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Summary of Contents for Temptek VETERAN VTR Series
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I.O.M. #200 updated : 04/05/2023 INSTRUCTION MANUAL • INSTALLATION • OPERATION • MAINTENANCE Units with the LXG-300 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 :...
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INSTRUCTION MANUAL Veteran VTR Series with LXG-300 Control 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...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument TABLE OF CONTENTS 1.0 GENERAL Receiving Instructions Introduction Safety Water Treatment Components 2.0 INSTALLATION General To and From Process Connections Water Supply Connection Drain Connection Electrical Connection 3.0 START UP SEQUENCE...
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument 6.0 COMPONENTS Mechanical system Electrical system 7.0 RELATED DRAWINGS Physical : Cabinet Style for Units up to 16 kW Heaters and Pumps to 3 HP Physical : Cabinet Style for Units up to 24 & 34 kW Heaters and Pumps to 3 HP Physical : Cabinet Style for Units up to 5 &...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument GENERAL Receiving Instructions Introduction Safety Water Treatment Components Page: 7 Advantage Engineering, Inc. 525 East STEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument RECEIVING INSTRUCTIONS Temperature control units are generally shipped skid mounted, boxed and wrapped in plastic prior to shipment. Unbox the unit before accepting delivery. Check for visible damage and document any evident damage on the delivery receipt or refuse the shipment.
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument Observe all safety precautions during installation, startup and service of this equipment due to the presence of high voltage. Only qualified personnel should install, startup and service this equipment.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument WARNING: Improper water treatment will void unit warranty. WATER TREATMENT The fluid used in your temperature control unit will greatly effect its short and long- term operation. Lack of as well as improper water treatment can damage the temperature control unit by causing scale build-up, excessive corrosion and/or bacterial contamination.
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument Pressure Gauges (Across-the-process to provides full Control Instrument performance information) (unseen from this angle) Heater Electrical Cabinet Connection : To Process Probe Connections Stainless Steel Cabinetry Copper Drain Line Polymer front panel (up to 3 hp &16 kW)
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument INSTALLATION General To and From Process Connections Water Supply Connection Drain Connection Electrical Connection Page: 13 Advantage Engineering, Inc. 525 East STEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument GENERAL Care should be taken to use materials (hose, rigid piping, valves or filters) rated for the temperature and pressure duty of your unit. Most units have a maximum operating temperature of 300°F or less and a maximum pressure of 150 PSI.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument WARNING: Check local codes to determine proper use of back flow prevention device in water supply line. WATER SUPPLY CONNECTION Connect the unit’s Water Supply port to the plant’s city water, well water, tower water or chilled water supply.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument In general the standard ½” cooling valve will provide approximately 24,0000 Btu/hr (7 kW) of cooling per every 10°F difference between the cooling water temperature and the process set point based on 25 psi delta p across the cooling valve with ½”...
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument WARNING: Do not connect the unit to a voltage supply not equal to the unit’s voltage requirements as specified on the unit’s data plate. Use of incorrect voltage will void the unit’s warranty and cause a significant hazard that may result in serious personal injury and unit damage.
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument WARNING: Check that all electrical connections are tight before starting. Disconnect power before servicing. Follow all facility lock-out tag-out procedures. Control Instrument Terminal Strip Power Entry Transformer Fuse Blocks...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument OPERATIONS General Machine Start Up and Operation Instrument Operation : Quick Start Instrument : Basic Navigation Instrument : Operating Screens Instrument : Fault Screens Instrument : Main Menu Instrument : Setpoints Menu...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument GENERAL Failure to follow the factory required operation procedures may adversely affect the unit’s ability to adequately control process temperature and may create a hazardous operating condition which may result in unit damage or serious operator injury.
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument Adequate water fill and pressure must be supplied to the unit for efficient and safe operation. To ensure sufficient water fill, an electrical panel mounted pressure switch is supplied with the unit. A capillary line feeds the pressure switch.
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument switch. Follow proper lockout procedures before proceeding. Once the electrical power supply is disengaged, reverse any two power leads of the power cord at the fused disconnect terminals. Note: The operator must reverse the...
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument Some older models have overload relay where a red button that pops out if the overloads are tripped. Simply push the button in until the overloads are reset. Other overload relays have a switch. This switch will be positioned with the indicator pointing up when in normal operation.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument line. The throttling valve can be a gate valve or a ball valve. With the throttling valve installed, fully close the valve and then engage the pump motor. Slowly open the throttling...
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument Apply power. The Standby screen will illuminate. When Standby is displayed on the screen, the unit is not running. To Process 50°F Standby Status : Ready S e t p o i n t : 50°F...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument INSTRUMENT : BASIC NAVIGATION Back The instrument has 5 soft keyed buttons. The Home button, when pressed , shows the Home screen. The Up button, when pressed, will add one unit of value or will scroll up through a menu.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument displays “Success” as indication the value was saved. Use the Go or Back buttons to acknowledge the prompt. After acknowledging the success, the screen returns to the parent screen.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument INSTRUMENT : FAULT SCREENS Faults Preventing Start Up or Operation : System Safety. This fault screen appears if the following occurs: Water Pressure. The unit will not operate without adequate water supply pressure.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument INSTRUMENT : MAIN MENU The Main Menu offers the ability to set and change values in the following areas: Setpoints. Utilities. Network. Features. Flow. Machine. The Main Menu is accessible from the Standby screen by pressing the Go button.
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument Hi Deviation. The High Deviation value programs the controller to sound the alarm if the process temperature exceeds the set difference from setpoint. For example, Hi Deviation = 5°F, Setpoint = 200°F. Hi deviation alarm will sound if the temperature reaches 205°F.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument INSTRUMENT : UTILITIES MENU Items in the Utilities menu include the operations for the Mold Purge, Manual Vent, Software Version Number and Display Test. Mold Purge (optional feature not included on all units). The mold or system purge system contains several solenoid valves and check valves.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument Select the Software Version item from the Utilities Menu to advance to the software version screen. Press the Back button to return to the Utilities menu. Display Test. The Display Test will test the entire for bad pixels or sectors.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument Use the Select button to save the selection and confirm success. Baud Rate: This is the data transfer rate of between the unit and the host computer. Press the Select button to select Baud Rate.
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument for the “autovent time” (factory default is 45 seconds). When the unit is in the autovent sequence "autovent" is displayed on the home screen. During the autovent sequence the cooling valve is 100% open and pump is running to remove entrapped air from the process.
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument When activated, the pump seal cooling features is engaged by pressing the stop button once. The cooling valve will open and the pump will continue to run until the pump seal cooling temperature or time limit is met.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument 3.12 INSTRUMENT : OPTIONS MENU Two selections are available under the Options menu : Mold Purge and Remote Start/ Stop. These selections will enable or disable these options. Please note: these options require factory or field installation of optional equipment.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument 3.13 INSTRUMENT : MACHINE MENU The Machine Menu allows the units to set values for the Max Setpoint and Units. Main Menu Main Menu Main Menu Main Menu Machine...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument 3.14 SHUT DOWN - DISCONNECT UNIT SHUT DOWN Decrease the setpoint temperature lower than 85°F and allow the unit to cool to the temperature. A pump seal cooling feature can be selected from the features menu to automatically cool the unit once the stop button is pressed.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument TROUBLESHOOTING Unit will not start (Display is not Illuminated) Unit will not start (Display Illuminated) Unit Stops Unit Overheats Unit Underheats Pressure Relief Valve Leaks Page: 39 Advantage Engineering, Inc.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument UNIT WILL NOT START (DISPLAY IS NOT ILLUMINATED) One or more fuses at the main disconnect device are open (blown). Determine continuity at each fuse. If continuity is not determined, replace the fuse. Then determine cause of blown fuse.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument Motor overload switch opened. The display shows a Fault : System Safety screen. The electric motor is protected from overload conditions by a set of thermal overload relays. These relays will open (trip). If the overload relay is open, it must be reset before operation can continue.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument Instrument defective. The instrument is life-tested and found to be field reliable. 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.
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument leak. Refer to section 7.3 for regulator installation drawing. Valve contamination. The pressure relief valve may become contaminated with water debris causing the valve not to close properly. If this is the case, flushing the valve for a moment will cleanse the seat and allow it to work properly.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument SERVICE/MAINTENANCE Pump Seal Replacement Heater Replacement Cooling Valve Service Voltage Change Sensor Probe Service Pressure Switch Service Electronic Instrument Repair Policy & Procedure Temperature Probe Calibration Heater Contactor and Pump Motor Starter Page: 45 Advantage Engineering, Inc.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument PUMP SEAL REPLACEMENT The pump seal is a carbon/ceramic shaft Rotating Member Tension Spring seal assembly including a stationary member, rotating member and tension spring. The life cycle of the pump seal is determined by hours of use, operating temperature and water quality.
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument The motor shaft is free to rotate, but must be secured to remove the impeller. To secure the motor shaft, insert a flat bladed screw driver in slot to hold the shaft stationary.
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument time. This is normal. After a few moments, the new seal will take seat and the leak will stop. Seal components Figure 5.1I Stationary member Figure 5.1J Rotating member Figure 5.1K...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument HEATER REPLACEMENT The heater is a flange mounted assembly and inserted into the cast cylinder tank and secured by 4 bolts. The operator can determine if the heater requires replacement when the heater draws “0”...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument COOLING VALVE SERVICE The unit uses the PVT (Pulsed Valved Technology) solenoid valve (figure 5.3A) as the cooling valve. The solenoid valve is controlled by the instrument. Generally, the PVT valve require service for a failed coil or more often it will not fully close because debris from poor make-up water quality is in the valve mechanism.
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument Coil and solenoid base sub assembly Valve body Core Body Diaphragm Diaphragm assembly Core spring assembly Gasket spring Page: 51 Advantage Engineering, Inc. 525 East STEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument VOLTAGE CHANGE Some units can undergo a field voltage conversion by qualified technicians. Consult with the Service Department to determine if your unit can be converted. Have your Serial Number ready and call 317-887-0729.
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument Rewire the heater to the new voltage. Schematics for heater brands used in typical temperature control units are shown below. Wiring Schematic for Watlow Brand Heaters : 10 kw & 16 kW...
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument Remove the thermoformed front panel and open the electrical cabinet panel door. Unplug the instrument connectors to fully extend the hinged panel. Rewire the pump motor for the new voltage. Most Sentra pump motors are dual voltage.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument SENSOR PROBE SERVICE Probe The temperature probe is a temperature transducer. The transducer is embedded into a bulb well, which is threaded into the tank. The transducer converts the...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument PRESSURE SWITCH SERVICE The unit is protected from low pressure operations by a pressure switch. This switch is mounted at the bottom of the electrical cabinet. The switch will close and consent the control circuit when sufficient water supply pressure is presented.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument ELECTRONIC INSTRUMENT REPAIR POLICY AND PROCEDURE All control instruments used in temperature control units are covered by the machine’s warranty. Proprietary ‘tailor made’ instrument are manufactured specifically for the Manufacturer.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument TEMPERATURE PROBE CALIBRATION Equipment Needed: Potentiometer adjustment tool / flat-blade screw driver (tip width of 0.050” or less works best Temperature reference (ice water bath) 1/2” plug Digital thermometer...
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument Adjust the potentiometer until the “to process” temperature on the display equals the temperature of the ice bath. When the two temperatures are equal, the calibration procedure is complete.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument HEATER CONTACTOR & PUMP MOTOR STARTER The “standard” mechanical contactor for the heater will cycle proportionally to the amount of heat input required for the process and may cycle frequently.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument COMPONENTS Mechanical System Electrical System Page: 61 Advantage Engineering, Inc. 525 East STEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument MECHANICAL SYSTEM Pump Casing/Cooling Tank/Heater tank. The pump casing/cooling/heater casting is an exclusive design (Standard 1/2-3 horsepower models). The pump casing is designed for high efficiency performance and houses the pump impeller. The integral heater tank houses the flange mounted immersion heater and the integral cooling tank provides a mixing chamber for return from process fluid and cooling water.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument ELECTRICAL SYSTEM INSTRUMENT. The instrument is a custom designed and assembled microprocessor controller. The instrument is mounted to the electrical panel cover. The instrument controls the cycling of the heater, motor pump and AVT cooling valve.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument RELATED DRAWINGS Physical : Cabinet Style for Units up to 16 kW Heaters and Pumps to 3 HP Physical : Cabinet Style for Units with 24 & 34 kW Heaters and Pumps to 3 HP Physical : Cabinet Style for Units with 5 &...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument PHYSICAL : Cabinet Style for Units up to 16 kW Heaters and Pumps to 3 HP Page: 66 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument PHYSICAL : Cabinet Style for Units with: 24 & 34 kW Heaters and Pumps to 3 HP Provided for display purposes only. Refer to electrical drawing supplied with unit for details.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument PHYSICAL : Cabinet Style for Units with : 5 & 7½ HP Pumps Page: 68 TEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument REGULATOR/BYPASS INSTALLATION TO PROCESS FROM PROCESS DRAIN PRESSURE REGULATOR VALVE WATER BYPASS VALVE TYPE: WATTS U5B 1/2" SUPPLY TYPE: WATTS BP-30 1/2" 25-75psi RANGE. 45-100psi RANGE. Page: 69 Advantage Engineering, Inc.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument DUAL ZONE DOLLY Molders often need to run different temperatures on each mold half to produce the best quality part. The Manufacturer can provide a dual zone dolly that holds two standard single zone temperature control units to meet this need.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument STACKING RACK Page: 71 Advantage Engineering, Inc. 525 East STEMPTEK, INC. 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Email: service@Temptek.com...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument APPENDIX Model Number & Suffix Coding Interpretation of Process Pressure Gauges Operation of Mold Purge Remote and Autostart Feature Configuration SPI Commands Communication Cable Optional Alarm Operation Standard G English Factory Default Settings...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument MODEL NUMBER & SUFFIX CODING The data tag on your Temperature Control Unit provides general information about the unit. Compare the information below with your data tag for more information about your unit. Some data tags may have other or different information. If you need specific information about the configuration of your unit contact the factory with the serial number from your unit.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument INTERPRETATION OF PROCESS PRESSURE GAUGES READ AVAILABLE WATER PRESSURE AT UNIT’S LOCATION. When a temperature control unit is attached to the process with the water supply on and the pump off, both gauges will read the water supply pressure at the unit’s location.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument OPERATION OF MOLD PURGE The mold purge system includes valves and piping that when activated and supplied with compressed air will expel process water from the mold or process to the central water return line or drain.
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument ALERT: The Purge cycle must be started and stopped. If not stopped, the Purge cycle will continue and will consume compressed air until stopped. WARNING: Use caution when disconnecting process lines because residual pressure will remain in the lines.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument REMOTE AND AUTOSTART FEATURE CONFIGURATION Because the on/off button on the unit is a momentary switch, the standard design of the Sentra with G-Series control instrument requires the unit to be manually started and manually restarted if the unit was running and power is interrupted.
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument Field installed Remote Start Option Wire user supplied dry contact closure wiring to the contacts provided on the board (see picture). A relay is recommended. Follow the instructions in 8.4.G to activate Remote Start option on the control panel.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument SPI COMMANDS INTRODUCTION: In 1987 a group of member companies of the Society of the Plastics Industries began development of a communication protocol for use by their processing and auxiliary equipment. Their goal was to allow the exchange of information between various pieces of equipment from different manufacturers to be simple and reliable.
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument Check the Data Transfer Rate and Address of each piece of equipment. For example, if both Temperature Controllers have the same address, they will both try to ‘talk’ at the same time and garble each other’s data.
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Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument POLL SELECT C1 C2 C1 C2 COMMAND DESCRIPTION 20 48 20 49 Machine 15 14 13 12 11 10 ALARM - ACKNOWLEDGE ALARM - ON/OFF POLL SELECT C1 C2...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument COMMUNICATIONS CABLE Machine Connections Primary Machine Connections 3-State Driver Enable SHIELD COMMON +5 volts Pull Up Resistor Data To Network 3rd COND 2.2k ohms Termination Resistor Driver 120 ohms...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument OPTIONAL ALARM OPERATION The Temptender and G Series instruments are standard with a 110 volt AC alarm output. The alarm output can be connected to customer provided alarm annunciation, plant-wide monitoring system or optional annunciation provided by the factory.
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument STANDARD G ENGLISH FACTORY DEFAULT SETTINGS Set Points Temperature Set Point 100°F Hi Deviation 10°F Low Deviation 10°F Low Flow 0 GPM Network Protocol Baud Rate 9600 Address Features...
Temperature Control Units : Veteran VTR Series with LXG-300 Control Instrument PARTS : #119 PUMP #119 Pump, Standard 1/2-3 horsepower. Contact the factory for other pump horsepower and custom units. (4x) 5 (4x) 10 Model 119, 119S 0.5-3.0HP Description AEI Part# Scot Part# Case 119, Iron, 1.25x1.25 with Integral Tanks...
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