed when the fluid is heated or handled remove victim from exposure 1f breathing has stopped or is irregular administer artificial respiration and supply oxygen if it is available If victim is unconscious remove to fresh air and seek medical attention Do not use compressed oxygen in hydrocarbon atmospheres INGESTION May act as a laxa
105. tely one hour 6 Do not allow the pump to run dry or continue to operate the pump when it is noisy vibrating or leaks are observed These noticeable signs give a warning that something is wrong with the equipment and must be investigated to avoid possible damage or injury from burns caused by hot oil MP PUMPS HTO SERIES HTO 80 ASSEMBLY INSTRUCTIONS Assemble drive sleeve 11 29166 impeller 1 25910 and nut 3 22655 Thread pipe plug 16 21255 into housing 14 25666 With the housing on the bench suction down place the impeller and drive sleeve assembly into the housing Assemble the adaptor 9 29160 to the housing with gasket 15 25662 between them Use six 3 8 16 bolts 18 21950 and washers 17 21266 Install three gaskets 6 29165 two carbon isolators 10 29158 and one O ring 8 29230 onto drive sleeve The O ring and one gasket go between the two carbon isolators The second gasket goes between the carbon isolators and the adaptor The third gasket goes between the carbon isolator and the seal housing Assemble seal 2 29168 onto the drive sleeve with a liberal amount of grease to prevent the seal from being damaged Press the ceramic seal seat into the seal housing 12 29162 Turn the seal housing over and press the lipseal 13 29167 into the other side of the seal housing NOTE Follow oil manufacturers guide for fill and start up The seal cavity will vent
106. ter 11 2 Cooling Valve Venting Valve 1 Ej Test Mode A v SPI Communication Auto Start Display Low Oil Alarm Temperature elec Supply Temp Low Water Flow Alarm High Deviation Return Temp High Temp Safety Low Deviation Average Temp Address Baud Rate Cool Down Press and hold the Setpoint key for 3 seconds to index to each test menu until the controller displays 45 4 Press any key to clear all displays 5 Repeatedly press any key to test displays With each key press a new segment of all six 8 segment LEDs and a select group of LED indicator lights will illu minate Exit the test and enter the next test Press and hold the Setpoint key for 5 seconds to exit and index to the next test 5 6 MAINTENANCE Thermolator heaTrac TH 1 and TH 2 control UGH002 0514 The Input Test verifies the function of inputs available on the various models of TH 1 or TH 2 Not all inputs are used on all models The performance evaluation of the inputs is based on the voltage sensing device VSD 1 Connect all inputs to the system Select the Input Test menu 2 Press any key to display the first test menus Press and hold the Setpoint 5 key for 3 seconds to index to each test menu until the controller displays InP TH 2 Microprocessor Setpoint er Actual vrai Display Temperature elect Supply Temp
107. the screw on the front panel counterclockwise to open Mark or label each wire connected to the mother board The orange shield is labeled with the connection information You must label the wires to ensure they are con nected to the correct terminals on the new motherboard LL I Disconnect the wires from the motherboard by pulling the terminal blocks up Loosen the screws hold ing the orange shield Remove the mother board and shield from the electrical enclosure as a unit Remove the mother board from the shield and replace with the new motherboard Reattach the shield and new motherboard in the electrical enclosure Tighten the screws N CONFIGURATION DIP SWITCH Reconnect the terminal blocks and wires to the new board Make sure you align the terminal blocks with the correct pins on the board Push the terminal blocks onto the pins taking care not to bend any pins Set dip switches 7 and 8 to the correct unit type Set Dip switch 7 to OFF and dip switch 8 to ON Program output monitors on the new board See Disabling or Enabling Output Monitors in the MAINTENANCE section Thermolator heaTrac TH 1 and TH 2 control REPLACING THE MOTHERBOARD IMPORTANT Always refer to the wiring dia grams that came with your Thermolator to locate specific electrical compo nents Illustrations in the User Guide are intended to be representative only 40062 TROUBL
108. this User Guide Thermolator heaTrac TH 1 and TH 2 control UGHO002 0514 We design equipment with the user s safety in mind You avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide N WARNING Improper installation operation or servicing may result in equipment damage or personal injury This equipment should be installed adjusted and serviced by qualified technical personnel who are familiar with the construction opera tion and potential hazards of this type of equip ment All wiring disconnects and fuses should be installed by qualified electrical technicians in accordance with electrical codes in your region Always maintain a safe ground A properly sized conductive ground wire from the incoming power supply must be connected to the chassis ground terminal inside the electrical enclosure Improper grounding can result in personal injury and erratic machine operation Do not operate the equipment at power levels other than what is specified on the the equip ment serial tag and data plate Ai WARNING Electrical shock hazard This equipment is powered by three phase main voltage as specified on the machine seri al tag and data plate Always disconnect and lock out the incoming main power source before opening the electri cal enclosure or performing non standard oper ating procedures such as troubleshooting or maintenance On
109. tive Do not induce vomiting due to possible aspira tion If vomiting occurs lower head below knees to avoid aspiration Seek immediate medical attention organic vapor respirator with a dust and mist filter All respirators must be NIOSH certified Do not use compressed oxygen in hydrocarbon atmospheres VENTILATION If vapor or mist is generated when the fluid is heated or handled ade quate ventilation in accordance with good engineering practice must be provided to maintain concentrations below the specified exposure or flammable limits OTHER Consumption of food and beverages should be avoided in work areas where hydrocarbons are present Always wash hands and face with soap and water before eating drinking or smoking E 3 FLASH POINT 345 F 174 C FLASH POINT 335 F 169 C FIRE POINT 385 F 196 C AUTOIGNITION TEMPERATURE 690 F 366 C AUTOIGNITION TEMPERATURE 691 F 367 C LOWER No data TEST METHOD ASTM D 92 COC TEST METHOD ASTM D 93 PMCC TEST METHOD ASTM D 92 COC TEST METHOD ASTM D 2155 TEST METHOD ASTM E 659 78 UPPER No data FLAMMABLE LIMITS IN AIR BY VOL EXTINGUISHING MEDIA Use dry chemical foam water fog or carbon dioxide SPECIAL FIRE FIGHTING PROCEDURES Water may be ineffective but can be used to cool containers exposed to heat or flame Caution should be exercised when using water or foam as frothing may occur especially if sprayed into containers of hot burn ing li
110. use of a problem The actual tempera ture of oil supplied to the process exceeds the programmed 510 F safety limit N WARNING Only qualified electri cal service personnel should examine and correct problems that require opening the unit s electrical enclosure or checking electrical current to diagnose the cause of a problem UGH002 0514 Possible cause Has oil stopped flowing through the unit or between the supply outlet and return inlet Is the electro mechanical safety switch improperly set or defective Has the heater contactor failed Has oil stopped flowing through the unit or between the supply outlet and return inlet Has the heater contactor failed Thermolator heaTrac TH 1 and TH 2 SHUT DOWN ALARMS Solution O Verify that the unit is run ning and that the pump is working Verify all process line valves are open Check the switch setting A too low setting will cause nuisance trips Check the switch and replace if defective See Checking and Replacing Switches Replace the contactor if defective See Replacing the Heater Contactor Verify that the unit is run ning and that the pump is working Verify all process valves are open Replace the contactor if defective See Replacing the Heater Contactor TROUBLESHOOTING 6 5 The Thermolator has detected a problem that could lead to equip SHUT DOWN ment damage or personal injury if it is not corrected ALARMS T
111. x wrench to remove the bolts holding the pump to the volute case The bolt in the rear will require a 9 16 inch crows foot wrench Lift the pump assembly straight up to remove The pump can now be replaced or disassembled for repair Reverse the steps to reassemble the unit NOTE Before restarting close all drain openings using sealant on the threads and refill the unit with fluid Do not start the the pump when the unit is dry Pump assembly bolts Pump seal flush line j Thermolator heaTrac 1 and TH 2 control REMOVING THE PUMP TROUBLESHOOTING 6 21 1 50002 0296 Conair has made the largest investment customer support in the plastics industry Our service experts are available to help with any problem you might have installing and operating your equipment Your Conair sales representative also can help analyze the nature of your problem assuring that it did not result from misapplication or improper use To contact Customer Service personnel call PARTS amp SERVICE 24 HOURS A DAY 7 DAYS A WEEK REA catu XD 91960 From outside the United States call 814 437 6861 You can commission Conair service personnel to provide on site service by contacting the Customer Service Department Standard rates include an on site hourly rate with a one day minimum plus expenses

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