Mokon HTF System H4 Instruction Manual

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INSTRUCTION MANUAL OIL SYSTEM

Models Covered Are: H4, H5, H6, MK, HC, XC

T:\DATA\MOKON\JOYCE\OIL MANUALS\COMPLETE OIL MANUAL REV P FEB. '08.DOC

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Page 1 INSTRUCTION MANUAL OIL SYSTEM Models Covered Are: H4, H5, H6, MK, HC, XC T:\DATA\MOKON\JOYCE\OIL MANUALS\COMPLETE OIL MANUAL REV P FEB. '08.DOC...
Page 2: Table Of Contents
OIL TABLE OF CONTENTS SECTION 1 – WARNINGS AND CAUTIONS SECTION 2 – INSTALLATION UNPACKING LOCATION WARNINGS ELECTRICAL CONNECTIONS FILLING RESERVOIR FLUID CONNECTIONS SECTION 3 – OPERATION INITIAL STARTING PROCEDURE CHANGING TEMPERATURE SETTING SHUT DOWN PROCEDURE RESTARTING PROCEDURE SECTION 4 – MAINTENANCE AND SERVICE PREVENTATIVE MAINTENANCE 4.1.1 ELECTRICAL 4.1.2 PUMP/MOTOR...
Page 3 OIL TABLE OF CONTENTS SECTION 4 – MAINTENANCE AND SEVICE CONT. SUPPLY PUMPAK SEAL REPLACEMENT SUPPLY PUMP FOR SINGLE ZONE “H6” UNITS, 24 KW OR LESS PUMP RELIEF VALVE PROCESS PURGE OPTION (REVERSE FLOW SWITCH) PROCESS PURGE OPTION (AIR CONNECTIONS) 4.10 HEATER ELEMENT WIRING 4.11...
Page 4: Section 1 - Warnings And Cautions
1.3 – COLD WEATHER CAUTION If the Mokon temperature control system will be moved from your plant and will be subjected to freezing temperatures, the water in the system must be completely drained and/or sufficient antifreeze added to prevent serious water damage from freezing.
Page 5 1.5 - OVERHEAD PIPING WARNING When overhead piping is connected to a Mokon temperature control system equipped with an open or non pressurized expansion tank there is risk of overflow of the system’s reservoir tank upon shutdown, this is due to the back flow of fluid volume from the overhead piping system.
Page 6: Section 2 - Installation
For optimum system performance, allow adequate space and ventilation around entire system as well as a means to direct vapors away from work area. There should be a minimum of four (4) feet of clearance around the entire Mokon system (all sides) for adequate ventilation and operation of the system.
Page 7: Warnings
Note: If your unit was purchased with a process purge option, review section 4.7 or 4.8 for operating instructions. 2.4 – ELECTRICAL CONNECTORS WARNING: THE MOKON SYSTEM, AS WITH ALL HIGH VOLTAGE ELECTRICAL EQUIPMENT, SHOULD BE CONNECTED ACCORDING TO ALL APPICABLE NATIONAL AND LOCAL CODES. ALL INSTALLATION, MAINTENANCE, SERVICE,...
Page 8: Filling Reservoir
LEVEL OF ½ FULL IS RECOMMENDED (OPTIMUM FLUID LEVEL IS ¾ FULL). IT MUST BE MAINTAINED AT ALL TIMES. IF THE PROPER FLUID LEVEL IS NOT MAINTAINED, SERIOUS DAMAGE MAY OCCUR TO THE MOKON SYSTEM. IT IS MANDATORY TO PERIODICALLY INSPECT THE FLUID...
Page 9: Fluid Connections
If the strainer must be mounted in the vertical position, below the process connection on the Mokon unit, a drip leg should be installed to trap debris that will dislodge from the screen upon shutdown. Consult the factory if the strainer must be installed in this fashion.
Page 10: Section 3 - Operation
SECTION 3 – OPERATION NOTE: Prior to starting the Mokon system it may be necessary to tighten the mechanical fittings on the piping. Vibration cause during transport can loosen the fittings. Before proceeding, check and tighten all of the mechanical fittings.
Page 11: Changing Temperature Setting
3.2 - CHANGING TEMPERATURE SETTING If a new temperature setting is required while the unit is in operation, adjust the controller to the new desired setpoint temperature. See section 5 for specific controller instructions. 3.3 - SHUT DOWN PROCEDURE COOL THE UNIT BY REDUCING THE SETPOINT TEMPERATURE TO 150F (66ºC) OR LOWER.
Page 12: Section 4 - Maintenance And Service
HOT SURFACE 4.1 – PREVENTATIVE MAINTENANCE Mokon temperature control systems are designed for a long, trouble free service life under a variety of conditions, with a minimum of maintenance. Performing the following preventative procedures will extend the life of your system. Refer to section 4.2 – 4.10 in the instruction manual for specific adjustment or service procedures.
Page 13 4.1.1 – ELECTRICAL PREVENTATIVE MAINTENANCE WEEKLY CHECKS CORRECTIVE PROCEDURES • Correct component wiring Check electrical box interior components • Verify voltage and frequency on serial tag for any discoloration, or any burn marks, matches customer supply voltage and frequency. • Correct excessive system load (current draw) •...
Page 14: Pump/Motor
4.1.2 – PUMP/MOTOR PREVENTATIVE MAINTENANCE WEEKLY CHECKS CORRECTIVE PROCEDURES • Remove all dust, lint, grease, or oil with a cloth Check for foreign materials obstructing airflow in the motor and pump area. and/or brush. • Apply external lubrication slowly with a hand Check the pump for lubrication.
Page 15 Observe that the process temperature output is within the accuracy of the controller. are secure. (Power On) • If controller does not respond to any of the above steps, consult the Mokon factory. Do not attempt repairs as the warranty could become void.
Page 16 4.1.3 – MISCELLANEOUS PREVENTATIVE MAINTENANCE MONTHLY CHECKS CORRECTIVE PROCEDURES • Repair leaks and/or tighten fittings. Check the system for leaks at operating temperatures. As the system reaches the setpoint temperature, visually check for leakage. Pay close attention to the heater elements.
Page 17: High Temperature Pump (Zone Pump)
4.2 – HIGH TEMPERATURE PUMP (ZONE PUMP) MAINTENANCE WARNING: DISASSEMBLING THE VIKING PUMP WILL VOID THE PUMP MANUFACTURERS WARRANTY AS WELL AS THE MOKON WARRANTY. DANGER: BEFORE OPENING ANY VIKING PUMP OR LIQUID CHAMBER (PUMPING CHAMBER, RESERVOIR, JACKET, ETC.) BE SURE: 1.
Page 18 Figure 1 Figure 1 Exploded View Exploded View Figure 2 Figure 2 Cut-away View Cut-away View PART DESCRIPTION PART DESCRIPTION Locknut 032019 Grease Fitting Lock Washer Bracket Cap Screws For Bracket/ End Cap Outer Casing Lip Seal for End Cap 032039 Bracket Gasket Bearing Spacer Collar Outer...
Page 19: Pump Alignment
4.2.1 – PUMP ALIGNMENT The pump and motor were properly aligned during assembly. During shipping and with time the alignment can be disturbed. Use the following procedure to check the alignment: 1. Check the pump ports to be sure that they are square and in the proper position. 2.
Page 20: Thrust Bearing Adjustment
Back off outer end cap (3) counterclockwise nine notches. Each notch represents 0.001 inch (0.0254mm) end clearance. 5. End clearances set per Step 4 are for Mokon recommended heat transfer fluids (see section 4.11) or other heat transfer fluids with similar viscosity characteristics within the operating range of 150F to 600F (38C to 316C).
Page 21: Packing Gland Lubrication
The pump gland should drip approximately 1 drop per minute at 150F (66C) operating temperature. EXERCISE EXTREME CAUTION WHILE WORKING ON OR IN THE AREA OF THE MOKON TEMPERATURE CONTROL SYSTEM. THE HIGH TEMPERATURE OF THE FLUID WILL CAUSE THE PROCESS LINES, SYSTEM COMPONENTS, AND METAL CABINETRY TO BECOME VERY HOT AND THEREFORE THEY SHOULD NOT BE TOUCHED.
Page 22: Recirculating Pump
4.3 – RECIRCULATING PUMP Mokon 500 series models feature a “Continuous Flow” cool oil reservoir using a recirculating pump to force the flow. When cooling is needed, hot oil from the process loop is released into the reservoir and is replaced by cool oil. The fluid is cooled by forcing the released process oil through the continuous flow heat exchanger where it is mixed with a continuous flow of cool oil from the reservoir.
Page 23 4.3 – RECIRCULATING PUMP CONT. ELECTRICAL All electrical work should be performed by a qualified electrician in accordance with the latest edition of the National and local codes and regulations. The proper operating voltage and other electrical information can be found on the nameplate attached to the top of the motor.
Page 24 NOTE: This section applies only to systems, which include a supply pumpak. Only the H6, XA, and XC series systems contain a supply pumpak. If your system is a single zone, H6 Unit, 24 KW or less, skip to Section 4.6. REF. MOKON REF. MOKON QTY.
Page 25: Supply Pumpak Maintenance & Installation
2. Loosen the drive clamp assembly (1) but do not remove. NOTE: If the motor shaft is a keyed shaft, remove the key before installing the Mokon Pumpak. The drive clamp assembly on the Mokon Pumpak is all that is required to drive the pump.
Page 26 4.4.2 – SUPPLY PUMPAK IMPELLER CLEARANCE ADJUSTMENT Remove the strip stock shim from the suction eye of the pump housing. This shim was inserted to establish clearance between the face of the impeller and the housing. Rotate the motor slowly, by hand, to make certain that the impeller does not rub the housing or the adaptor frame.
Page 27 4.4.4 – SUPPLY PUMPAK DISASSEMBLY 1. Close the gate valve on the reservoir tank. 2. Remove the S.S. studs (7) holding the housing (11) to the adaptor. 3. Remove S.S. bolts (3) which hold the adaptor frame (5) to the motor. 4.
Page 28 4.5 – SEAL ASSEMBLY REPLACEMENT NOTE: This section applies only to systems, which include a supply pumpak. Only the H6, XA, and XC series systems contain a supply pumpak. 1. Make sure impeller shaft is CLEAN and free of nicks or burns. Use fine steel wool to polish sleeve.
Page 29 4.5 – SEAL ASSEMBLY REPLACEMENT CONT. 9. Place the impeller and the seal assembly in the pump housing. Affix the gasket on the frame over the drive sleeve onto the housing. 10. Attach the pump frame to pump head with bolts and secure evenly. Install the shaft retaining collar onto the shaft and attach entire assembly to motor.
Page 30: Supply Pump For Single Zone H6 Units, 24 Kw Or Less
4.6– SUPPLY PUMP FOR SINGLE ZONE H6 UNITS, 24 KW OR LESS 4.6 – SUPPLY PUMP REPAIR AND MAINTENANCE The pump has a viton seal that may last several thousand hours based upon the application. If the motor is replaced, the mechanical shaft seal should also be replaced. A seal that leaks will show leakage through the slot between the pump housing and the motor.
Page 31 4.6.1 – SUPPLY PUMP DISASSEMBLY 1. Remove three cover screws and remove the cover, discarding the o-ring. 2. Secure the impeller and remove the impeller locknut. Pull the impeller straight out off the motor shaft. 3. Remove the seal-rotating porting by pulling the seal off by hand. 4.
Page 32: Pump Relief Valve
“Process Purge” on the control plate if you have this option. NOTE: If additional fluid has been added to the Mokon system after initial start up, it will be necessary to drain the excess fluid prior to using the process purge as to avoid overflowing the reservoir tank.
Page 33: Process Purge Option (Air Connections)
NOTE: If additional fluid has been added to the Mokon system after initial start up, it will be necessary to drain the excess fluid prior to using the process purge as to avoid overflowing the reservoir tank.
Page 34: Heater Element Wiring
4.10 – HEATER ELEMENT WIRING Using the following chart to select between wiring method A and wiring B to wiring Mokon replacement heaters (dual element – hair pin type). Refer to the Mokon system electrical schematic in section 8 for complete heater wiring illustrations.
Page 35: Low Pressure Safety Switch
4.11 – LOW PRESSURE SAFETY SWITCH Mokon systems are equipped with a low pressure safety shut down switch. The low pressure switch is standard on the 500 and 600 Series systems but optional on MK, HC, and XC oil systems. This switch incorporates an interlock to prevent the operation of the system should the heat transfer fluid be insufficient.
Page 36: Recommended Heat Transfer Fluids
4.13 – RECOMMENDED HEAT TRANSFER FLUIDS All Mokon Heat Transfer Fluid Systems are tested using Duratherm 600 Heat Transfer Fluid. Mokon recommends the following heat transfer fluids for use in Mokon systems. A short description of each fluid is given including the recommended application and the manufacturing company name and address.
Page 37 Duratherm 600 is engineered to give unsurpassed levels of protection and service life all at an economical price. All Mokon HTF systems are tested using this fluid. DURATHERM LITE Duratherm Lite - Heat transfer fluid with the same physical properties as Duratherm 600 but formulated with a lighter dose of additives.
Page 38 It can take the stress of electrical elements and system shocks without requiring premature replacement. MultiTherm PG-1 and IG-4 may be used safely in the Mokon MK, MR, HC, HA, XC, XA, 350, 500, 600, and HF Series systems.
Page 39 Its greater purity allows it to strongly resist degradation while holding thermal properties and maintaining efficiency. PARATHERM NF AND PARATHERM HE may be used safely in the Mokon MK, MR, HC, HA, XC, XA, 350, 500, 600, and HF Series systems.
Page 40 The high boiling point of THERMINOL 66 helps reduce the volatility and fluid leakage problems associated with other fluids. THERMINOL 66 may be used safely in the Mokon MK, MR, HC, HA, XC, XA, 350, 500, 600, and HF Series systems.
Page 41 CALFLO FG and HTF may be used safely in the Mokon MK, MR, HC, HA, XC, XA, 350, 500, 600, and HF Series systems.
Page 42 4.13 – RECOMMENDED SYSTEM CLEANING FLUIDS SYSTEM CLEANING FLUIDS Mokon recommends the following system cleaning fluids for use in Mokon HTF systems. A short description of each fluid is given, the manufacturing company name and address. The important technical characteristics are also outlined in a chart following the descriptions.
Page 43 4.13 – RECOMMENDED SYSTEM CLEANING FLUIDS CONT. PARATHERM SC Paratherm SC® system cleaning liquid is expressly formulated to dissolve and suspend sludge and carbon lumps frequently produced in hot oil temperature control units where petroleum or glycol-based heat transfer fluids have been used. The SC liquid is a multi- component synergistic liquid that is compatible with any mineral oil-based thermal fluid, and many of those synthetic fluids as well.
Page 44 4.13 – RECOMMENDED SYSTEM CLEANING FLUIDS CONT. DURATHERM DURACLEAN DuraClean - a long life, preventative maintenance and light duty system cleaner, in addition to functioning as a long-term heat transfer fluid. DuraClean is the perfect preventative maintenance tool. It is capable of running in systems up to 550°F, is odorless and easily handles long term operation while seamlessly allowing production to continue uninterrupted for a complete oil cycle.
Page 45 4.13 – RECOMMENDED SYSTEM CLEANING FLUIDS CONT. MULTITHERM PSC MultiTherm PSC Cleaning Fluid is designed for use in general maintenance of larger heat transfer fluid systems. MultiTherm PSC can be used with the Heat Transfer Fluid that is currently in the system or new flush fluid. It is formulated to breakdown the sludge deposits and resin residue as a result of the detergency.
Page 47 Characteristics of Recommended Fluids Density @ Viscosity (cSt) Flash Point Fire Point Autoignition Max Operating For Use in Mokon Fluid Name 60F/16C F/C F/C Temp F/C F/C Systems Temp F/C (Lb/gal) MK, MR, HC, HA, 15.0 @ 104/40 Calfo FG 7.11...
Page 48 Characteristics of Recommended Fluids Cont. Density @ Viscosity (cSt) Flash Point Fire Point Autoignition Max Operating For Use in Mokon Fluid Name 60F/16C F/C F/C Temp F/C Temp F/C Systems F/C (Lb/gal) MK, MR, HC, HA, 32.1 @ 104/40 Duratherm Lite 7.15...
Page 49 RECOMMENDED CLEANING FLUIDS FOR MOKON HTF SYSTEMS Flash Point Fluid Name Operating For Use in Mokon Systems F Temp F MK, MR, HC, HA, 350, 500, can be DURACLEAN used in 600 series unit as long as temp. Duratherm Extended Life Fluids...
Page 50 MODEL CODE IN SECTION 10 TO DETERMINE YOUR CONTROLLER TYPE 5.1 – OPERATION This section of the manual contains all essential information needed to operate the controller. Contact Mokon Customer Service with controller problems as well as warranty and repair issues.
Page 51 5.1.2 – KEYS * NOTE: Pictured is the 3216 Eurotherm controller - this also applies to all 3000 series controllers Button or Name Explanation Indicator When lit, it indicates that heating output is on. Output 1 “HEATING” will scroll. When lit, it indicates that cooling output is on. Output 2 “COOLING”...
Page 52 5.2 - AUTOMATIC TUNING In tuning, you match the characteristics (PID parameters) of the controller to those of the process being controlled in order to obtain good control. Good control means: ➢ Stable, ‘straight-line’ control of the PV as setpoint without fluctuation ➢...
Page 53 5.2 - AUTOMATIC TUNING CONT. A One-Shot tune can be performed at any time, but normally it is performed only once during the initial commissioning of the process. However, if the process under control subsequently becomes unstable (because its characteristics have changed), you can re-turn again for the new conditions.
Page 54 5.3 - TROUBLESHOOTING DIAGNOSTIC ALARMS: Display Shows What it means What to do about it A change made to a E.ConF Enter configuration mode parameter takes a finite time then return to the required to be entered. If the power operating mode.
Page 55 5.3.1 - TO ACKNOWLEDGE AN ALARM Press together. Non-Latched Alarms Alarm condition present when the alarm is acknowledged. • ALM beacon on continuously. • The alarm message(s) will continue to scroll This state will continue for as long s the alarm condition remains. When the alarm condition disappears all indication also disappears.
Page 56 NOTE: Maximum system operating temperature value is reflective of the series system purchased, (refer to serial tag for maximum operating temperature located on Mokon system). CONSULT CUSTOMER SERVICE AT THE MOKON FACTORY (716) 876-9951, REGARDING SYSTEM’S MINIMUM AND MAXIMUM TEMPERATURES IF THERE ARE ANY QUESTIONS.
Page 57: Section 6 - Options
• Once the purge gas is introduced, the Dwyer 1950-02 pressure switch will close, energizing a time delay relay. The relay prevents start up of the Mokon unit until an adequate sweep inside the unit has taken place. •...
Page 58: Automatic High-Low Heat
6.5 - IN-LINE HEAT EXCHANGER FOR ADDITIONAL COOLING • To achieve a lower “to process” fluid temperature. Mokon provides an option of installing a shell-and-tube heat exchanger directly in the “to process” line. This is to supplement the indirect cooling already provided by the cool-oil reservoir.
Page 59: Section 7 - Trouble Shooting Guide
SECTION 7 – TROUBLE SHOOTING GUIDE PROBLEM POSSIBLE CAUSE CORRECTIVE MEASURE 1. System will not - System unplugged / power off - Plug system in / turn power on start - Check wiring (electrical - Improper power source wiring schematics) and correct - Blown fuse at power supply - Isolate open fuse and replace - Replace and check for ground...
Page 60 10. Variance in - Plugged flow paths, inadequate - Inspect; if plugged, dislodge temperature circulation through process and - Clean strainers readings connecting lines - Contaminated fluid - Drain & replace fluid - Kilowatt capacity inadequate - Consult Mokon engineering...
Page 61 - Temperature Controller - Inspect / replace controller or slow response after changing - Kilowatt capacity inadequate - Consult Mokon engineering temperature - Tighten connection or replace setting - Loose electrical connections broken wires - Thermocouple or RTD...
Page 62: Section 8 - Condensed Parts List
032-069 Lip Seal for Compact Oil Systems (H2 and H3) 032-072 Seal Kit for Mechanical Pumps 040-002 Type J Thermocouple FOR ADDITIONAL PART NUMBERS REFER TO THE SPECIFIC SECTION IN THE INSTRUCTION MANUAL OR CONSULT THE MOKON FACTORY (716) 876-9951...
Page 63: Section 9 - Model Codes
SECTION 9 – MODEL CODES...
Page 64 Oil Model Codes Model # H34109H6 Maximum Operating Temperature See Option Code C 345o F Maximum (1987) Kilowatt Capacity H 500o F Maximum (1985*/1997**) Special Combination or no M 450o F Maximum (1985) heat X 600o F Maximum (1985) 3 KW 6 KW *1985-500ºF Max when followed by C, H, K ** 1997-HTF series when followed by 3, 4, 5, 6...
Page 65 All Standard Microprocessor controllers are covered by a five (5) year warranty, Microprocessors with special features are covered by a three (3) year warranty and Solid State controllers are covered by a one (1) year warranty. MOKON'S obligation under the WARRANTY SHALL BE LIMITED, TO THE ORIGINAL CUSTOMER, TO...

This manual is also suitable for:

Htf system h5 Htf system h6 Htf system mk Htf system hc Htf system xc