® Thermolator vacuTrac Positive/Negative Pressure Water Temperature Controller with TW-1 or TW2 Microprocessor Installation Operation Maintenance Troubleshooting Instant Access Parts and Service (800) 458-1960 (814) 437-6861 www.conairnet.com The Conair Group, Inc.
TPHM011/1101 TEMPERATURE CONTROL UNITS Thermolator® vacuTrac (VTR1-DI and VTR2-DI) Positive/Negative Pressure CONTROL TEMPERATURE AND STOP MOLD LEAKS Keep your operation up and running with the Thermolator vacuTrac water temperature controller. This positive/negative pressure unit can be used as a temporary fix for a leaky mold or bad O-rings.
TPHF017/1101 FEATURES TEMPERATURE CONTROL UNITS Thermolator® vacuTrac (VTR1-DI and VTR2-D2) Positive/Negative Temperature Controller FEATURES Expansion/fluid reservoir accepts thermal expansion of fluid when heated. Overflow connection relieves system static pressure. Level switches control tank fluid level. Venting line prevents trapped air in system. Pressure relief valve prevents system over pressurization. Air/water separation tank allows entrapped air to escape to the expansion tank.
TPHO017/1101 FEATURES TEMPERATURE CONTROL UNITS Thermolator® vacuTrac (VTR1-DI and VTR2-D2) Positive/Negative Pressure CONTROLS vacuTrac Control (TW-1) Our waterproof, durable control is operator friendly and smart. Standard features: vacuTrac Plus Control (TW-2) Includes all of the features of the standard vacuTrac control, PLUS: ● Automatic fine-tuning of PID control parameters provides uniform temperature control regardless of external loading.
TPHS017/1101 SPECIFICATIONS TEMPERATURE CONTROL UNITS Thermolator® vacuTrac (VTR1-DI and VTR2-DI) Positive/Negative Pressure A B VTR1-DI (single zone) MODELS Performance Characteristics Minimum setpoint Maximum setpoint Pump Performance per zone Pump Size Hp {kW} Nominal flow gpm {l/min} Pressure @ nominal flow psi {bar} Dimensions inches {mm} A -Height B- Width C- Depth Weight Ib {kg} Operating Shipping Water Connections NPT inches (Female) To/From Process Cooling Water Inlet/Outlet ELECTRICAL REQUIR
CONAIR THERMOLATOR VTR POSITIVE/N EGATIVE OPERATION 1.0 PROCESS WATER CONNECTIONS PROCESS CONNECTIONS Connect the FROM PROCESS and TO PROCESS connections on the back of the Thermolator using 1- 1/4” NPT piping. Viewed from the rear, the FROM PROCESS connection is located on the left hand side of the unit, and is clearly marked “ FROM PROCESS”. The TO PROCESS connection is located on the right hand side of the unit, and is marked “ TO PROCESS” in close proximity on the back panel.
water level float switch will make, opening the hot discharged water with cooler water. COOLING/MAKE-UP (3/8”) solenoid valve, replacing the This unit’s operation is similar to a TW-DI unit except that a VTR unit has a reservoir tank that is open to the atmosphere, which allows a maximum 180° F PROCESS water temperature. Notes: 1. The DIN units do not have pressure switches. The y use float switches instead 2. The make up water level float switch is the higher one in the reservoir tank.
Figure 1.
THE TW-1 CONTROL OPERATION Starting the Thermolator®. Run/Stop Setpoint display The window displays the setpoints entered for the fluid temperature, the high and low temperature deviation alarms, the SPI baud rate and the SPI address. 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.
TROUBLESHOOTING If there is a problem, the Thermolator® activates the red Alarm light and changes the RUN/STOP light from green to flashing red. 1 Press 2 Check the indicator lights and messages to help determine the cause of the problem. Quick Card to silence the optional audible alarm. Pump Positive/Negative Water Temperature Controller with TW-1 Microprocessor ! WARNING: Before servicing the Thermolator ® Allow the unit to cool to below 100˚ F. Disconnect and lockout the main power source.
THE TW-2 CONTROL OPERATION Run/Stop Setpoint display The window displays the setpoints entered for the fluid temperature, the high and low temperature deviation alarms, the SPI baud rate and the SPI address. 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.
TROUBLESHOOTING If there is a problem, the Thermolator® activates the red Alarm light and changes the RUN/STOP light from green to flashing red. 1 Press 2 Check the indicator lights and messages to help determine the cause of the problem. Quick Card to silence the optional audible alarm. Pump Positive/Negative Water Temperature Controller with TW-2 Microprocessor ! WARNING: Before servicing the Thermolator ® Allow the unit to cool to below 100˚ F. Disconnect and lockout the main power source.
Thermolator TW-1 and TW-2 ® Water Temperature Control Units Installation Operation Maintenance Troubleshooting Instant Access Parts and Service (800) 458-1960 (814) 437-6861 www.conairnet.com The Conair Group, Inc.
Please record your equipment’s model and serial number(s) and the date you received it in the spaces provided. It’s a good idea to record the model and serial number(s) of your equipment and the date you received it in the User Guide. Our service department uses this information, along with the manual number, to provide help for the specific equipment you installed. Please keep this User Guide and all manuals, engineering prints and parts lists together for documentation of your equipment.
INTRODUCTION . . . . . . . . . . . . . . . . . . .1-1 Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . .1-2 How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . .1-2 Your responsibility as a user . . . . . . . . . . . . . . . . . . . . . . .1-2 ATTENTION: Read this so no one gets hurt . . . . . . . . . . .1-3 TABLE OF CONTENTS DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1 What is the Thermolator TW Series? . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS MAINTENANCE . . . . . . . . . . . . . . .(continued) Performing System Tests . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 The Key/Display Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Input Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Disabling and Enabling Outputs . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION ● Purpose of the User Guide . . . .1-2 ● How the guide is organized . . . .1-2 ● Your responsibilities as a user .1-2 ● ATTENTION: Read this so no one gets hurt . . . . . . . . . . .
PURPOSE OF THE USER GUIDE This User Guide describes the Conair Thermolator® TW-1 and TW-2 water temperature control units and explains step-bystep how to install, operate, maintain and repair this equipment. HOW THE GUIDE IS ORGANIZED Symbols have been used to help organize the User Guide and call your attention to important information regarding safe installation and operation.
We design equipment with the user’s safety in mind. You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide. ATTENTION: READ THIS SO NO ONE GETS HURT WARNING: Improper installation, operation or servicing may result in equipment damage or personal injury.
ATTENTION: WARNING: Hazardous substance READ THIS The electrical contactors in the Thermolator have mercury contactors. Mercury is considered a hazardous substance and must be dealt with accordingly. Material Safety Data Sheet (#743997) 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.
DESCRIPTION ● What is the Thermolator TW Series? . . . . . . . . . . . . . . .2-2 ● Typical applications . . . . . . . . . .2-2 ● How it works: Direct Injection (DI) models . . .2-3 ● How it works: Closed Circuit (CC) models . . .2-4 ● How it works: Isolated Circuit (IC) models . . .2-5 ● Specifications . . . . . . . . . . . . . .2-6 ● Features and options . . . . . . . . .
WHAT IS THE THERMOLATOR ? The Thermolator TW models circulate water at a temperature higher than the available water supply, to add or remove heat as needed to maintain a uniform temperature setpoint in the process. The TW-2 offers an enhanced control, with additional diagnostic features and autostart capabilities. Both the TW-1 and TW-2 models are available in single or multiple-zone configurations, using direct injection or closed circuit process heating and cooling.
Direct injection models maintain the process temperature by electrically heating and injecting cool water supplied to the Thermolator by a chiller, tower or other water source. 1 HOW IT WORKS: DIRECT INJECTION 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 A to the mold or process. The fluid returns to the unit through the “From Process” line B for reheating or cooling.
HOW IT WORKS: CLOSED CIRCUIT 1 Closed Circuit models maintain the process temperature by heating and cooling fluid for the process circuit. Cooling water supplied by a chiller, tower or other water source, is mixed with the process fluid only during the initial filling or when water is needed to make up process fluid loss. 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 A to the mold or process.
Isolated Circuit models maintain the process temperature by heating and cooling fluid for the process circuit. The process fluid, which is stored in a reservoir, is isolated from cooling water supplied by a chiller, tower or other source 1 3b 4 HOW IT WORKS: ISOLATED CIRCUIT The vent line allows warm process fluid to expand to the reservoir G . The reservoir supplies process fluid through a make-up line as needed. The temperature of the process fluid is measured as it leaves the unit’s heater tank.
SPECIFICATIONS 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.
MODEL DESIGNATIONS TW1 TW2 Zones (1, 2 or 3) SPECIFICATIONS Direct Injection (DI) Closed Circuit (CC) Isolated Circuit (IC) PERFORMANCE CHARACTERISTICS - *Lower operating temperatures can be obtained with larger cooling valves. Consult your Conair representative.
FEATURES OPTIONS AND Incoloy heaters minimize chemical and high temperature damage Two-piece cast construction Motor drip cover protects motor windings from moisture damage. High efficiency pumps from 3/4 to 7.5 Hp. Silicon carbide seals are standard. Pump seal flush line continuously cleans the pump seal for extended life. Built-in sediment trap settles contaminants away from the pump seals.
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 (TW-2) . . . . . . . . .
UNPACKING THE BOXES Thermolator TW models come fully assembled. If they were specified at the time of the order, the optional purge valve or motorized cooling valve is factory-installed.
The Thermolator is easy to install, if you plan the location and prepare the area properly. 1 Position the Thermolator as close to the process machine as possible. PREPARING FOR INSTALLATION Thermolator Process machine Alternate locations 2 Make sure the installation area provides: ❒ A three-phase power source supplying the correct current for your Thermolator model.
CONNECTING PROCESS AND WATER SUPPLY LINES Tools for installation: ❒ Pipe wrench large enough for a 2-inch pipe ❒ Premium quality Teflon thread sealant NOTE: We recommend that you install an external ball valve on the cooling water inlet of the Thermolator. This valve is required when the purge valve option is installed. The Thermolator process inlets and outlets must be connected to the plumbing that will circulate the temperature-controlled water or fluid through the process.
A purge valve is available as an option on Direct Injection and Closed Circuit units only. This valve quickly evacuates fluid from the process circuit, allowing faster disconnection of the temperature controller from molds and hoses. An optional manual purge button controls this valve on TW-1 models. TW-2 models have a purge button on the control panel.
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 component information. 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.
WARNING: Only qualified personnel should perform this procedure. 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 this type of equipment should perform this test procedure. 1 TESTING THE INSTALLATION Turn on the cooling water supply and check for leaks. If any leaks appear, stop the test and fix the problem before continuing.
INITIAL SETUP 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.
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. CHANGING TEMPERATURE UNITS The temperature units are factory-set as degrees Celsius or degrees Fahrenheit, as specified when the unit was ordered.
ENABLING AND DISABLING PASSCODE PROTECTION 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 TW-1 and TW-2 Thermolators provide the ability to protect system parameters from unauthorized changes during normal operating mode.
ENABLING AND DISABLING PASSCODE PROTECTION 7 Press the RUN button to save the passcode. ◆ The control will display “Pr OFF” to 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 to the unit. Disconnect and lock out 9 Open the electrical enclosure. the main power supply. 8 7 6 5 4 3 2 1 10 Set dip switch 3 to OFF. the electrical enclosure and restore 11 Close power to the unit.
SELECTING THE TEMPERATURE CONTROL POINT (TW-2 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.
SELECTING THE TEMPERATURE CONTROL POINT (TW-2 8 ONLY) 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. 9 10 Turn off power to the unit. Disconnect and lock out the main power supply. Open the electrical enclosure. 8 7 6 5 4 3 2 1 11 Set dip switch 5 to OFF. 12 Close the electrical enclosure and restore power to the unit.
ENTERING SETPOINT DEVIATION PARAMETERS You can establish a normal operating range around the process temperature setpoint using the high and low deviation parameters. If the process temperature exceeds the high deviation limit, or falls below the low deviation limit for longer than 15 minutes, the Thermolator will alert you to the unacceptable temperature variation with an alarm light. These temperature deviation limits will adjust automatically relative to the process temperature setpoint.
TW-1 and TW-2 Thermolators provide SPI compatible support for RS-485 serial communications with a host machine.
INSTALLING THE AUTO START FEATURE 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.
6 Set dip switch 4 to the ON position. 7 Close the electrical enclosure and restore power to the unit. 8 7 6 5 4 3 2 1 INSTALLING THE AUTO START FEATURE (TW-2 ONLY) NOTE: All dip switch illustrations in this manual show switches 7 and 8 set to ON. If you have an Isolated Circuit model, these switches should be set to OFF. When Auto Start is enabled: ◆ The Auto Start indicator light flashes to indicate that the Thermolator can start at any time.
OPERATION ● TW-1 control . . . . . . . . . . . . . . . .4-2 ● TW-2 control . . . . . . . . . . . . . . . .4-3 ● Mounting the TW-2 control in a remote location . . . . . . . .4-4 ● Entering a passcode . . . . . . . . .4-5 ● Starting the Thermolator . . . . . .4-6 ● Stopping the Thermolator . . . . .4-7 ● Using the manual purge option . . . . . . . . . . . . . . . . . . .4-8 ● Using the TW-2 purge feature . .4-9 ● Performing an Auto Tune . . . . .
TW-1 CONTROL All normal operating functions can be controlled from the TW-1 control panel. If you have the optional manual mold purge, the control button is located on the side of the Thermolator electrical enclosure. Setpoint display Run/Stop Actual values display The Setpoint display shows the setpoints entered for fluid temperature, high and low temperature deviation alarms, the SPI baud rate, and the SPI address. Press RUN button to start normal operation.
TW-2 CONTROL All normal operating functions can be controlled from the TW-2 control panel, including the optional mold purge. Setpoint display Run/Stop Actual values display The Setpoint display shows the setpoints entered for fluid temperature, high and low temperature deviation alarms, the SPI baud rate, and the SPI address. Press RUN button to start normal operation. Press STOP to stop the temperature control unit. The green window displays the temperature at the middle of the mold.
MOUNTING THE TW-2 CONTROL IN A REMOTE LOCATION CAUTION: Improper use of the swiveling control panel can damage the unit. ● Do not use the control panel handles or control cables to move the Thermolator. The handles are designed only for orientation of the control panel. ● Do not mount the detached TW-2 control panel to a hot surface. The TW-2 control panel can be mounted up to 50 feet from the unit, using a remote control cable and the magnetic back on the back of the panel. Do not stretch the cable.
ENTERING A PASSCODE TW-1 and TW-2 Thermolators have a security feature that prevents accidental or unauthorized changes to the setpoint temperature, 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 indicate a passcode is needed.
STARTING THE THERMOLATOR 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. IMPORTANT: If you are operating the Thermolator for the first time since installation, you should perform an Auto Tune after two hours of normal operation.
WARNING: Electrical shock and hot surface hazards 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 100° F (38° C). STOPPING THE THERMOLATOR You must shut down the Thermolator whenever you: ● Change the water hookups. ● Shut down the process machine. ● Purge the process circuit of the water or fluid. ● Run the unit’s diagnostic tests. ● Perform routine or preventative maintenance.
USING THE MANUAL PURGE OPTION TW-1 and TW-2 direct injection and closed circuit models can be ordered with an optional purge valve, which clears the process lines of fluid using compressed air. The valve is operated by a manual purge switch on the side of the unit. IMPORTANT: Before purging the process lines, be sure that the cooling water source feed is closed. If the feed is open and the air line has a higher pressure than the cooling water, air may be injected into the cooling water system.
The TW-2 direct injection models can be ordered with an optional purge valve, which clears the process lines of fluid using compressed air. The valve is operated by a purge button on the control panel. USING THE TW-2 PURGE FEATURE IMPORTANT: Before purging the process lines, be sure that the cooling water source feed is closed. If the feed is open and the air line has a higher pressure than the cooling water, air may be injected into the cooling water system.
PERFORMING AUTO TUNE 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.
PERFORMING AUTO TUNE 5 AN Press Run and (the Setpoint Select button) simultaneously to begin the Auto Tune. The Actual display will flash “At” 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.
MAINTENANCE ● Maintenance schedule . . . . . . . .5-2 ● Accessing the Thermolator enclosure . . . . . . . . . . . . . . . . .5-3 ● Checking fluid level in the reservoir (IC models) . . . . . . . . . .5-4 ● Performing system tests . . . . . .5-5 ● Key/Display Test . . . . . . . . . . . . .5-6 ● Input Test . . . . . . . . . . . . . . . . . .5-7 ● Output Test . . . . . . . . . . . . . . . . .5-8 ● Disabling or enabling output monitors . . . . . . . . . . .5-9 ● Calibrating temperature sensors . . . . . . . . .
PREVENTATIVE MAINTENANCE SCHEDULE Thermolator TW-1 and TW-2 water temperature controllers are essentially maintenance-free. However, to maintain the best performance, we recommend the following maintenance schedule. ● Whenever process variables change ❒ 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..
● Annually (every 12 months) ❒ Test and calibrate the unit’s control systems. The Thermolator’s Test Mode checks the operation of displays, control buttons, inputs and outputs. You can also calibrate the supply and return thermocouples. See PERFORMING SYSTEM TESTS in this section.
CHECKING THE FLUID LEVEL IN THE RESERVOIR (IC MODELS ONLY) The isolated, or totally closed, circuit models separate the cooling water from the process fluid, which is held in a reservoir inside the unit. This reservoir should be kept at least three-quarters full of the process fluid. You can check the fluid level in the reservoir using the sight glass on the back of the Thermolator. Sight glass To fill the reservoir: 1 Disconnect and lockout power, and remove the top panel of the Thermolator.
TW-1 and TW-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 supply and return line thermocouples. PERFORMING SYSTEM TESTS System tests and calibration should be performed annually. To enable Test Mode: 1 Press 2 Disconnect and lock out main power to the unit, then open the electrical enclosure. 3 Set dip switches 3 and 5 to OFF. 4 5 Set dip switch 6 to ON.
KEY/DISPLAY TEST The Key/Display Test verifies the function of displays, LEDs and buttons on the control panel. 1 Enable Test Mode. 2 3 Press any key. If necessary, index to the Key/Display menu. Press and hold the Setpoint key for 3 seconds to index to each test menu until the controller displays “dSP”. 4 5 Press any key to clear all displays. 6 Exit the test and enter the next test. Repeatedly press any key to test displays.
The Input Test verifies the function of inputs available on the various TW-1 and TW-2 models. 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. 2 3 Press any key to display the first test menus. INPUT TEST Select the Input Test menu. Press and hold the Setpoint key for 3 seconds to index to each test menu until the controller displays “InP”. 4 Repeatedly press and release any key to test.
OUTPUT TEST The Output Test verifies the function of outputs available on the various TW-1 and TW-2 models. Not all outputs are used on all models. The performance evaluation of the inputs is based on the output monitors (OM). 1 Connect all outputs to the system. IMPORTANT: Testing each output requires the firing of the associated solid state relay. Make sure an output device is connected to the controller, otherwise the test result will be erroneous. 2 3 4 Enable Test Mode.
All output monitors on the Thermolator can be enabled or disabled permanently through the OM Enable/Disable Menu in Test Mode. You need to use this feature if you have replaced the motherboard, or if dip switches 7 and 8 have been changed erroneously. This will enable any required output monitors that were disabled and give fuse failures. 1 2 Enable Test Mode. 3 Select the OM Enable/Disable menu. DISABLING ENABLING OUTPUT MONITORS OR MAINTENANCE 5-9 Press any key to display the first test menus.
CALIBRATING TEMPERATURE SENSORS Special Tools Needed: ❒ type K thermocouple calibrator TW-1 and TW-2 Thermolators use type “K” thermocouples to sense the temperature in the return and supply process lines. These thermocouples should be calibrated annually, or when a new thermocouple is installed, to ensure correct operation. The Thermolator’s Calibration Mode provides zero and span calibration of both the supply and return line thermocouples. You access the Calibration Mode while in Test Mode.
6 Press the up ▲ 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). 7 CALIBRATING TEMPERATURE SENSORS Wait until the control displays “don” or “bad.” A “don” message in the Setpoint display indicates the calibration was successful. A “bad” message in the Setpoint display indicates a bad calibration.
LOGGING OPERATING HOURS You can see the total numbers of operation by accessing the Total Operating Hours Log in Test Mode. 1 2 Enable Test Mode. 3 Index through test menus to the operating log. Press any key to display the first test menus. 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 operating hours in 100-hour units. 4 Exit the Operating Hours Log.
TROUBLESHOOTING ● Before beginning . . . . . . . . . . . .6-2 ● A few words of caution . . . . . . .6-2 ● How to identify the cause of a problem . . . . . . . . . . . . . . .6-3 DIAGNOSTICS ● Shut down alarms . . . . . . . . . . .6-4 ● Warning alarms . . . . . . . . . . . . .6-8 ● System alarms . . . . . . . . . . . . .6-11 ● Thermolator will not power up .6-12 REPAIR ● Checking and replacing fuses .6-13 ● Resetting overloads . . . . . . . . .6-14 ● Replacing the pump overload .
BEFORE BEGINNING 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 shipped with your equipment. These diagrams are the best reference for correcting a problem.
Most Thermolator malfunctions are indicated by an illuminated 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 equipment 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.
SHUT DOWN ALARMS The Thermolator has detected a problem that could lead to equipment damage or personal injury if it is not corrected. ◆ The Alarm LED lights and the STOP/RUN LED flashes red. ◆ The Thermolator automatically shuts down. ◆ The control displays a red LED or alarm code indicating the source of the problem. Alarm Low Water Pressure Possible cause Solution Is the water supply pressure at least 25 psi? Verify that the water supply is on and delivering water at a pressure of at least 25 psi.
The Thermolator has detected a problem that could lead to equipment damage or personal injury if it is not corrected. ◆ The Alarm LED lights and the STOP/RUN LED flashes red. ◆ The Thermolator automatically shuts down. ◆ The control displays a red LED or alarm code indicating the source of the problem. Alarm High Temp. Safety The actual temperature of water supplied to the process exceeds the 260° F safety switch limit.
The Thermolator has detected a problem that could lead to equipment damage or personal injury if it is not corrected. ◆ The Alarm LED lights and the STOP/RUN LED flashes red. ◆ The Thermolator automatically shuts down. ◆ The control displays a red LED or alarm code indicating the source of the problem. SHUT DOWN ALARMS Alarm Lo SAF Possible cause Solution Is the cooling valve stuck open? Disassemble the cooling valve and check for particles blocking the valve seat.
SHUT DOWN ALARMS The Thermolator has detected a problem that could lead to equipment damage or personal injury if it is not corrected. ◆ The Alarm LED lights and the STOP/RUN LED flashes red. ◆ The Thermolator automatically shuts down. ◆ The control displays a red LED or alarm code indicating the source of the problem.. Alarm PHS Err Possible cause Solution Is the pump rotating in the wrong direction? Check pump rotation against the arrow stamped on the pump.
The Thermolator has detected a problem that could lead to a shut down condition if it is not corrected. ◆ The Alarm LED lights. ◆ The Thermolator continues operating. ◆ The control displays a red LED or alarm code indicating the source of the problem. WARNING ALARMS Alarm Low Deviation The Thermolator will not heat to the setpoint temperature, or takes too long to reach the setpoint temperature. The actual temperature of fluid supplied to the process is lower than the setpoint deviation allows.
The Thermolator has detected a problem that could lead to a shut down condition if it is not corrected. ◆ The Alarm LED lights. ◆ The Thermolator continues operating. ◆ The 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 actual temperature of fluid supplied to the process is higher than the setpoint deviation allows.
WARNING ALARMS The Thermolator has detected a problem that could lead to a shut down condition if it is not corrected. ◆ The Alarm LED lights. ◆ The Thermolator continues operating. ◆ The control displays a red LED or alarm code indicating the source of the problem. Alarm SPI Communication Possible cause Solution Is the unit connected to a host machine? If the Thermolator is not connected to a host device, set the SPI address to OFF using the Setpoint adjustment buttons on the control panel.
The Thermolator has detected a non-recoverable error involving 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 ERR 001 RAM hardware failure. ERR 002 ROM, checksum failure. ERR 003 ERR 004 SYSTEM ALARMS Cause Solution Electrical noise or failed CPU on the motherboard caused system write tests do fail during power up.
THERMOLATOR WILL NOT POWER UP 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 unit’s microprocessor board. Symptom Possible cause Solution Applying power does not turn on the Thermolator or light the control panel. Is power reaching the Thermolator? ❒ Verify that the main power supply and any customerinstalled electrical disconnect or emergency stop devices are in the ON position.
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 3 4 CHECKING AND REPLACING FUSES Open the electrical enclosure door. Turn the screw on the front panel counterclockwise to open. WARNING: Replace the fuse.
The pump motor overload is located inside the unit’s electrical enclosure. RESETTING OVERLOADS REPLACING THE PUMP OVERLOAD 1 Disconnect and lockout the main power. 2 Open the electrical enclosure door. Turn the 3 Check the overload. 1 Disconnect and lockout the main power. 2 Open the electrical enclosure door. Turn the screw 3 4 Motor contactor screw on the front panel counterclockwise to open. If the yellow button is out, the overload has tripped. Press the blue button to reset the overload.
1 Disconnect and lockout the main power supply. 2 Open the electrical enclosure door. Turn the screw 3 Mark or label each wire connected to the motherboard. The orange shield is L1 L3 4 3 2 1 OPS OPS FSTAT FSTAT IMPORTANT: Always 3 PHASE INPUT refer to the wiring diagrams that came with your Thermolator to locate specific electrical components. Illustrations in the User Guide are intended to be representative only.
REPLACING THE HEATER CONTACTOR IMPORTANT: Always refer to the wiring diagrams that came with your Thermolator to locate specific electrical components. Illustrations in the User Guide are intended to be representative only. WARNING: Electrical Shock Hazard Only qualified service personnel who have been trained on electrical testing and the procedures for avoiding the hazards should diagnose or correct problems that require opening the unit with power on.
The Thermolator uses two type ‘K’ thermocouples to monitor supply and return process temperatures. One thermocouple 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. CHECKING THERMOCOUPLES To check a thermocouple after a probe error: 1 Disconnect and lockout the main power. 2 Open the electrical enclosure door.
REPAIRING SOLENOID VALVES Every Thermolator has a solenoid valve assembly that controls the cooling water out flow. Closed circuit (CC) and Isolated Circuit (IC or TCC) units also have a vent valve assembly. Solenoid valves also are found on the optional purge valve.
REPAIRING SOLENOID VALVES *Indicates Parts Supplied in Solenoid Enclosure Kit Retaining Clip* or Retaining Cap* Nameplate Cover* Sleeve* Grounding Wire Yoke* (Not present on all constructions) Insulating Washer Housing* 7/8" Dia. Hole for 1/2" Conduit Coil Solenoid Base Sub-Assembly Insulating Washer Sleeve* 0.9375-26 UNS-2A Thread Core (AC) Tapped Hole in Core 0.250-28 UNF-2B 0.
REPLACING HEATER ELEMENTS WARNING: Electrical shock and hot surface hazards 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 100° F (38° C) 1 Disconnect and lockout the main power. 2 3 Remove the top panel of the Thermolator. 4 Remove the heater wiring harness. Remove the heater cap.
8 Lift the heating element out of the heater tube. Lift the element straight up. Heater cap REPLACING HEATER ELEMENTS Heater element Heater gasket 9 Replace the heater gasket if it is worn or cracked. Use a high termpertaure Teflon paste to ensure a good seal. 10 Reverse these steps to install the new heater element and reassemble the unit.
REMOVING THE PUMP WARNING: Electrical shock and hot surface hazards 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 100° F (38° C) 1 Disconnect and lockout the main power. 2 Shut off the cooling water in feed. 3 Drain the unit of all fluid. Remove Cooling water out Cooling water out Cooling water in the drain plugs at the rear of the unit.
To replace a failed seal, you must disassemble the pump. 1 Remove the impeller nut. Insert a screwdriver in one 2 Remove the impeller. Insert a screwdriver in the slot 3 Remove the seal, gasket case, adapter and flinger. See the exploded view for detail. Pump motor *Indicates Parts Supplied of the impeller waterway passages and back off the impeller nut. DISASSEMBLING AND ASSEMBLING 3/ - 2 HP PUMPS 4 of the motor shaft. Unscrew the impeller while holding the shaft against the rotation.
DISASSEMBLING AND ASSEMBLING 3 - 7.5 HP PUMPS To replace a failed seal, you must disassemble the pump. 1 Remove the impeller retaining assembly. Insert a 2 Remove the impeller. Be careful not to lose the key, 3 Remove the seal, adapter, shaft and flinger. See screwdriver in one of the impeller waterway passages to hold the impeller steady while removing the retainer. spring and seal retainer. If the impeller is difficult to remove, you may need to use a bearing puller. the exploded view for detail.
9 DISASSEMBLING AND ASSEMBLING 3 - 7.5 HP PUMPS Reattach the pump to the volute case. Make sure you replace any damaged gasket or O-ring between the pump assembly and volute case. Check for free rotation after assembly is completed. NOTE: Before restarting, close all drain openings using sealant on the threads and and refill the unit with fluid. Do not start the the pump when the unit is dry.
Conair has made the largest investment in 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.
EQUIPMENT GUARANTEE PERFORMANCE WARRANTY 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 use and service for which it was recommended (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.). Conair’s guarantee is limited to replacing, at our option, the part or parts determined by us to be defective after examination.
PLUMBING DIAGRAMS Cooling Water Out Check Valve Cooling Valve Thermocouple From Process Mixing Tank Cooling Water In Heater Thermocouple Supply Pressure Gauge To Process Check Valve Return Pressure Gauge Relief Valve Pump Purge Valve (optional) Direct Injection Check valves included only with optional mold purge.
PLUMBING DIAGRAMS Cooling Water In Manual Fill and Vent Port Cooling Water Out Cooling Valve 3 Gal. Reservoir Low Level Switch Level Sight Glass Return Thermocouple Vent Line From Process Cooling Heat Exchanger Make-Up Line Heater Supply Thermocouple To Process Relief Valve Supply Pressure Gauge Pump Isolated Circuit NOTE: There is a 180˚ F operating temperature limit on isolated circuit units.
UGH015/0100 TECHNICAL INFORMATION 61 140 52 120 43 100 80 43 37 30 24 17 9 12 6 20 30 Liters/Minute Gallons/Minute 26 18 40 69 160 49 35 78 180 55 0 0 MTRS PSI FEET 10 38 20 76 30 114 3/4 40 152 HP 50 190 60 228 1 HP 70 266 2 HP 80 304 90 342 100 380 3 HP 110 418 5 HP 120 456 7.
The SPI commands supported by Conair Thermolator® mold temperature controllers are listed in the following tables. The standard required commands and three optional commands are listed in the SPI Command Pairs table, along with the Select and Poll command pairs in hexadecimal format. Select commands set or change Thermolator functions. Poll commands retrieve information from the Thermolator.
SPI STATUS WORDS Status, Process Reserved Reserved Alarm, Low flow Reserved Alarm, Low pressure condition Alarm, High pressure condition Alarm, Low temperature deviation Alarm, High temperature deviation 13 12 11 10 9 8 7 6 5 4 EEprom error A/D converter error CJC Error RAM hardware ROM checksum Probe Failure E/M Hi temp safety Prog. Hi temp safety Output monitor failure Low water pressure High deviation alarm Low deviation alarm Prog.
SPI STATUS WORDS Status, Machine 1 Alarm, Low volts Alarm, High volts Reserved Reserved Alarm, Low pressure safety limit Alarm, High pressure safety limit Alarm, Low temperature safety limit Alarm, High temperature safety limit 13 12 11 10 9 8 7 6 5 4 Processing Alarm, High current 14 Alarm, System Alarm, Low current 15 Alarm, Process Alarm, Phase Word BIT position Alarm, Machine SPI STATUS WORD Open Poll: 0x20 0x42 3 2 1 0 SET SET SET SET SET SET SET SET SET SET SET SE
SPI STATUS WORDS Status, Machine 2 SPI STATUS WORD Open Open Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Fault, CAL Fault, Sensor Alarm, Machine Alarm, Process Alarm, System Processing Poll: 0x20 0x44 Word BIT position 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 EEprom error A/D converter error CJC Error RAM hardware ROM checksum Probe Failure SET SET SET SET SET SET SET SET SET SET SET SET SET E/M Hi temp safety Prog.
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 Chemical name: Mercury Formula: HG Trade name: Not applicable Supplier of MSDS information: The Conair Group Inc. One Conair Drive Pittsburgh, PA 15202 412-312-6000 CAS-Number: 7439-97-6 Synonyms: Quicksilver; Liquid silver Molecular weight: 200.
MSDS: 7439-97-6 MERCURY 5. Fire and Explosion Data Fire and explosion hazards: Firefighting media: Firefighting procedures: Mercury presents a slight fire and explosion hazard when exposed to heat or flame. Mercury vapors are heavier than air and may travel a considerable distance to a source of ignition and flash back. 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).
PARTS/DIAGRAMS ● Spare Parts Lists . . . . . . . . . .PD-1 ● TW-1 Wiring . . . . . . . . . . . . . . .PD-5 ● TW-1 Circuit Board . . . . . . . . .PD-6 ● TW-2 Wiring . . . . . . . . . . . . . . .PD-7 ● TW-2 Circuit Board . . . . . . . . .
RECOMMENDED SPARE PARTS TW-1 and TW-2 Thermolators 208-230/460V 9kW & 12kW units ¾ HP through 7½ HP PUMP ASSEMBLIES Nickle resistant seal, open drip proof type motor Part No.
TW-1 and TW-2 Thermolators 208-230/460V, 9kW & 12kW units, ¾ HP through 7½ HP PUMPMOTORS Part No. 09001403 09000378 09000381 09000384 09000387 09000390 RECOMMENDED SPARE PARTS Description ¾ HP 208/230/460V/3/60 ODP (Open Drip Proof) 1 HP 208/230/460V/3/60 ODP (Open Drip Proof) 2 HP 208/230/460V/3/60 ODP (Open Drip Proof) 3 HP 208/230/460V/3/60 ODP (Open Drip Proof) 5 HP 208/230/460V/3/60 ODP (Open Drip Proof) 7 ½ HP 208/230/460V/3/60 ODP (Open Drip Proof) REPLACEMENT HEATERS Part No.
RECOMMENDED SPARE PARTS TW-1 and TW-2 Thermolators 208-230/460V, 9kW & 12kW units, ¾ HP through 7½ HP HEATER CONTACTORS Part No. Description 20004401 Heater contactor for 9kW 208/230/460V 20004401 Heater contactor for 12kW 230/460V 09000417 Heater contactor for 12kW 208V REPLACEMENT BOARDS for TW-1 and TW-2, single- and two-zone Part No.
UGH015/0100 TW-1 230/460V WIRING DIAGRAM PD-5
L2 L3 L3 L2 L1 L1 4 3 2 1 OPS OPS FSTAT FSTAT 4 6 5 4 3 2 1 LLS/WPS LLS/WPS NOT USED NOT USED HPS/LPS HPS/LPS F1 3 FR O FR M O X FI M FR L X M FI L-IC FR R LL M -IC (TC R (T C)/ C W C PUR P )/P G WS U E PS R -D G I E- C D C IC C 2 1 2 3 4 3 2 1 AC IN 4 AC IN + 3 AC OUT 2 AC OUT + 1 3 PHASE INPUT TW-1 CIRCUIT BOARD F5 UNLDR 1/ VENT 2 SOL UNLDR 1/ VENT 2 SOL UNLDR 2/ COOL 1 SOL UNLDR 2/ COOL 1 SOL + 4 3 2 1 10 2 2 9 VENT SOL VENT SOL COOL SOL COOL SOL 4 3 2 1 2 6 6 5 PUMP PUMP PUMP O
2 UGH015/0100 TW-2 230/460V WIRING DIAGRAM PD-7
L2 L3 L3 L2 L1 L1 4 3 2 1 OPS OPS FSTAT FSTAT 4 15 4 6 5 4 3 2 1 LLS/WPS LLS/WPS AUTOSTART AUTOSTART HPS/LPS HPS/LPS F1 3 FR O FR M O X FI M FR L X M FI L D FR R LL IN M R D IN W P WS P AU S AU TO TO STA ST RT A RT 2 1 2 3 4 3 2 1 AC IN 4 AC IN + 3 AC OUT 2 AC OUT + 1 TW-2 CIRCUIT BOARD 3 PHASE INPUT F5 UNLDR 1/ VENT 2 SOL UNLDR 1/ VENT 2 SOL UNLDR 2/ COOL 1 SOL UNLDR 2/ COOL 1 SOL + 4 3 2 1 10 2 2 9 VENT SOL VENT SOL COOL SOL COOL SOL 4 3 2 1 2 6 6 5 PUMP PUMP PUMP OL PUMP OL PM
