Conair Thermolator TW-S User Manual
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Conair Thermolator TW-S User Manual

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www.conairgroup.com
U S E R G U I D E
UGH056-0917
Thermolator
TW-S and TW-P
®
Temperature Control Units
TW-S
TW-P
Corporate Office: 724.584.5500 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861

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  • Page 1 www.conairgroup.com U S E R G U I D E UGH056-0917 Thermolator TW-S and TW-P ® Temperature Control Units TW-S TW-P Corporate Office: 724.584.5500 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861...
  • Page 2 Serial Number(s): Model Number(s): DISCLAIMER: Conair shall not be liable for errors contained in this User Guide or for incidental, consequential damages 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.

  • Page 3: Table Of Contents

    Ta b le of C onte nt s 1 - 1 I n t r o d u c t i o n 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 ............
  • Page 4 Starting the Thermolator .................. 4-4 Stopping the Thermolator ................4-5 Using the Optional Mold Purge Option ............. 4-6 Conair TW-P Thermolator ................4-7 5 - 1 M a i n t e n a n c e Maintenance of your Thermolator ..............5-2 Preventative Maintenance Schedule ..............
  • Page 5 Replacing Immersion Heaters ................ 6-36 Removing the Pump ..................6-38 A p p e n d i x Customer Service Information ................ A-1 Warranty Information ..................A-2 A p p e n d i x PID Parameters ....................B-1 Setting the Security Passcode ................. B-4 A p p e n d i x Plumbing Diagram...................
  • Page 6 Ta b l e o f C o n t e n t s...
  • Page 7 S E C T I O N I ntrod uc t i on Pur p ose of t h e U s e r G u id e ........1- 2 H o w th e G u id e Is O r g a n iz e d ........1- 2 You r R esp on s i b il it ie s a s a U s e r ...

  • Page 8: I N T R O D U C Ti O N

    Pu rp ose of th e U se r Guide This User Guide describes the Conair Thermolator ® TW-S and TW-P and explains step- by-step how to install and operate this equipment. Before installing this product, please take a few moments to read the User Guide and review the diagrams and safety information in the instruction packet.
  • Page 9 We encourage all personnel to familiarize themselves with this manual’s contents. Failure to do so may unnecessarily prolong equip- ment down time. Contact Conair Follow good piping practices and the information in this manual to ensure successful Parts and Service installation and operation of this equipment.
  • Page 10 ATT ENT ION : Re ad This So N o One Gets Hurt 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.

  • Page 11: How To Use The Lockout Device

    Lockout is the preferred method of isolating machines or equipment from energy sources. Your Conair product may be equipped with the lockout device pictured below. To use the lockout device: Stop or turn off the equipment.
  • Page 12 I n t r o d u c ti o n...

  • Page 13: Des Crip T Io N

    S E C T I O N Des crip t io n W h a t is th e T h e r m o la t o r TW-S a nd T W-P ? ....2- 2 Ty pic al A pp l ic a t io n s .

  • Page 14: Typical Applications

    Wha t i s the T he rmo la to r T W-S a nd T W- P The Thermolator TW-S and TW-P Series circulates 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.

  • Page 15: H Ow Th E Tw- S A Nd Tw- P S E Ri E S D I Rec T In Jec T I On Wo R Ks

    H ow th e TW- S a nd TW- P S e ri e s D i rec t In jec t i on Wo r ks Direct injection models maintain the process temperature by electrically heating and/or injecting cool water supplied to the Thermolator by a chiller, tower, or other water source. The temperature of the process fluid is measured as it leaves the unit’s primary heater tank.

  • Page 16: How The Closed Circuit Works

    How t he Clo se d Ci rcuit Wo rks Closed Circuit models maintain the process temperature by electrically heating and indirectly cooling fluid in 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.

  • Page 17: How The Closed Circuit Separate Source Works

    H o w th e C l os ed C i r cu i t S e pa rate So urce Wor ks Closed Circuit Separate Source models maintain the process temperature by electrically heating and indirectly cooling fluid in the process circuit. Cooling water supplied by a chiller, tower or other water source, is never mixed with process fluid.

  • Page 18: Tw-S Contr Ol Fe Atur Es Vs Tw-V A Nd T W-P

    TW-S Contr ol Fe atur es vs TW-V a nd T W-P The TW-S Control Control features on the TW-S Series Thermolators Control features on the TW-P and TW-V Series Thermolators Model TW-S Model TW-P TW-V Direct Injection  Direct Injection ...

  • Page 19: Tw-P Control Features Vs Tw-V And Tw-S

    T W- P C o ntr ol Fe at ur e s vs TW-V a nd T W-S Control Power Autostart Signal Pump Heat Cool Coolant Pressure Temperature Limit Flow GPM (flash) Electrical Phase Error Heat Error Process Cool Down Mold Rapid Process...

  • Page 20: Sp Ecif Ications: T W-S

    1.00 inches Pump Performance - Consult your Conair representative for pump performance characteristics at other operating points. Pump 3/4 Hp {0.56 kW} 1 Hp {0.75 kW} 2 Hp {1.49 kW} 3 Hp {2.24 kW} 5 Hp {3.73 kW} 7.5 Hp {5.59 kW} 10 Hp {7.46 kW}...

  • Page 21: Specifications: Tw-P

    1.00 inches Pump Performance - Consult your Conair representative for pump performance characteristics at other operating points. Pump 3/4 Hp {0.56 kW} 1 Hp {0.75 kW} 2 Hp {1.49 kW} 3 Hp {2.24 kW} 5 Hp {3.73 kW} 7.5 Hp {5.59 kW} 10 Hp {7.46 kW}...

  • Page 22: Tw-P Features And Options

    T W-S a nd TW-P Fe a tures a nd O ptio ns Incoloy heaters minimize chemical and high temperature damage, and maximizes life. Two-piece cast construction High efficiency pumps from 3/4 to 10 Hp. Silicon carbide seals are standard. Built-in sediment trap settles contaminants away from the pump seals.

  • Page 23: I Nst A Llati On

    S E C T I O N I nst a llati on U np ac king t h e B o x es ..........3- 2 Pr epar in g f o r In s t a ll a t io n .

  • Page 24: Unpacking The Boxes

    Unpa ck in g the Boxe s Thermolator TW models come fully assembled. If they were specified at the time of the order, the optional purge valve or modulating valve is factory-installed. CA U TI O N: Lif t ing To avoid personal injury or damage to the Thermolator, lift the unit using a forklift or hoist with straps that have been positioned at the center of gravity.

  • Page 25: Preparing For Installation

    P rep arin g f o r In s t a l l a t i on The Thermolator is easy to install, if you plan the location and prepare the area properly. WA R NING : Im pr o pe r in s t a lla t ion , op er at i on, or s e r v i c- in g may re s u lt i n e qu i pm ent d am a ge o r pe r s ona l in j u r y.

  • Page 26: Rig Gin G

    Rig gin g The unit has a structural steel base with casters to facilitate easy movement and position- ing. Follow proper rigging methods to prevent damage to components. Avoid impact load- ing caused by sudden jerking when lifting or lowering the unit. Use pads where abrasive surface contact may occur.

  • Page 27: Ins Talla T Ion - E Le C T R I C A L

    I n sta llatio n - E l e c t ri ca l All wiring must comply with local codes and the National Electric Code (NEC). Full Load Amperes (FLA) and other unit electrical data are on the unit nameplate. A unit specific electrical schematic ships with the unit.

  • Page 28: Connecting Process And Water Supply Lines Without Purge

    Install pipe to the rear of the Thermolator. Use male 1 -inch NPT piping for NOTE: Conair recommends that process connections and male 1-inch NPT piping for water connections. Pipe and you install an external ball valve pipe threads must be clean and new. Clean threads with solvent, removing all oil, on the cooling water inlet of the grease and dirt.

  • Page 29: Mold Purge Valve Connections

    Parts and Service NOTE: For information about how to add a purge valve to your Thermolator if you did not order it equipped that Phone: 800-458-1960 way from the factory, contact Conair Service. From outside of the United States, Call: 814 437 6861...

  • Page 30: Connecting The Main Power Source

    Conn ec ti ng the M a in Po we r So urce Before beginning, note the electrical specifications on the serial tag mounted to the side of the unit. The electrical connection must match these specifications with +/- 10% maxi- mum voltage variance.

  • Page 31: Testing The Installation

    Tes tin g t h e I n s ta l l a t i on WA R N ING : O nl y q u a l if ie d p e r s on ne l s h oul d p e r f or m t h is pro ce dure .

  • Page 32: Initial Setup

    Init ial Setup (Continued) r Operating Mode r Temperature Units r Setpoint r Alarm Points CA U TI O N: The Thermolator will not operate correctly if certain factory-set parameters are changed. Parameters should only be changed by qualified technical personnel who are familiar with the operation of this type of equipment. If the Thermolator does not appear to be working correctly, verify the parameters against the list of factory settings.

  • Page 33: Temperature Units

    Te mpe ra tu r e Un i t s To select the desired temperature units for your system (°F vs. °C), follow this procedure: Stop the Thermolator or ensure that you are on the home screen by pressing the STOP button.

  • Page 34: Setpoint

    Se tp oin t To select the proper setpoint of the system, follow this procedure: From the home screen you should observe the current setpoint in green in the up- per display and the actual process temperature in the lower window. Change the setpoint using the “Up”...

  • Page 35: Alarm Points

    A larm Po in t s To select the desired alarm points for your system (low alarm and high alarm), follow this procedure: Stop the Thermolator or ensure that you are on the home screen by pressing the STOP button. Function Enter the user configuration menu by holding the “Function”...
  • Page 36 3-14...

  • Page 37: O Peratio N

    S E C T I O N O peratio n Th e T W- S C o nt r o l ..........4- 2 Th e T W- P C on t r o l ..

  • Page 38: T He Tw-S Co Ntro L

    T he TW-S Co ntro l Raise and Lower Key Used to enter the setpoint temperature, index through the operating modes or change other parameter values. Press increase a value. Press to decrease a value. TIP: Press and hold the key for faster scrolling speed. Setpoint Value Display The window displays the fluid temperature setpoint...

  • Page 39: The Tw-P Control

    T he T W- P Co nt r ol Raise and Lower Key Used to enter the setpoint temperature, index through the operating modes or change other parameter values. Press increase a value. Press to decrease a value. TIP: Press and hold the key for faster scrolling speed. Setpoint Value Display The window displays the fluid temperature setpoint...

  • Page 40: C Ont Ro L Le R Op Era Tin G Button S

    C ont ro l le r Op era tin g Button s Button Description of Operation Start Pressing the Start button initiates a vent sequence. The vent sequence removes air that may have separated out from the water to prevent improper operation and premature heater failure. When initiated, the vent sequence opens the cooling valve for 30 seconds to allow air to escape then runs the pump for 30 seconds while the cooling valve is open to remove any remaining air from the sys- tem.

  • Page 41: Te Mpe Ra Tu R E Di S Pl Ays

    Te mpe ra tu r e Di s pl ays Display Description of Operation Setpoint The Setpoint display normally shows the set point temperature. A decimal point in the lower right corner of this display indicates the temperature unit of measure is set to °F, no decimal point indicates the temperature unit of measure is set to °C. See the Program Menu section to change the temperature scale units of measure.

  • Page 42: Default Display

    O perating L igh ts (Continued) Display Description of Operation Rapid Cool The Rapid Cool light flashes green when the unit is executing a Rapid Cool sequence. The Cool light will also flash green dur- (Optional) ing a rapid cool sequence. After the Rapid Cool sequence is complete, the unit stops and the Rapid Cool light remains green to indicate the completion of the sequence.

  • Page 43: Starting The Thermolator

    S tarti n g th e T he r m ol a t or Before starting the Thermolator, verify that the system has been installed correctly for your application. See the Installation section. Turn on the water supply to the Thermolator. The supply pressure must be at least 25 psi for most units.
  • Page 44 Start-up Every unit is factory set to deliver water in accordance with the standard operating speci- fications for that particular unit. Due to variables involved with different applications and different installations, minor adjustments may be required during the initial start-up to ensure proper operation.
  • Page 45 75 psi {5.2 bar}. If the total pres- sure in the unit (cooling source inlet pressure plus the pump pressure) exceeds Contact Conair 150 psi {10.3} the pressure relief valve in the unit will open. If this becomes an issue,...
  • Page 46 Start-up (Continued) Sys t em Fi l l Wa t er C hemis t r y Requir em ent s The properties of water make it ideal for heat transfer applications. It is safe, non-flamma- ble, non-poisonous, easy to handle, widely available, and inexpensive in most industrial- ized areas.
  • Page 47 Sta rt-u p (Continued) Fil l Wate r C he mi s t r y R eq ui r e me n t s Water Characteristic Quality Limitation Alkalinity (HCO3-) 70-300 ppm Aluminum (Al) Less than 0.2 ppm Ammonium (NH3) Less than 2 ppm Chlorides (Cl-) Less than 300 ppm...
  • Page 48 Star t- up (Continued) S t e p 3 – In i t i a l Un it Oper at i on Enter the set point temperature. Refer to the Control Panel Operation section for further information. Start the unit by pressing the Start button on the control panel. Pressing the Start button enables the microprocessor control functions, initiates an Auto-vent sequence, and turns on the Run indicating light which is green when on.

  • Page 49: Stopping The Thermolator

    Sto ppi n g th e Th e r mol a to r WA R NING : E l e c t r i ca l S ho c k a nd H ot S ur fac e Ha z a r ds 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°...

  • Page 50: Pr Ogr Am M En U

    Pr og ra m Me nu Access to the program menu is password protected to prevent unintended alteration to the program settings and parameters. To access the programming menu the unit must be in a stopped state. To enter the program menu stop the unit then press and hold the Display/Program button for 10 continuous seconds to put the controller in program mode.

  • Page 51: Pr Ogr Am M En U It E M S

    P rog ra m Me nu I t e m s Item Name Item Default Range Code Valve Alarm delay for high deviation alarm 0 to 60 minutes (10 to 60 minutes on program versions prior to version 1.33) Alarm delay for low deviation alarm 0 to 60 minutes (10 to 60 minutes on program versions prior to version 1.33) Alarm deviation alarm delay after start...

  • Page 52: Pr Oce Ss Cool D O Wn Seq Uenc E I Ni Tia Tio N

    Pr oce ss Cool D o wn Seq uenc e I ni tia tio n The Process Cool Down sequence reduces the water temperature before the unit shuts off to extend the life of the pump seal. See the Program Menu section for instructions on how to enable or disable this feature.

  • Page 53: Spi O P Tion Pa R Am Et E Rs

    SPI O p tion Pa r am et e rs Command Poll Select Description Echo 20 20 20 21 Controller integrity command used to accept and retain data and provide it in response to a poll inquiry in an open 4-byte ASCII format with ASCII units. Version 20 22 Controller version command used to provide a version number following format: AABB,...

  • Page 54: M Odb Us Rtu (Opti Ona L )

    M odb us RTU (Opti ona l ) The Modbus RTU option provides a RS-485 communications port for Modbus RTU communications. Note the ModBus Parity = None, Stop Bits = 1, and default Baud Rate = 9,600. M odb us Op tio n Pa ra m et ers Register Command Poll...

  • Page 55: Mod Bu S R Eg I S T Er S

    Mo db u s O p ti on Pa r am e te rs (Continued) Register Command Poll Select Description 8018 Supply Temperature Retransmit Range Low (°C) Floating Point 8020 Supply Temperature Retransmit Range High (°C) Floating Point 8022 Low Temperature Safety – User Set (°C) Floating Point 8024 High Temperature Safety –...

  • Page 56: Using The Optional Mold Purge Option

    Usi ng the Optio na l Mo ld Purge Optio n Only the TW-P Thermolator can be ordered with an optional purge valve (Mold Purge), which clears the process lines of fluid using compressed air. The valve is operated by an optional manual purge button on the control panel.

  • Page 57: Conair Tw-P Thermolator

    Co nai r TW- P Th e r mol a t or N o rmal O pera t i o n For normal operation of the TW-P Thermolator, set the setpoint on the temperature controller using the buttons. On the display, the lower red display shows the current temperature, and the upper green display shows the setpoint.
  • Page 58 4-22 O p e r a t i o n...

  • Page 59: Ma Inten Anc E

    S E C T I O N Ma inten anc e Maint enanc e o f y o u r T h e r m o l a t o r ......5- 2 Pr even ta tive M a in t e na n c e Sc he dul e ..

  • Page 60: Maintenance Of Your Thermolator

    - including manuals from the manufacturer of any valves, heat exchangers, and parts used on your Thermolator - when completing any maintenance or troubleshooting tasks. Contact Conair If you have any questions or concerns about your Thermolator, feel free to call Conair’s Parts and Service Parts and Service departments for assistance.

  • Page 61: Accessing The Thermolator Enclosure

    Ac ce ss in g t h e Th e r mol a to r E n clo su re Depending on which features, options, and additions you ordered with your Thermolator, your Thermolator may appear different and operate differently from the illustrations and photos shown in this user guide.
  • Page 62 Remove the casing O-ring. Inspect for damage or wear. If in good condition, set Contact Conair Parts and Service aside for re-use. If a new part is needed, contact Conair Parts and request part number Phone: 800-458-1960 267204-0160-02 From outside of the...

  • Page 63: R Em Ovin G T H E P U M P M O T O R A N D Se A L (1/2 To 2 Hp, Any Frequency And 3 Hp, 60 Hz Units)

    Re mo vi n g t h e P um p Mot or a n d Seal (1 /2 to 2 Hp, an y fre que ncy and 3 H P, 60 Hz units) ( C on t inu ed ) Remove the dust cap from the bell end motor housing to expose the motor shaft.

  • Page 64: (1/2 To 2 Hp, Any Frequency And 3 Hp, 60 Hz Units)

    Re mo vin g the Pu mp M o to r a nd S ea l ( 1/ 2 t o 2 Hp, a n y fr e que ncy and 3 H P, 6 0 H z uni ts) (C o nt i n ue d) Slide the rotating half of the shaft seal off of the shaft.
  • Page 65 Re as semb li n g t he Pu m p M ot o r an d Sea l ( 1/ 2 to 2 Hp, an y fre que ncy and 3 H P, 6 0 H z units) The following procedure can be used on all models with 1/2 to 3 Hp motors for reassem- bly: Tools Required r 9/16-inch wrench...
  • Page 66 Re assem bli ng t he P ump Mo to r a nd S eal ( 1/ 2 t o 2 Hp, a n y fr e q. a nd 3 H P, 6 0 H z uni ts) (Co n t .) Align the impeller and screw on to shaft.

  • Page 67: Re Mo Vin G T He Pu Mp Mot Or A Nd S Eal ( 3 H P, 50H Z And 5 To 10 Hp, An Y Fr Equency Units)

    The following procedure can be used on all models with 5 to 10 hp pump motors for disassembly: Remove eight (8) pump casing bolts using a 9/16-inch wrench. Remove motor and adapter from casing. Contact Conair Parts and Service Phone: 800-458-1960 Inspect pump casing to adapter o-ring for damage. If appropriate obtain replace- From outside of the ment part number 267204-0265-02.
  • Page 68 Re mo vin g the Pu mp M o to r a nd S ea l ( 3 Hp, 5 0H z a nd 5 to 10 H p, a n y f re que ncy uni ts) (C o nt i n ue d) This area interfaces with volute Witness line Clamp in this region if needed...

  • Page 69: Reassembling Pump Motor And Seal

    Re as semb li n g P um p M ot or a nd Seal ( 3 H p, 50H z and 5 to 10 Hp, an y fr equency units) The following procedure can be used on all models with 5 to 10 Hp motors for disassem- Tools Required bly: r 9/16-inch wrench...
  • Page 70 Re setting Pump Ove rlo a d Tools Required Phillips Screwdriver The pump motor overload is located inside the unit’s electrical enclosure. Disconnect and lockout the main power. Open the electrical enclosure door. Turn the screw on the front panel counterclockwise to open. Check the overload.

  • Page 71: Re Pl Aci N G Th E C On Tr O L L E R Boa Rd S

    If replacing the main board, insert all terminal strips. Replace all daughter cards Contact Conair on plastic standoffs. Take care to ensure that daughter card connections to the main Parts and Service Phone: 800-458-1960 board are properly aligned.
  • Page 72 5-14 Ma i n t e n a n c e...
  • Page 73 S E C T I O N Tro uble s h oot i n g B ef or e B eg i n ni n g ..........6- 2 A Few Wor d s o f C a u ti o n.

  • Page 74: Tr O U B L E Sh O O T I N G

    Most manuals can be details about troubleshooting and repairing specific components are found in these downloaded free of charge from the product section of the Conair materials. website.www.conairgroup.com r Check that you have manual for other equipment connected in the system. Trouble- shooting may require investigating other equipment attached to, or connected with the Thermolator.

  • Page 75: A Few Words Of Caution

    A Fe w Wo r ds of C au t i o n WA R NING : I mp r o p er i ns t a llat io n, oper at i on o r se r vi c i ng m a y r e s ul t in equ ipm e n t da m age or p er so na l i nj u r y.

  • Page 76: Identifying The Cause Of A Problem

    Identifying the C a use of a Pro ble m The Troubleshooting section covers problems directly related to the operation and maintenance of NOTE: Additional troubleshooting the TW-P. This section does not provide solutions to problems that originate with other equipment. help can be found in the docu- Additional troubleshooting help can be found in manuals supplied with the other equipment.
  • Page 77 C ont ro ller A l ar m s When an alarm occurs, the Thermolator has detected a problem with the process. Without correction, the TCU will not be able to produce process fluid of the correct temperature. Under certain conditions, an alarm could lead to equipment damage or personal injury if it is not corrected.

  • Page 78: Controller Alarms

    C on t ro ller Alar ms Control Power (Continued) Autostart Signal When an alarm occurs, the Thermolator has detected a problem with the process. Without correction, the Function TCU will not be able to produce process fluid of the correct temperature. Under certain conditions, an Pump Control Power alarm could lead to equipment damage or personal injury if it is not corrected.
  • Page 79 C ont ro ller A l ar m s (Continued) When an alarm occurs, the Thermolator has detected a problem with the process. Without correction, the TCU will not be able to produce process fluid of the correct temperature. Under certain conditions, an alarm could lead to equipment damage or personal injury if it is not corrected.
  • Page 80 Con tr oll er Alar ms (Continued) When an alarm occurs, the Thermolator has detected a problem with the process. Without correction, the TCU will not be able to produce process fluid of the correct temperature. Under certain conditions, an alarm could lead to equipment damage or personal injury if it is not corrected.
  • Page 81 C ont ro ller A l ar m s (Continued) When an alarm occurs, the Thermolator has detected a problem with the process. Without correction, the TCU will not be able to produce process fluid of the correct temperature. Under certain conditions, an alarm could lead to equipment damage or personal injury if it is not corrected.
  • Page 82 Verify that the unit is running and  thought the unit or between the that the pump is working. 2 Contact Conair supply outlet and return inlet? Check for closed or defective Parts and Service Factory Temperature – High cooling or vent valves and plugged...
  • Page 83 C o ntro l ler Al a r ms (Continued) When an alarm occurs, the Thermolator has detected a problem with the process. Without correction, the TCU will not be able to produce process fluid of the correct temperature. Under certain conditions, an alarm could lead to equipment damage or personal injury if it is not corrected.
  • Page 84 Con tr ol ler Al ar ms (Continued) When an alarm occurs, the Thermolator has detected a problem with the process. Without correction, the TCU will not be able to produce process fluid of the correct temperature. Under certain conditions, an alarm could lead to equipment damage or personal injury if it is not corrected.
  • Page 85 C o ntro l ler Al a r ms When an alarm occurs, the Thermolator has detected a problem with the process. Without correction, the TCU will not be able to produce process fluid of the correct temperature. Under certain conditions, an alarm could lead to equipment damage or personal injury if it is not corrected.

  • Page 86: Controller Control Fault Logic

    Cont r oll er Cont ro l Fa ul t Lo gic Fault Alarm Indication Pump Heater Unit Alarm Manual Remote Shut Shut Shut Reset Reset Alarm Required Required Activated Low Coolant Inlet Pressure The Coolant Pressure In Light flashes red Temperature Limit Safety The Set Point and Process Temperatures Flash and the Temperature Limit Light flashes red...

  • Page 87: Unit Faults

    Unit Fa u lts The Thermolator has detected a problem with the internal components, wiring, electrical power, or operat- ing environment. Without correction, the fault could lead to equipment damage or personal injury if it is not corrected. • The controller displays an error code indicating the cause of the problem. •...
  • Page 88 Un i t Faul ts (Continued) The Thermolator has detected a problem with the internal components, wiring, electrical power, or operat- ing environment. Without correction, the fault could lead to equipment damage or personal injury if it is not corrected. •...
  • Page 89 Unit Fa u lts (Continued) The Thermolator has detected a problem with the internal components, wiring, electrical power, or operat- ing environment. Without correction, the fault could lead to equipment damage or personal injury if it is not corrected. • The controller displays an error code indicating the cause of the problem.
  • Page 90 The heater contactor is NOT dis- for initial machine warm up. For connecting the heater when told applications requiring continuous to open by the controller. The heating regulation, contact Conair heater is likely running continu- customer service and inquire ously. about Mercury or SSR upgrade kits for the heater contactor.
  • Page 91 For closing when told to open by the applications requiring continuous controller. The heater is likely heating regulation, contact Conair not able to run. customer service and inquire about Mercury or SSR upgrade Note: This fault is only valid for kits for the heater contactor.
  • Page 92 Uni t Faul ts (Continued) The Thermolator has detected a problem with the internal components, wiring, electrical power, or operat- ing environment. Without correction, the fault could lead to equipment damage or personal injury if it is not corrected. • The controller displays an error code indicating the cause of the problem.
  • Page 93 Un it Fau lts (Continued) The Thermolator has detected a problem with the internal components, wiring, electrical power, or operat- ing environment. Without correction, the fault could lead to equipment damage or personal injury if it is not corrected. • The controller displays an error code indicating the cause of the problem.
  • Page 94 Un it Fa ult s (Continued) The Thermolator has detected a problem with the internal components, wiring, electrical power, or operat- ing environment. Without correction, the fault could lead to equipment damage or personal injury if it is not corrected. •...
  • Page 95 Uni t Fa u lts (Continued) The Thermolator has detected a problem with the internal components, wiring, electrical power, or operat- ing environment. Without correction, the fault could lead to equipment damage or personal injury if it is not corrected. •...
  • Page 96 Un i t Faul ts (Continued) The Thermolator has detected a problem with the internal components, wiring, electrical power, or operat- ing environment. Without correction, the fault could lead to equipment damage or personal injury if it is not corrected. •...
  • Page 97 Uni t Fa u lts (Continued) The Thermolator has detected a problem with the internal components, wiring, electrical power, or operat- ing environment. Without correction, the fault could lead to equipment damage or personal injury if it is not corrected. •...

  • Page 98: Unit Will Not Power Up

    Un i t Wi ll No t Po we r U p If you press the control power button and the control panel does not light, you have a problem with the main power circuit or the unit’s temperature controller. WA R N ING : E le ct r i ca l S hock Haz ar d Di sc on ne ct a nd l oc k out t he m ai n pow er supply be for e p ro cee di n g .
  • Page 99 Tro ublesh oo t i n g Symptom Possible Cause Solution Alternating overheating and Poor water flow. Check connectors and increase overcooling or rapid cycling size if necessary. If there are a from heat to cool. large number of hoses and/or they are long, try to shorten hose runs and use as large of a hose as possible to minimize water-circuit...

  • Page 100: Troubleshooting

    IMPORTANT: Always refer to the wiring Tr o ubl esh ooti ng (Continued) diagrams that came with your Thermolator to locate specific electrical components. Illustrations in the User Guide are intended to be representative only. Symptom Possible Cause Solution Unable to cool properly. Cooling water supply is not suf- Check to make sure the cool- ficient.

  • Page 101: Replacing The Heater Contactor

    R epl acin g t he He a t e r C o nt a c to r WA R NING : E l ec t r i c a l Sh o ck H a z ar d 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.

  • Page 102: Checking The Rtd

    Ch ec k ing th e RT D WA R NIN G : Electr i cal Shock Hazar d 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.
  • Page 103 C hec kin g t he RTD (Continued) Pt 1 00 Temp Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Temp at T at T+1°F at T+2°F at T+3°F at T+4°F at T+5°F at T+6°F at T+7°F at T+8°F at T+9°F °F Ohms...
  • Page 104 Re pl a ci ng RT Ds WARN I NG : H o t S ur face s Allow the Thermolator to cool to below 100° F {38° C} before servicing the unit. To replace an RTD: Disconnect and lockout the main power. Shut off the cooling water in and drain the unit.

  • Page 105: Repairing Cooling Valves

    Remove foreign par- ticles and replace damaged parts as necessary. Reassemble the valve and other components. Reassemble in reverse order. Seal Contact Conair Parts and Service all pipe fittings with pipe sealant. Check that all flows are in the correct direction.

  • Page 106: Disassembly Of Alternate Direct Acting Solenoid Valves

    Di sa sse mb ly o f Alte rna te D irect Acti ng So le no id Va l ves Di sa ssem bl y Mounting Screw Loosen the mounting screws. The coil assembly, seal, return spring, armature assembly and body can be removed.

  • Page 107: Alternate Pilot Operated Solenoid Valves

    Al tern a te Pi l ot Op e r at e d S ol e n oid Valve s Clip Name Plate Solenoid Coil Assembly NOTE: Within the valve body and coil assembly there are no user serviceable parts. Tro ub l es hoo ti n g 6-35...

  • Page 108: Replacing Immersion Heaters

    Rep laci ng Im me rsio n H ea ters WA R NI NG : Ele ctr i cal Shock and Hot Sur face Haz ard 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 100°...
  • Page 109 Lift the heating element out of the heater tank. Lift the element straight up. Heater cap Immersion Heater Heater gasket Clean the heater tank. Remove any rust or solids that may have built up before Contact Conair Parts and Service inserting the heater elements. Phone: 800-458-1960 From outside of the Replace the heater gasket if it is worn or cracked.

  • Page 110: Removing The Pump

    Re mo vi ng th e P ump WA R NIN G : Ele ct r ical Shock and H ot Sur face Haz ar d 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 100°...

  • Page 111: Appendix

    We’re Her e to He lp Conair has made the largest investment in customer support in the plastics industry. Our Additional manuals and prints for your Conair equipment may service experts are available to help with any problem you might have installing and oper- be ordered through the Customer ating your equipment.
  • Page 112 Equipm ent Gua ra nte e 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 typi- cally replaced after normal usage, such as filters, liner plates, etc.).

  • Page 113: Appendix

    PID Para me te r s The Conair TW-S and TW-P Thermolator features a PID (“proportional-integral- derivative”) control-loop algorithm implemented in the programming of the control- ler board. This algorithm is used to achieve the proper temperature of the process fluid quickly and accurately.
  • Page 114 PID Pa ram e te rs (Continued) In t e gr a l Using only proportional control will cause the Thermolator to have steady-state error (it will never exactly reach setpoint). Integral response is used to eliminate this undesirable condition. Integral logic introduces the awareness of the passage of time into the logic by looking into the past—and observing how far the process has been from the setpoint over time.

  • Page 115: Pid Parameters

    PID Paramete rs (Continued) STEPS: Set Default Parameters Turn off all derivative control by setting Er and EH to “0”. Minimize integral control by setting nt and nH to “800”. Set proportional control of bn and PBH to an initial value of approximately 10% of setpoint.

  • Page 116: Setting The Security Passcode

    PID Par ame te rs (Continued) Finished You should review your work and make sure your system is not on the verge of oscillating. If your system oscillates intermittently, you probably have your gains too aggressive. It is better to be mild in your tuning than over-aggressive. You are now finished tuning your system.

  • Page 117: Plumbing Diagram

    Pl um bing D ia gr am From Process RTD From Process Low Pressure Switch Cooling Water In Mixing Tank Cooling (or Optional Valve 2nd Heater) Cooling Water Out From Process Pressure Bypass/ Gauge Heater De-aeration To Process RTD To Process Process Pressure Gauge...
  • Page 118 Pl um bing D ia gr am (Continued) Clos ed C ircui t S ep a r a t e S o ur ce TW-P Closed Circuit Separate Source In this configuration process and cooling fluids do not mix. (Continued) A p p e n d i x...
  • Page 119 Plum bin g Di agr am (Continued) C los e d C irc ui t C om mo n S o ur c e Optional From Process RTD TW-S Closed Circuit In this configuration process and cooling fluids mix only at filling. Fill line is used for both pressurization and expansion of process fluid (causes limited inter- action of process and cooling water).

  • Page 120: Plumbing Curves

    Plumbi ng Cur ves Di re c t Inje ction (Continued) A p p e n d i x...
  • Page 121 Plum bing Cu r ves (Continued) C lo sed C ircuit S t a nda r d Pe r f or m a n ce (Continued) A ppendi x...
  • Page 122 Plumbi ng Cur ves (Continued) C lo sed C irc uit Hi gh Per f or m a n ce A p p e n d i x...
  • Page 123 TW-S and T W-P T her m ol a t o r s Manuals Contact Conair PART NUMBER DESCRIPTION Parts and Service UGH056/0417 User Guide, Thermolator TW-S and TW-P Phone: 800-458-1960 From outside of the United States, PUMP ASSEMBLIES VOLTAGE POWER...

  • Page 124: Service Parts

    Se r vi ce Pa rts Lis t (Continued) T W-P Th er m olat or s PUMP ASSEMBLIES VOLTAGE POWER FREQUENCY FERROUS IMPELLERS 2672030000G8 208-230/460 2672030000G9 208-230/460 2672030000G10 208-230/460 2672030000G11 208-230/460 2672030000G12 208-230/460 2672030000G13 208-230/460 2672030000G14 208-230/460 SEAL KITS 267203SK0101 267203SK0102 267203SK0101...

  • Page 125: Appendix

    E xt e rn a l In t e r fac e s Analog Remo t e Se t poi nt / Pr oc es s Tem p R e t r an s mi t Con necting t o t he T her mo l a t or WAR NIN G: Imp ro per i ns ta ll at ion, o pe r a t i o n , o r s e r v i c- ing ma y re s ul t i n e qui pment da mag e o r p er so n a l injur y.
  • Page 126 Ex te rn al In te rfa c es (Continued) 1TC Input #4 Jumper Positions Analog Input Jumper Placement Placement Number (4-20mA) (0-10V) Input #4 J1-9 JMP10 & J1-10 JMP11 JMP13 JMP22 NOTE: Signal is not ground-isolated. Customer’s interface must be isolated from ground (or ground loop damage will result).

  • Page 127: External Interfaces

    External In te r face s (Continued) Setting the So f t wa r e If you ordered the “remote setpoint” option with the TCU, your TCU will come pre-configured to accept a remote setpoint. This means that you will NOT be able to select a setpoint directly from the temperature controller (without changing the default parameters).

  • Page 128: Appendix

    A p p e n d i x...

  • Page 129: Pressure Switch Settings

    Pressu r e Swi tc h Se tti ng s All 250° F {121° C} maximum set point temperature units require 25 psig to operate. For 250° F {121° C} maximum set point temperature and 48 kW heater units the unit with 36 kW of heat will operate at 25 psig, the last 12 kW of heat will not operate without at least 35 psig in the suction side tank.
  • Page 130 Pr essur e Switc h Se tting s (continued) Closed Circuit Units at 300 °F {149° C} Minimum System Pressure Required for System Operation (in psig) for 60 Hz Input Power (Digit 7 of Part # is B,C, F, A or D) Heater Capacity Pump Power (Digit 6 of Part #) (Digit 7 of Part #)

  • Page 131: Appendix

    Mold Purge Installation Instruction Sheet PRH 020- 0 9 1 5 Install external ball valve at cooling water inlet, if not already installed, in order to shut off water supply during installation and when using mold purge. Remove any plumbing used to connect the unit to the process. NOTE: The unit’s ‘To Process’...
  • Page 132 Mold Purge Installation Instruction Sheet (continued) T W- V Attach the flexible metallic conduit to 1/2” NPT elbows (quantity 2) to the solenoid valves. Attach the 1/2” pulling elbow to the back of the mechanical enclosure with the male end going through the hole labeled in Detail A, and the female end pointing straight up.

  • Page 133: Appendix

    Mold Purge Installation Instruction Sheet (continued) T W- P Attach the two 1/2” pipe nipples to the solenoid valves. Attach the two electrolet elbows to the 1/2” pipe nipples. Attach the two clamp connectors to the electrolet elbows. Cut power cord into two equal lengths. Wire one end of each of the pieces of cable to each of the valves, connecting the wires inside the electrolet elbows.
  • Page 134 A p p e n d i x...

  • Page 135: Flo Wmeter Installa Tion Instructions

    Flowmeter installation instruction sheet PRH021-0915 Flowmeter Installation Instruction Sheet 1. Remove the plumbing connection from the unit to the process. PRH 021- 0 9 1 5 2. Add sealant to threads and attach flow meter and fittings to the unit according to the figure Remove the plumbing connection from the unit to the process.
  • Page 136 A p p e n d i x...

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Thermolator tw-p

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