Page 1 www.conairgroup.com U S E R G U I D E UGH025-0504 Thermolator ® TW Series Water Temperature Control Units TW, TW-1 and TW-2 Corporate Office: 724.584.5500 | Instant Access 24/7 (Parts and Service): 800.458.1960 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
....1-1 ABLE OF NTRODUCTION Purpose of the User Guide ......1-2 ONTENTS How the Guide is Organized .
Page 4 ..... . PERATION ’ ABLE OF CONT TW Control Performing an Auto Tune ....4-13 TW-1, TW-2 Control Performing an Auto Tune .
Page 5: Introduction
NTRODUCTION l Purpose of the User Guide ..1-2 l How the Guide is Organized . . .1-2 l Your Responsibilities as a User 1-2 l ATTENTION: Read this so no one gets hurt ... .1-3 UGH025-0504 Thermolator TW Series...
Page 6: Purpose Of The User Guide
This User Guide describes the Conair Thermolator ® URPOSE OF Series water temperature controllers and explains step-by-step how to install, operate, maintain and repair this equipment. UIDE Before installing this product, please take a few moments to read the User Guide and review the diagrams and safety infor- mation in the instruction packet.
Page 7: Attention: Read This So No One Gets Hurt
We design equipment with the user’s safety in mind. You can ATTENTION: avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the EAD THIS SO NO User Guide. ONE GETS HURT WARNING: Improper installation, operation or servicing may result in equipment damage or personal injury.
Page 8 ATTENTION: WARNING: Hazardous substance The contactors used in the Thermolator are EAD THIS SO NO mercury displacement relays. Mercury is con- ONE GETS HURT sidered a hazardous substance and must be dealt with accordingly. See the Material Safety Data Sheet which explains the potential haz- ards, how to avoid them and how to clean up and dispose of the mercury if it spills.
Page 9: Description
ESCRIPTION l What is the Thermolator TW Series? ....2-2 l Typical Applications ..2-2 l How it Works: Direct Injection (DI) Models .
Page 10: What Is The Thermolator
HERMOLATOR process. Conair TW Thermolators are available in single or dual-zone configurations, using resistance heating and direct injection or closed circuit cooling. Dual-zone models can control at two different temperatures at different locations in the process.
Page 11 Direct injection models maintain the process temperature OW IT ORKS by electrically heating and injecting cool water supplied to the Thermolator by a chiller, tower or other water source. IRECT NJECTION The temperature of the process fluid is measured as it leaves the unit’s heater tank. The fluid then flows through the “To Process”...
Page 12: How It Works: Closed Circuit
Closed Circuit models maintain the process temperature by ORKS electrically heating and indirectly cooling fluid in the process circuit. Cooling water supplied by a chiller, tower LOSED IRCUIT 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 13: How It Works: Isolated Circuit
Isolated Circuit models maintain the process temperature ORKS by electrically heating and indirectly cooling fluid in the process circuit. The process fluid, which is stored in a SOLATED IRCUIT reservoir, is isolated from cooling water supplied by a chiller, tower or other source. The vent line allows warm The temperature of the process fluid to expand to the...
Page 14: Specifications
Dimensions and performance characteristics vary according to PECIFICATIONS 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. CABINET STYLE REFERENCE Heater Voltage Selection...
Page 15 MODEL DESIGNATIONS PECIFICATIONS 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. Models TW-DI TW-CC TW-IC Minimum Setpoint Temperature °F {°C} 32 {0} 32 {0} 32 {0} Maximum Setpoint Temperature °F {°C}...
Page 16: Features And Options
EATURES AND Incoloy heaters minimize chemical and PTIONS 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.
Page 17: Installation
NSTALLATION l Unpacking the Boxes ... . .3-2 l Preparing for Installation ..3-3 l Connecting Process and Water Supply Lines ... . .3-4 l purge Valve Hookups .
Page 18: Unpacking The Boxes
Thermolator TW models come fully assembled. If they were NPACKING THE specified at the time of the order, the purge valve or motor- ized cooling valve is factory-installed. OXES Thermolator Carefully remove the Thermolator and components from their shipping containers. Remove all packing material, protective paper, tape and plastic.
Page 19: Preparing For Installation
The Thermolator is easy to install, if you plan the location and REPARING FOR prepare the area properly. NSTALLATION Position the Thermolator as close to the process machine as possible. Thermolator Process machine Alternate locations Make sure the installation area provides: r A three-phase power source supplying the correct current for your Thermolator model.
Page 20: Connecting Process And Water Supply Lines
The Thermolator process inlets and outlets must be connected ONNECTING to the plumbing that will circulate the temperature-controlled water or fluid through the process. Cooling water inlets and ROCESS AND outlets are connected to the cooling water supply. ATER UPPLY Remove the shipping pipe plug from the female connections on the back of the Thermolator.
Page 21: Purge Valve Hookups
A purge valve is available as an option on Direct Injection and URGE ALVE Closed Circuit units only. This valve quickly evacuates fluid from the process circuit, allowing faster disconnection of the OOKUPS temperature controller from molds and hoses. An optional manual purge button controls this valve on models with TW or TW-1 controls.
Page 22: Connecting The Main Power Supply
ONNECTING 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 OWER UPPLY involving electrical connections. All wiring, disconnects and fusing should conform to your region’s electrical codes and should be installed only by qualified personnel.
Page 23: Testing The Installation Tw Control
ESTING THE WARNING: Only qualified personnel should perform this procedure. NSTALLATION Parts of this test requires opening the unit while it TW C is energized. Only qualified personnel who have ONTROL 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.
Page 24: Testing The Installation Tw-1, Tw-2 Control
ESTING THE WARNING: Only qualified personnel should perform this procedure. NSTALLATION Parts of this test requires opening the unit while it TW-1, TW-2 is energized. Only qualified personnel who have been trained in the use of electrical testing devices and in avoiding the safety hazards involved in ONTROLS safely troubleshooting this type of equipment should perform this test procedure.
Page 25: Tw Control Initial Setup
Menus on the Controller: TW C ONTROL The controller has information available in 5 areas. Four of them are user accessible. These are: the Main Menu, the NITIAL ETUP Setpoint Menu, the Configuration menu and the Alarm Page. The service page also has additional parameters that are accessible in cases of need.
Page 26: Tw Control Changing Temperature Units
The Temperature units parameter allows selection of the dis- TW C ONTROL played temperature units. The available selection is either degrees Celsius or Fahrenheit. ºC or ºF depicts this. HANGING Press the Enter key unit the default con- EMPERATURE figuration page UN is displayed. NITS Press Enter again to show ºC or ºF.
Page 27: Control Initial Setup
TW-1, TW-2 WARNING: Electric shock hazard This equipment is powered by high voltage. Always ONTROL disconnect and lock out the main power source before opening the unit or the electrical enclosure to NITIAL ETUP modify factory settings. Failure to disconnect and lock out the main power source can result in severe personal injury.
Page 28: Control Changing Temperature Units
TW-1, TW-2 WARNING: Electric shock hazard This equipment is powered by high voltage. Always ONTROL disconnect and lock out the main power source before opening the unit or the electrical enclosure to HANGING modify factory settings. Failure to disconnect and lock out the main power source can result in severe EMPERATURE personal injury.
Page 29: Tw-1, Tw-2 Control Enabling And
TW-1, TW-2 WARNING: Electric shock hazard This equipment is powered by high voltage. Always ONTROL disconnect and lock out the main power source before opening the unit or the electrical enclosure to NABLING AND modify factory settings. Failure to disconnect and lock out the main power source can result in severe ISABLING personal injury.
Page 30: Disabling Passcode Protection
TW-1, TW-2 ONTROL NABLING AND ISABLING ASSCODE ROTECTION CONTINUED 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.
Page 31: Control Selecting The Temperature Control Point
TW-2 C ONTROL WARNING: Electric shock hazard This equipment is powered by high voltage. Always ELECTING THE disconnect and lock out the main power source before opening the unit or the electrical enclosure to EMPERATURE modify factory settings. Failure to disconnect and lock out the main power source can result in severe ONTROL OINT...
Page 32 TW-2 C ONTROL ELECTING THE EMPERATURE ONTROL OINT CONTINUED 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.
Page 33: Parameters
TW-1, TW-2 You can establish a normal operating range around the process temperature setpoint using the high and low deviation parame- ters. If the process temperature exceeds the high deviation ONTROL limit, or falls below the low deviation limit for longer than the set delay time, the Thermolator alerts you to the unacceptable NTERING temperature variation with an alarm light, and optional audible...
Page 34: Control Installing The Auto Start Feature
TW-2 C ONTROL WARNING: Electric shock hazard This equipment is powered by high voltage. Always NSTALLING THE disconnect and lock out the main power source before opening the unit or the electrical enclosure to TART modify factory settings. Failure to disconnect and lock out the main power source can result in severe EATURE personal injury.
Page 35 Set dip switch 4 to the TW-2 C ONTROL 8 7 6 5 4 3 2 1 ON position. NSTALLING THE Close the electrical enclosure and restore power TART to the unit. EATURE NOTE: All dip switch illus- trations in this manual show switches 7 and 8 set to ON.
Page 36: Positioning The
Grasp the black control panel handles and pull upward. Use the magnetic back to mount the control panel in the remote location. Connect the remote- mounted control to the unit with the cable provided. 3-20 NSTALLATION Thermolator TW-1 and TW-2 UGH015/0100...
Page 37: Operation
PERATION l TW Control Features ..4-2 l TW Control Menu ... .4-3 l TW-1 Control Features ..4-4 l TW-2 Control Features .
Page 38: Tw Control Features
TW C ONTROL EATURES Display 3-digit screen shows Process temperature, Alpha Alarms and Operation indicators. Indicator light shows hot gas unloading. Main Menu Contents Alarm Codes Setpoint Procedure Informs user of types of alarms Status Lights For Pump, Heater and Cooling Valve On/Off Button Raise Button...
Page 39: Tw Control Menu
The TW temperature controller uses a menu system to access TW C ONTROL different operating modes or change system parameters. Please see the Appendix for default parameter settings and detailed information on each of these modes and parameters Parameter Menus Temperature Units.
Page 40: Control Features
All normal operating functions can be controlled from the TW-1 C ONTROL TW-1 control panel. If you have the optional manual mold purge, the control switch is located on the side of the EATURES Thermolator electrical enclosure. Run/Stop Actual values display Setpoint display Press RUN button to The green window displays the temperature...
Page 41 TW-2 C All normal operating functions can be controlled from the ONTROL TW-2 control panel, including the optional mold purge. EATURES Run/Stop Actual values display Setpoint display Press RUN button to The green window displays the temperature The Setpoint display shows the start normal operation.
Page 42: Starting The Tw
Before starting the Thermolator, verify that the system has TARTING THE been installed correctly for your application. See Installation, section 3. Turn on the water supply to the Thermolator. The supply pressure must be at least 25 psi. Check for leaks in the cooling water and process fluid lines before continuing.
Page 43: Stopping The Tw
WARNING: Electrical shock and TOPPING THE 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). You must shut down the Thermolator whenever you: l Change the water hookups.
Page 44: Starting The Tw-1, Tw-2
Before starting the Thermolator, verify that the system has TARTING THE been installed correctly for your application. See Installation, TW-1, TW-2 Section 3. 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.
Page 45 WARNING: Electrical shock and TOPPING THE hot surface hazards TW-1, TW-2 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).
Page 46: Using The Tw Purge Option
The TW Thermolator can be ordered with an optional purge SING THE valve, which clears the process lines of fluid using com- pressed air. The valve is operated by an optional manual purge ANUAL URGE button on the control panel PTION IMPORTANT: Before purging the process lines, be sure...
Page 47 The TW-1 direct injection and closed circuit models can be TW-1 SING THE ordered with optional mold purge, which clears the process lines of fluid using compressed air. The purge is operated by a ANUAL URGE manual switch on the left side of the unit. PTION IMPORTANT: Before purging the process lines, be sure...
Page 48 The TW-2 direct injection and closed circuit models can be TW-2 SING THE ordered with optional mold purge, which clears the process lines of fluid using compressed air. The purge is operated by a ANUAL URGE button on the control panel. PTION IMPORTANT: Before purging the process lines, be sure...
Page 49: Tw Control Performing An Autotune
TW C The controller has three pre-configured tuning parameter sets, ONTROL one of which should allow optimum temperature control. Following is a description of each of the choices available to ERFORMING AN an operator: UTOTUNE Slow Responding system: Select the slow setting “SLO” for large systems*. More than 1,700 pounds (200 gallons) of water and more than 14,000 lbs of steel might be considered a large system.
Page 50: Cont
WARNING: Electric shock hazard TW-1, TW-2 This equipment is powered by high voltage. Always ONTROL disconnect and lock out the main power source before opening the unit or the electrical enclosure to ERFORMING AN modify factory settings. Failure to disconnect and lock out the main power source can result in severe personal injury.
Page 51 TW-1, TW-2 ONTROL ERFORMING AN Set the setpoint to desired value. Press (the Setpoint Select button) simultaneously to begin the Auto Tune. The pump ener- gizes, the Actual display flashes “At” and the current process temperature to indicate that an Auto Tune is underway.
Page 52: Control Entering Passcodes
TW-1, TW-2 ONTROL NTERING ASSCODES The TW-1 and TW-2 models have a security feature that pre- vents accidental or unauthorized changes to the setpoint tem- perature, high and low deviation limits, SPI address, and baud rate. If passcode protection is enabled, you must enter the correct passcode to change these parameters.
Page 53: Maintenance
AINTENANCE l Maintenance Schedule ... .5-2 l Accessing the Thermolator Enclosure .....5-3 l Checking Reservoir Fluid Levels .
Page 54: Maintenance Schedule
Thermolator TW Series water temperature controllers are REVENTATIVE essentially maintenance-free. However, to maintain the best performance, we recommend the following maintenance AINTENANCE schedule. CHEDULE FOR l Whenever process variables change TW-1 TW-2 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.
Page 55: Preventative Maintenance Schedule
l Annually (every 12 months) REVENTATIVE Test and calibrate the unit’s control systems. AINTENANCE The TW-1 and TW-2 control Test Mode checks the operation of displays, control buttons, inputs and out CHEDULE FOR puts. You can also calibrate the supply and return thermo- couples.
Page 56: Fluid Levels
The isolated, or totally closed circuit models separate the cool- HECKING THE ing water from the process fluid, which is held in a reservoir inside the unit. This reservoir should be kept at about three- ESERVOIR quarters full of the process fluid. LUID EVEL You can check the fluid level...
Page 57: Control Performing System Tests
Conair Thermolators with TW-1 or TW-2 controls provide a TW-1, TW-2 Test Mode that tests displays and keys on the control panel, as well as inputs and outputs. The Test Mode also allows calibra- ONTROL tion of the supply and return line thermocouples.
Page 58: Control Key/Display Test
The Key/Display Test verifies the function of displays, LEDs TW-1, TW-2 and buttons on the control panel. ONTROL Enable Test Mode. ISPLAY 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”.
Page 59: Control Input Test
The Input Test verifies the function of inputs available on TW-1, TW-2 models with TW-1 or TW-2 controls. Not all inputs are used on all models. The performance evaluation of the inputs is ONTROL NPUT based on the voltage sensing device (VSD). Connect all inputs to the system.
Page 60: Control Output Test
The Output Test verifies the function of outputs available on TW-1, TW-2 the models with TW-1 or TW-2 controls. Not all outputs are used on all models. The performance evaluation of the inputs ONTROL is based on the output monitors (OM). UTPUT Connect all outputs to the system.
Page 61: Tw-1, Tw-2 Control Disabling Or
All output monitors on the Thermolator can be enabled or dis- TW-1, TW-2 abled permanently through the OM Enable/Disable Menu in Test Mode. ONTROL You need to use this feature if you have replaced the mother- ISABLING OR board, or if dip switches 7 and 8 have been changed erro- neously.
Page 62: Control Calibrating Temperature Sensors
Thermolators with TW-1 or TW-2 controls use type “K” ther- TW-1, TW-2 mocouples to sense the temperature in the return and supply process lines. These thermocouples should be calibrated annu- ONTROL ally, or when a new thermocouple is installed, to ensure cor- rect operation.
Page 63 TW-1, TW-2 Press the up s key to begin calibrating. The controller displays the name of the current calibration ONTROL (examples: 32 SC.L; 32 rC.L; 510 SC.H; or 510 rC.H). ALIBRATING EMPERATURE ENSORS Wait until the control displays ‘don’ or ‘bad’. A “don”...
Page 64: Control Logging Operating Hours
You can see the total numbers of operation by accessing the TW-1, TW-2 Total Operating Hours Log in Test Mode. ONTROL Enable Test Mode. OGGING Press any key to display the first test menus. PERATING OURS Index through test menus to the operating log. Press and hold the Setpoint key for 3 seconds to index to each test menu until the Actual display indicates...
Page 65: Control Pulse Mode Description
TW-1, TW-2 The Thermolator Direct Injection Model has a Pulse Mode in which software pulses the cool and vent valves at a predeter- mined rate under normal control and autotune when all of the ONTROL following conditions are met. ULSE l The Control Point temperature is less than 245°F.
Page 66: Alarm/Band And Delay
The table lists the limits and defaults for the pulse mode para- TW-1, TW-2 meters. ULSE IMITS AND Low Limit Parameter High Limit Default Value Pulse Cycle Time Off, 0.1 minute 15.0 minutes EFAULTS Pulse Time 0.5 seconds 5 seconds 1 second When the Pulse Cycle Time is set to Off the Pulse Mode is disabled.
Page 67: Adjustment
When the unit starts, i.e. on/off is pressed the Vent sequence is TW-1, TW-2 initiated. ONTROL The venting sequence is divided into two phases. In the first phase the cool output energize for the set venting sequence IMER time, VT1. This is followed by a second phase in which the cool, and pump outputs are energized for the VT2 time.
Page 68 5-16 AINTENANCE Thermolator TW Series UGH025-0504...
Page 69: Troubleshooting
ROUBLESHOOTING l Before Beginning ..... .6-2 l A Few Words of Caution ....6-2 l Identifying the Cause of a Problem for the TW Control .
Page 70: Before Beginning
You can avoid most problems by following the recommended EFORE installation, operation and maintenance procedures outlined in this User Guide. If you do have a problem, this section will EGINNING help you determine what caused it and tell you how to fix it. Before you begin troubleshooting: o Find the wiring, plumbing or other diagrams that were shipped with your equipment.
Page 71: Identifying The Cause Of A Problem
Illuminated alarm lights and error codes on the temperature DENTIFYING THE controller will alert you to many malfunctions. If the optional alarm package is installed, an audible alarm also will activate. AUSE OF A ROBLEM FOR ONTROL Standard indicator lights and alarm codes.
Page 72 Most Thermolator malfunctions are indicated by an illuminat- DENTIFYING THE ed alarm light and error codes displayed on the control panel. AUSE OF A A problem can trigger three types of alarms: l Shut Down Alarms: The Thermolator detected a problem ROBLEM FOR that caused it to shut down automatically to prevent equip- TW-1, TW-...
Page 73: Tw Control Alarms
The Thermolator has detected a problem that could lead to equip- TW C ONTROL ment damage or personal injury if it is not corrected. u The controller displays a red alarm LED or an error code indi- LARMS cating the cause of the problem. u If the optional alarm package is installed, the Fault button will illuminate and the audible alarm will activate.
Page 74 The Thermolator has detected a problem that could lead to equip- TW C ONTROL ment damage or personal injury if it is not corrected. u The controller displays a red alarm LED or an error code indi- LARMS cating the cause of the problem. u If the optional alarm package is installed, the Fault button will illuminate and the audible alarm will activate.
Page 75 The Thermolator has detected a problem that could lead to equip- TW C ONTROL ment damage or personal injury if it is not corrected. u The controller displays a red alarm LED or an error code indi- LARMS cating the cause of the problem. u If the optional alarm package is installed, the Fault button will illuminate and the audible alarm will activate.
Page 76 The Thermolator has detected a problem that could lead to equip- TW C ONTROL ment damage or personal injury if it is not corrected. u The controller displays a red alarm LED and/or an error code LARMS indicating the cause of the problem. Solution Cause Alarm...
Page 77 The Thermolator has detected a problem that could lead to equip- TW-1, TW-2 ment damage or personal injury if it is not corrected. u The Alarm LED lights and the STOP/RUN LED flashes red. ONTROL u The Thermolator automatically shuts down. u The control displays a red LED or alarm code indicating the LARMS source of the problem.
Page 78 The Thermolator has detected a problem that could lead to equip- TW-1, TW-2 ment damage or personal injury if it is not corrected. u The Alarm LED lights and the STOP/RUN LED flashes red. ONTROL u The Thermolator automatically shuts down. LARMS u The control displays a red LED or alarm code indicating the source of the problem.
Page 79: Control Shut Down Alarms
The Thermolator has detected a problem that could lead to equip- TW-1, TW-2 ment damage or personal injury if it is not corrected. u The Alarm LED lights and the STOP/RUN LED flashes red. ONTROL u The Thermolator automatically shuts down. u The control displays a red LED or alarm code indicating the LARMS source of the problem..
Page 80 The Thermolator has detected a problem that could lead to equip- TW-1, TW-2 ment damage or personal injury if it is not corrected. u The Alarm LED lights and the STOP/RUN LED flashes red. ONTROL u The Thermolator automatically shuts down. LARMS u The control displays a red LED or alarm code indicating the source of the problem.
Page 81 The Thermolator has detected a problem that could lead to a shut TW-1, TW-2 down condition if it is not corrected. u The Alarm LED lights. ONTROL u The Thermolator continues operating. ARNING u The control displays a red LED or alarm code indicating the source of the problem.
Page 82: Control Warning Alarms
The Thermolator has detected a problem that could lead to a shut TW-1, TW-2 down condition if it is not corrected. u The Alarm LED lights. ONTROL u The Thermolator continues operating. ARNING u The control displays a red LED or alarm code indicating the source of the problem.
Page 83: Control Other Warnings
TW-1, TW-2 The Thermolator has detected a problem that could lead to a prob- lem if it is not corrected. ONTROL u The Thermolator continues operating. THER u The control displays a red LED indicating the source of the problem. ARNINGS Solution Possible cause...
Page 84: Control System Alarms
The memory has exceeded Cycle power to the unit. Contact its usable life or there is a Conair service if an operating software bug. This error parameter such as the setpoint is occurs only after changes not being saved or if this error have been made to non- persists.
Page 85: Thermolator Will Not Power Up
If you apply power to the Thermolator and the control panel does HERMOLATOR not light, you have a problem with the main power circuit or the unit’s microprocessor board. WARNING: Electrical Shock Hazard OWER Disconnect and lockout the main power supply before proceeding.
Page 86: Replacing The Tw Control
The temperature controller used in the Thermolator TW slides EPLACING THE in and out of its casing for easy replacement. Disconnect and lockout the main power. EMPERATURE Unscrew the nuts and then remove the control ONTROLLER metal. Disconnect connectors on back of controllers. Remove controller by squeezing plastic returning clip tabs.
Page 87: Checking And Replacing Fuses
This procedure covers the factory-installed fuses on the unit’s HECKING AND motherboard. If you have installed an electrical disconnect or emergency stop switch, additional fuses and/or breakers may EPLACING have been used elsewhere in the main power circuit. USES To replace a blown fuse: Disconnect and lockout the main power.
Page 88: Resetting Overloads
The pump motor overload is located inside the unit’s electrical ESETTING enclosure. VERLOADS Disconnect and lockout the main power. Open the electrical enclosure door. Turn the screw on the front panel counterclockwise to open. Check the overload. If the red button is out, the over- load has tripped.
Page 89: Replacing The Motherboard Tw-1, Tw-2
EPLACING THE Disconnect and lockout the main power supply. OTHERBOARD Open the electrical enclosure door. Turn the screw on the front panel counterclockwise to open. Mark or label each wire 3 PHASE INPUT connected to the motherboard. The orange shield is labeled UNLDR 1/ VENT 2 SOL with the connection informa- UNLDR 1/ VENT 2 SOL...
Page 90: Replacing The Heater Contactor
WARNING: Electrical Shock Hazard EPLACING THE Only qualified service personnel who have been EATER trained on electrical testing and the procedures for avoiding the hazards should diagnose or correct prob- ONTACTOR lems that require opening the unit with power on. Thermolators use mercury displacement heater contactors.
Page 91: Checking Thermocouples
The Thermolator uses two type ‘K’ thermocouples HECKING to monitor supply and return process temperatures. One ther- mocouple is installed in the wall of the heater tank at the “to HERMOCOUPLES process” outlet. The other thermocouple is installed in the wall TW-1 TW-2 of the cooling tank at the “from process”...
Page 92 SENSOR If you receive a sensor failure SF2 a possible cause may be the process temperature sensor failed. Check with OHM TEST READINGS meter and see if the resistance matches the table below. TW C Replace if needed. In addition the sensor wiring may be ONTROL incorrect or failed.
Page 93: Repairing Cooling Valves
Every Thermolator has a solenoid valve assembly that con- EPAIRING trols the cooling water out flow. Closed circuit (CC) units also have a vent valve assembly. Solenoid valves also are found on OOLING the optional purge valve. ALVES WARNING: Electrical shock and hot surface hazards Before attempting maintenance of any kind on the Thermolator, you must stop the unit;...
Page 94: Repairing Solenoid Valves
EPAIRING Indicates Parts Supplied in Solenoid Enclosure Kit OLENOID Retaining Clip ALVES Nameplate Retaining Cap Cover Sleeve Grounding Wire Yoke (Not present on all constructions) Insulating Washer Housing 7/8" Dia. Hole for 1/2" Conduit Coil Solenoid Base Insulating Washer Sub-Assembly 0.9375-26 UNS-2A Sleeve Thread...
Page 95 EASSEMBLY OTORIZED Verify that the valve is in the ALVES closed position. The position of the ball opening is indicated by the index on top Using a 10 mm of the shaft. wrench or socket, 2 Slide the actuator evenly tighten the straight down two nuts on the over the valve...
Page 96: Replacing Heater Elements
WARNING: EPLACING Electrical shock and hot surface hazards EATER Before attempting maintenance of any kind on the Thermolator, you must stop the unit; LEMENTS disconnect and lockout the main power supply; and allow the unit to cool to less than 100°F (38°C) Disconnect and lockout the main power.
Page 97 Unscrew the locking screws on the wiring harness and EPLACING remove the wires. EATER Shut off the cooling water in feed. LEMENTS Drain the Thermolator using the drain plugs located at the rear of the unit. CONTINUED Remove the four bolts that hold the heater element in place.
Page 98: Removing The Pump
WARNING: Electrical shock and EMOVING 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) Disconnect and lockout the main power.
Page 99: Disassembling And Assembling 3/4 To 2 Hp Pumps
To replace a failed seal, you must disassemble the pump. ISASSEMBLING Remove the impeller nut. SSEMBLING Insert a screwdriver in one of the impeller waterway pas- sages and back off the impeller nut. UMPS Remove the impeller by inserting a screw- driver in the slot of the motor shaft.
Page 100: Disassembling And Assembling
To replace a failed seal, you must disassemble the pump. ISASSEMBLING Remove the impeller retaining assembly. Insert a screwdriver in one of the impeller waterway passages to SSEMBLING hold the impeller steady while removing the retainer. 3 - 7.5 UMPS Remove the impeller being careful not to lose any parts.
Page 101 ISASSEMBLING Reattach the pump to the volute. Make sure you SSEMBLING replace any damaged gasket 3 - 7.5 or O-ring between the pump UMPS assembly and volute case. Check for free rotation after CONTINUED assembly is completed. NOTE: Before restarting, close all drain openings using sealant on the threads and and refill the unit with fluid.
Page 102 6-34 ROUBLESHOOTING Thermolator TW Series UGH025-0504...
Page 103: Appendix
Conair equipment may be ordered through the Customer Conair has made the largest investment in customer support in the plastics industry. Service or Parts Department for a Our service experts are available to help with any problem you might have nominal fee.
Page 104 (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. The customer assumes the cost of transportation of the part or parts to and from the factory.
Page 105: Pump Curves
URVES PPENDIX UGH025-0504 Thermolator TW Series...
Page 107 The Thermolator will not operate correctly if certain factory-set TW C ONTROL parameters are changed. Parameters should be changed only by qualified technical personnel who are familiar with the operation of EFAULT this type of equipment. ARAMETERS If the Thermolator does not appear to be working correctly, verify the parameters against the list of factory settings.
Page 109 The SPI commands supported by Conair Thermolator ® mold TW-1, TW-2 temperature controllers are listed in the following tables. ONTROLS The standard required commands and three optional com- mands are listed in the SPI Command Pairs table, along with OMMANDS the Select and Poll command pairs in hexadecimal format.
Page 110 TW-1, TW-2 C SPI S ONTROL TATUS ORDS Status, Process Poll: 0x20 0x40 SPI STATUS WORD Word BIT position EEprom error SET SET A/D converter error SET SET CJC Error SET SET RAM hardware SET SET ROM checksum SET SET Probe Failure E/M Hi temp safety Prog.
Page 111 TW-1, TW-2 C SPI S ONTROL TATUS ORDS Status, Machine 1 Poll: 0x20 0x42 SPI STATUS WORD Word BIT position EEprom error SET SET A/D converter error SET SET CJC Error SET SET RAM hardware SET SET ROM checksum SET SET Probe Failure E/M Hi temp safety SET SET Prog.
Page 112 TW-1, TW-2 C SPI S ONTROL TATUS ORDS Status, Machine 2 Poll: 0x20 0x44 SPI STATUS WORD Word BIT position EEprom error SET SET A/D converter error SET SET CJC Error SET SET RAM hardware SET SET ROM checksum SET SET Probe Failure SET SET E/M Hi temp safety Prog.
Page 113: Parts /Diagrams
ARTS IAGRAMS l TW-1 Circuit Board ..PD-2 l TW-2 Circuit Board ..PD-3 PD-1 UGH025-0504 Thermolator TW Series...
Page 114 PD-2 TW-1 C IRCUIT OARD UGH025-0504...
Page 115: Circuit Board
PD-3 TW-2 C IRCUIT OARD UGH025-0504...

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Conair Thermolator TW-1 User Manual

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