Temptek G-500 Series Instruction Manual
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Temptek G-500 Series Instruction Manual

Temperature controller
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I.O.M. #152 updated : 05/10/2017
INSTRUCTION MANUAL
• INSTALLATION • OPERATION • MAINTENANCE
Oil Unit
Temperature Controller
For Models with the G500 Series Control Instrument
TEMPTEK, INC.
525 East Stop 18 Road Greenwood, IN 46142
317-887-6352 fax: 317-881-1277
Model:
Service Department fax: 317-885-8683
www.Temptek.com
Serial Number :
E-mail: sales@Temptek.com

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  • Page 1 I.O.M. #152 updated : 05/10/2017 INSTRUCTION MANUAL • INSTALLATION • OPERATION • MAINTENANCE Oil Unit Temperature Controller For Models with the G500 Series Control Instrument TEMPTEK, INC. 525 East Stop 18 Road Greenwood, IN 46142 317-887-6352 fax: 317-881-1277 Model: Service Department fax: 317-885-8683 www.Temptek.com Serial Number : E-mail: sales@Temptek.com...
  • Page 3 Oil Unit Temperature Controller INSTRUCTION MANUAL VTO Series with G500 Series Instrument COVERING INSTALLATION OPERATION MAINTENANCE TEMPTEK, INC. 525 East Stop 18 Road Greenwood, IN 46143 Phone: 317-887-6352 Fax: 317-881-1277 Service Department fax: 317-885-8683 www.Temptek.com E-mail: sales@Temptek.com...

  • Page 4: Table Of Contents

    Pressure Relief Valve Leaks MAINTENANCE Preventative Maintenance Pump Seal Replacement Heater Replacement Cooling Valve Service Pressure Switch Service Electronic Instrument Repair Policy And Procedure Page: 4 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
  • Page 5 Physical 36-48 kW Heaters & 5 - 7.5 HP Pumps Circuit Schematic with Cooling Circuit APPENDIX Model # And Suffix Coding Water Cooled Process Pumps Mold Purge Operation Page: 5 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
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  • Page 7: General

    Temperature Control Unit : VTO Series with G500 Series Instrument GENERAL Receiving Instructions Introduction Safety Components Page: 7 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...

  • Page 8: Receiving Instructions

    Observe all warning and safety placards applied to the unit. Failure to observe all warnings can result in serious injury or death to the operator and severe mechanical damage to the unit. Page: 8 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...
  • Page 9 Alerts users to the danger of high voltage. Alerts the user to possible explosive danger. CAUTION Alerts the user to a hot surface danger due to high operating temperatures. Page: 9 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...

  • Page 10: Components

    Expansion Tank From Process Valve and Connection Process Pump Fluid Drain Valve Water Drain Connection Water Supply Connection Typical unit with lift-off cabinetry. Page: 10 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
  • Page 11 Sight Glass From Process Valve and Connection Process Pump Fluid Drain Valve Water Drain Connection Water Supply Connection Typical unit with clam shell cabinetry. Page: 11 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
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  • Page 13: Installation

    Temperature Control Unit : VTO Series with G500 Series Instrument INSTALLATION General To and From Process Connections Water Supply Connection Drain Connection Electrical Connection Page: 13 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...

  • Page 14: General

    Cooling Unit including a heat exchanger, the water supply must be a minimum of 3 GPM at a minimum temperature of 100°F. High water flow may be required for your application depending on the process cooling requirement. Page: 14 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...

  • Page 15: Water Supply Connection

    The temperature difference between the unit set point and the cooling water temperature Consult factory when selecting the correct cooling valve for your application. Page: 15 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...

  • Page 16: Electrical Connection

    Electrical power supply requirements are identified on the equipment data tag. Verify that available voltage supply is the same as the unit’s voltage requirements. Page: 16 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...
  • Page 17 Make certain all electrical connections are tightly affixed. Any loose wiring connections must be tighten before engaging the power supply. Make certain no moisture or standing water is present inside the electrical cabinet. Page: 17 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
  • Page 18 Note : typically included on most 12 kW models with up to 3 HP pumps. Units with 16 kW to 48 kW heaters and pumps do not include a power cord. Page: 18 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...

  • Page 19: Start Up Sequence

    Instrument : Network Menu 3.11 Instrument : Features Menu 3.12 Instrument : Options Menu 3.13 Instrument : Machine Menu 3.14 Shut Down / Disconnect Page: 19 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...

  • Page 20: General

    Proper unit fill is essential for efficient and safe operation. An oil level sight glass is provided to determine unit fill. For initial fill: units up to 12 KW - fill until Page: 20 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
  • Page 21 If the unit is phased correctly, continue with the start up procedure at step C. If the unit is phased incorrect, continue with step 2. Page: 21 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...
  • Page 22 The indicator will be pointing to the left when the overloads are tripped. To reset, simply turn the Normal Operating Position Tripped Position Page: 22 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
  • Page 23 To Process and From Process lines, install a bypass line between the two tees with a throttling valve. Adjust the valve for a minimum of 50% of unit rated flow. Page: 23 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...

  • Page 24: Instrument : Quick Start

    Sample of Fault display screens. Not all Fault screens are shown here. Adjust the setpoint to the desired value by pressing the Increment or Decrement buttons. Page: 24 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...

  • Page 25: Instrument : Basic Navigation

    Prompts on Value Screens. Value screens allow the user to set or change parameter values. The Up button will add to the value of the parameter. Page: 25 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...

  • Page 26: Instrument : Operating Screens

    To Process temperature is shown with the operation indicated under the setpoint temperature, as shown in the example below. Heating. The amount of heating applied to the process is indicated in the Heating Screen. Page: 26 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...

  • Page 27: Instrument : Fault Screens

    To Process Sensor. This fault screen will appear if the To Process temperature sensor is defective and needs to be replaced or if the sensor connection is wet or loose. Page: 27 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...

  • Page 28: Instrument : Main Menu

    Once acknowledged, the unit will control to the new setpoint temperature. Press the Back button repeatedly to return to the Setpoints screen or press the home button to return to the Home screen. Page: 28 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...

  • Page 29: Instrument : Utilities Menu

    This number came be useful when troubleshooting at times. Utilities Software Version Software Version c4139887ele0729 Display Test maC8432_2017.a Display Sensors Back Back Pick Page: 29 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...

  • Page 30: Instrument : Network Menu

    • Modbus RTU • CAMAC. Network Protocol Change Setting Protocol Protocol SPI CCP Baud Rate Success Modbus RTU Address CAMAC Acknowledge Back Pick Adjust Cancel Page: 30 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
  • Page 31 One selections is available under the Options menu : Remote and Auto Start. Please note: this option requires factory or field installation of optional equipment. Page: 31 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...

  • Page 32: Instrument : Options Menu

    Units. This screen controls how the temperature is displayed. The options are English Machine Units Change Setting Units Max. Setpoint English Success Units Metric Heat Only Mode Back Pick Acknowledge Adjust Cancel Page: 32 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...

  • Page 33: Shut Down / Disconnect

    Relieve residual static pressure before disconnecting or servicing the unit. Follow all lock-out tag-out requirements. Confirm that no voltage is going to the unit heater. Page: 33 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...
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  • Page 35: Troubleshooting

    Unit will not start (Display is not Illuminated) Unit will not start (Display Illuminated) Unit Stops Unit Overheats Unit Underheats Water Pressure Relief Valve Leaks Page: 35 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...

  • Page 36: Unit Will Not Start (Display Is Not Illuminated)

    Sufficient water supply pressure must be present to close the switch. System Fault Screen. Indiacates a water supply or a pump overload fault. Page: 36 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...

  • Page 37: Unit Overheats

    The factory recommended minimum differential is 20 psi. If the differential is less than the factory Page: 37 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...

  • Page 38: Unit Underheats

    However, in the case where the instrument is determined to be defective, the operator contact the Service Department for information. The instrument is not a field serviceable component. Page: 38 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...
  • Page 39 If flushing the valve does not remedy the leaking, the valve must be replaced. Page: 39 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
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  • Page 41: Maintenance

    Temperature Control Unit : VTO Series with G500 Series Instrument SERVICE/MAINTENANCE Preventative Maintenance Pump Seal Replacement Heater Replacement Cooling Valve Service Voltage Change Pressure Switch Service Electronic Instrument Repair Policy & Procedure Page: 41 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
  • Page 42 In such cases, the sight glass may show an inaccurate level. Follow proper shut down procedures before removing sight glass to check feeder tubes. Tighten heater contactor terminals. Page: 42 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...

  • Page 43: Pump Seal Replacement

    Clean the motor shaft and lubricate with a mild soap solution. Install new stationary seal member in pump casing cavity. Be certain the stationary seal member is fully squared and seated in cavity. Page: 43 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...
  • Page 44 This is normal. After a few moments, the new seal will take seat and the leak will stop. Page: 44 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...

  • Page 45: Heater Replacement

    Reconnect the power cable to the heater terminals. Be certain to tighten the power cord junction box connector. Replace the junction box cover and the lift-off cover panel. When complete, restart the unit. Page: 45 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...

  • Page 46: Cooling Valve Service

    Place the coil onto the top bonnet and replace the retaining screw. Open the water supply to circulate water to the system. Check the solenoid valve for leakage. Restart the unit as outlined in section 3. Page: 46 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...

  • Page 47: Pressure Switch Service

    Install the brass elbow fitting. Teflon tape and leak preventative paste should be used to prevent water leakage. Install the capillary tube and resume operations. Page: 47 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...

  • Page 48: Electronic Instrument Repair Policy And Procedure

    Call the factory for current repair charges. Repair warranty: 1 year. Ship to Temptek, 525 East Stop 18 Road, Greenwood, IN 46143. Attention: Repairs (317-887-0729). Include in the shipping box: Part, purchase order, contact name, phone number, and symptom (if available).

  • Page 49: East Stop 18 Road Greenwood, Indiana

    Temperature Control Unit : VTO Series with G500 Series Instrument COMPONENTS Mechanical System Electrical System Page: 49 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
  • Page 50 TRANSFORMER. The transformer supplies 110 volts to the controlling instrument. Page: 50 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...
  • Page 51 PRESSURE SWITCH. The water pressure switch will close when sufficient pressure is supplied to the unit (20 psi). A closed pressure switch will consent the control circuit to the instrument controller to allow process operations. Page: 51 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...
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  • Page 53 Physical 16-24 kW Heaters & 1 - 3 HP Pumps Physical 27-48 kW Heaters & 5 - 7.5 HP Pumps Circuit Schematic with Cooling Circuit Page: 53 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277...
  • Page 54 12 KW HEATERS & 1-3 HP PUMPS PRESSURE TO PROCESS SERIES STATUS TEMPERATURE ERROR 16" STATUS TEMPERATURE ERROR TO PROCESS FROM PROCESS DRAIN WATER WATER DRAIN SUPPLY 40" 24" Page: 54 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
  • Page 55 Temperature Control Unit : VTO Series with G500 Series Instrument PHYSICAL 16 - 24 KW HEATERS & 1-3 HP PUMPS Page: 55 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
  • Page 56 Temperature Control Unit : VTO Series with G500 Series Instrument PHYSICAL 27-48 KW HEATERS & 5-7.5 HP PUMPS TWO-PIECE CLAM SHELL N-12 CABINET 65" 24" 12" 32 1/2" 22" Page: 56 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
  • Page 57 HEAT EXCHANGER THROTTLE VALVE COOLING SOLENOID VALVE COOLING ADJUSTMENT RELIEF VALVE VALVE PRESSURE WATER SUPPLY SWITCH CONNECTION SUPPLY MANIFOLD DRAIN CONNECTION DRAIN MANIFOLD Page: 57 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
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  • Page 59 Temperature Control Unit : VTO Series with G500 Series Instrument APPENDIX Model # Coding Water Cooled Process Pumps Mold Purge Page: 59 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
  • Page 60 Heating& Cooling H = Heating Only HC = Heating & Cooling Control Instrument G500 = G500 series instrument T500 = T500 series instrument Page: 60 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
  • Page 61 Rotating seal member Stationary seal member Impeller Pump Water casing wall channel cavity Oil drain Pump casing has been “cut away” for this photograph Page: 61 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
  • Page 62 MOLD PURGE PROCEDURE The Regal temperature controller is equipped with a mold purge feature. This enables the operator to change molds without losing a substantial amount of process fluid. Caution: the expansion reservoir is sized to allow the purging of most process systems.
  • Page 63 © 2018 Temptek, Inc. RE 05102018...

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