$30.00 Operation and Installation Manual MICRO Series Water Temperature Control Units Important! Read Carefully Before Attempting to Install or Operate Equipment Part No. 682.89373.00 Bulletin No. SC1-610.
Write down your unit serial number(s) here for future reference ________________ ________________ ________________ ________________ ________________ ________________ ________________ ________________ ACS Group is committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice. © Copyright ACS Group, Inc. 2008 All rights reserved. Effective 5/22/2008 Part No. 682.89373.00 Bulletin No. SC1-610.
Safety Considerations MICRO Series temperature control units are designed to provide safe and reliable operation when installed and operated within design specifications and when following national and local safety codes. To avoid possible personnel injury or equipment damage when installing, operating, or maintaining this equipment, use good judgment and follow these safe practices: ; Only PROPERLY TRAINED personnel familiar with the information within this manual should work on this equipment.
Table of Contents CHAPTER 1: GENERAL INFORMATION................................... 6 1-1 1-2 1-3 1-4 1-5 Introduction ................................................................................................ 6 Necessary Documents............................................................................... 6 Models Covered......................................................................................... 7 Standard MICRO Series Features........................................................
Table of Contents 6-1 6-2 6-3 6-4 6-5 6-6 Preventive Maintenance .......................................................................... 35 Corrective Maintenance........................................................................... 36 Restoring the Controller to Factory Setup ............................................... 37 Electrical Connections ............................................................................. 37 Safety Devices........................................................
Chapter 1: General Information 1-1 Introduction MICRO Series water temperature control units are reliable, accurate, and easy-touse process temperature control units. They are self-contained, portable, and shipped ready to use. The MICRO Series water temperature control unit is designed to circulate water through your process and to precisely, automatically, and reliably maintain it at a specified temperature. Standard unit operating range is from 0ºF (-17ºC) to 250°F (121°C).
1-3 Models Covered This manual provides operation, installation, and maintenance instructions for the MICRO Series water temperature control unit. Model numbers are listed on the serial tag. Make sure that you know the model number, serial number, and operating voltage of your temperature control unit if you contact the manufacturer.
• Auto system water purge (mold purge) • Y-strainer • Remote start/stop control • Casters; available in lieu of rubber feet • Audible and visual general fault alarm • Rotary, through-the-door disconnect switch • Electrical operation available in 208, 230, 460, and 575 volts, 60 Hz; 200, 380, and 415 volts, 50 Hz • UL/CUL-listed electrical subpanel • 10 ft.
Figure 1 Typical MICRO Series Water Temperature Control Unit and Specifications To Cool Fr Coolin Dimensions Model number Pump 460 / 230 H hp kW gpm 1/2 0.37 15 25 3/4 0.56 20 30 lpm psig kPa MICRO, 3 kW heater in. Shipping W in. weight lbs. Kg 17½ 44.0 9½ 24.0 23 58.0 110 50 cm in. cm D cm Figure 2 MICRO Series Unit Full-Load Amps Model Full-load amps at 460 volts hp kW 3 kW heater 6 kW heater 9 kW heater 0.5 hp 0.37 kW 4.8 amps 8.5 amps 12.3 amps 0.75 hp 0.
Chapter 2: Shipping Information 2-1 Unpacking and Inspection You should inspect your MICRO Series temperature control unit for possible shipping damage. If the container and packing materials are in reusable condition, save them for reshipment if necessary. Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc.
Reinspect the container and packing material to see if you missed any smaller items during unpacking. Determine that the item was not inadvertently taken from the area before you checked in the shipment. Notify the manufacturer immediately of the shortage. 2-4 If the Shipment is Not Correct If the shipment is not what you ordered, contact the parts and service department immediately at [262] 641-8610. Include the order number and item. Hold the items until you receive shipping instructions.
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Chapter 3: Installation 3-1 Installation Location Considerations MICRO Series systems are portable and can be installed almost anywhere. As with all equipment installations, follow all applicable codes and regulations. ; The recommended ambient temperature range for MICRO Series installations is from +14ºF (-10ºC) to a maximum operating ambient temperature of 131°F (55ºC). Recommended ambient storage temperature range is from -13ºF to 149ºF (-25ºC to 65ºC).
3-4 Piping Considerations for Permanent Installations We recommend an optional (or customer-installed) strainer on the COOLING WATER IN inlet. The unit must have at least 16 psig (110.32 kPa/1.1 bars) water supply pressure to prevent pump cavitation that can be caused by the water “flashing” to steam. To avoid damage to the pump or other components, make sure that maximum supply pressure does not exceed 40 psig (275.8 kPa/2.8 bars). Keep restrictions to a minimum by using proper inlet pipe sizing.
3-6 Process Water Considerations Raw Water Water treatment is vital in any piping system. In some cases, raw water may be used in the system without problems; in other cases, it can result in large deposits of scale and corrosion. The manufacturer offers a complete line of water treatment equipment. Contact your manufacturer sales representative for water testing and treatment options.
! CAUTION If a non-relieving device such as a regulator, ball valve, or check valve is installed on the WATER IN line, you MUST install an expansion tank of at least ½ gallon (about 2 liters) capacity. Failure to do so can result in system overpressure from thermal expansion. Install the tank configured as shown below: Check the expansion tank frequently to make sure it is not flooded. Water Out — ¾” NPT The cooling water return outlet leading back to the cooling tower, chiller, or drain.
Pressure Relief — ¾” The pressure relief valve is located at the back of the unit. It is recommended to run a hose or pipe to the floor. This hosing or piping reduces the chance of scalding nearby personnel if the relief valve should trip. 3-9 Making System Purge Connections MICRO Series systems equipped with the System Purge option have a compressed air inlet marked MOLD PURGE. Connect to a clean, dry 100 psig (689.50 kPa/6.90 bars) air line.
3-10 Making Electrical Connections MICRO Series systems are designed for three-phase voltage operation. Refer to the unit nameplate for proper voltage and amperage requirements. Make sure you provide a correctly sized and protected supply of electrical power to the unit. Important! Refer to National Electric Code (NEC) Article 430-24 through 430-26 for proper feeder conductor and supply disconnect sizing. Maintain a safe ground and disconnect the power supply before servicing the unit.
Bring properly sized power leads and ground from a fused disconnect (installed by your electrician) to the unit. Provide external overcurrent protection to the unit, using circuit breakers or fuses. If you use fuses, make sure that they are dual-element time-delay fuses, sized according to your electrical code. Make sure that all electrical connections are tight. Important! 1. Electrical connections must comply with all applicable electrical codes. 2.
Figure 3 Typical Electrical Wiring Schematic, Drawing 2 Page 20 MICRO Series Water Temperature Control Units
Figure 4 Typical Electrical Subpanel Layout MICRO Series Water Temperature Control Units Page 21
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Chapter 4: Identifying Controls and Features 4-1 Identifying Mechanical Controls and Features To Process Probe One (1) type K thermocouple probe is included with your MICRO temperature control unit. It is located in the heater tank to sense TO PROCESS temperature. Safety Thermostat The safety thermostat mounted on the side of the heater tank protects against thermal runaway. The thermostat guards against the unlikely event of “runaway” heating.
Heaters The specially designed 3, 6, or 9 kW three-phase low watt density electrical immersion heaters heat the water, and the controller regulates the temperature. The standard heater has an incolloy sheath for best heat transfer and low fouling properties. Solenoid Valves MICRO Series systems use rugged, industrial design solenoids with replaceable coils and/or internal components. The unit is equipped with a ¼” direct acting solenoid valve.
The 115V control circuit and controller outputs are fuse protected. The pump motor is controlled by a full voltage magnetic non-reversing motor starter, with fused branch circuit overcurrent and thermal overload protection. Automatic Vent This feature automatically triggers the purging of air from the system before you start the unit. The vent actuates the solenoid valve, and forces trapped air and water out through the drain, properly filling and priming the unit prior to startup.
4-2 The Microprocessor Controller The CAL 9000 controller is an easy-to-operate microprocessor-based PID control device. When the process reaches the set point, the PID control cycles the cooling valve and/or immersion heater to maintain the proper leaving water temperature. The controller is fully factory tested. Set the process temperature set point you want and the controller does the rest. Built-in range of operation on the controller is 0°F to 250°F (-18ºC to 121ºC).
The OUT1 indicator is on when the fluid temperature is below the set point and is being heated. OUT2 Indicator The OUT2 indicator is on when fluid temperature is above the set point and is being cooled. Display Indicators LED Indicator Under normal operation the LED indicator displays the temperature of the outgoing fluid. To view the setpoint press the star (*) key 4-4 Using CAL Controls Controller Keys Star (*) Key Press and hold the Star (*) key to view the setpoing.
4-5 Using Graphic Panel Buttons Figure 7 ON/OFF Switch Push the ON/OFF rocker switch to the ON ( | )energize the unit and begin the temperature control cycle. The switch will be illuminated whenever the unit is on. VENT Switch Push the VENT switch for additional manual venting. ALARM SILENCE Switch Optional Push the ALARM SILENCE button to silence the alarm. You should investigate the alarm condition and restore the unit to normal operation before continuing with the temperature control cycle.
4-8 Operating the Unit with the Controller To change the process temperature set point: • Press * together to decrease setpoint. • Press * together to increase setpoint. The set point automatically updates. 4-9 Communications A connection port on the electrical cabinet permits easy hook-up to the host computer for RS-232C and RS-485 communications. The connection port is a direct pin-to-pin extension from the back of the controller.
Chapter 5: Startup and Operation 5-1 Introduction The checklist below outlines start-up procedures for MICRO Series water temperature control units. This list assumes that installation information located in this manual has been read and followed. 5-2 Startup Checklist ; Check the shipping papers against the serial tag to make sure that system size, type, and voltage is correct for the process under control.
; Connect the main power to the unit disconnect switch, and press the ON/OFF switch to the ON position to check for proper pump rotation direction as described in Section 5-6 on Page 39. Pump rotation should be clockwise, viewed from the motor end. ; Check your work and proceed to the Startup Procedure section on the following page. 5-3 Starting the Temperature Control Unit ; Turn ON the water supply, and push the ON/OFF switch to the ON ( | )position.
! CAUTION 1) Your MICRO Series system operates with hot water under pressure. To reduce the risk of scalding: • • • • Always wear work gloves and safety glasses when operating the unit. Never operate the unit with panels or shields removed. Pipe the relief valve to an open drain. Never install a fitting or hose that is rated less than 150 psig and 250°F (1,034.25 kPa/10.34 bars and 121ºC).
bars, 68.95 kPa/0.69 bars differential]) opens. You need at least 16 psig (110.32 kPa/1.10 bars) for the best cooling capacity and to prevent water boiling in the process circuit at high temperatures, particularly at the pump suction. ; After venting, the microprocessor controller monitors the TO PROCESS RTD probe, cycling open the cooling/vent valve to discharge warm water or energizing the immersion heater to maintain the process set temperature.
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Chapter 6: Unit Maintenance ! CAUTION Never attempt to service a unit until a qualified electrician has opened and locked out the main disconnect using OSHA 1910.147 standards. The water supply should be turned off and internal pressure should be relieved before you remove panels. All electrical connections must be done by a qualified electrician. ! WARNING Disconnect all power to the unit, let the unit cool down, and turn off the water prior to any servicing.
cable, especially at the entrance point to the unit. This inspection should be made by a qualified electrician. Check for leaks, especially under the pump, as it may indicate a worn pump seal. 6-2 Corrective Maintenance Pumps and Seals Before leaving our factory, we test each unit extensively, then we calibrate each unit. Afterwards, the unit is drained and blown out with air to remove water from piping systems.
drip cover on top of the motor, you’ll have access to the end of the shaft. It has been slotted to make it easy to turn with a screwdriver. If the shaft is free to turn, next check that the motor overloads are set, check for blown fuses, and finally check the power supply on each leg to the motor. A qualified electrician should check the motor and its circuit.
6-5 Safety Devices Caution! Make sure that only qualified electricians test safety devices! Safety devices should be tested for function every six (6) months. Perform the following procedures for testing: Pressure Switch With the unit running, program a set point of 30ºF (-1ºC). Allow the process temperature to drop under 100ºF (38ºC). When the process temperature reaches that point, turn off the water supply. The pump should stop and the Low Water Pressure indicator should illuminate.
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Chapter 7: Troubleshooting Condition Possible cause No power. Check main disconnect, fuses, wiring, and power lead to unit. Wrong voltage supplied to unit. Voltage must be within plus or minus 10% of nameplate rating. Defective on/off switch. Replace. Control circuit fuse blown. Replace. Defective control transformer. Check transformer. Broken or loose wire in pump motor control circuit. Locate and repair. Pump motor contactor holding coil is open. Repair or replace.
Condition Temperature fluctuations/ rapid cycling from hot to cold. Possible cause Solution Undersized connectors/ water lines. Increase size of connectors/ water lines. Long connecting lines between unit and mold. Move the unit closer to the mold and shorten connecting lines. Serpentine flow through mold. Connect lines for parallel flow instead of series flow. Blocked water line in mold. Check mold for metal chips or lime buildup. Clean mold. Quick disconnect fitting with check valve.
Technical Assistance Parts Department Call toll-free 7am—5pm CST or call [800] 423-3183, [262] 641-8610, or fax [262]641-8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone or fax order, please have the model and serial number of your unit when you contact us.
Service Notes MICRO Series Water Temperature Control Units Page 43
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MICRO Series Water Temperature Control Units Page 45
