Related Manuals for ACS TCU
Summary of Contents for ACS TCU
- Page 1 Open Reservoir Water Temperature Control Units Models Covered: TCU, 2600/2700, CWT Part Number: 882.12043.00 Bulletin Number: WTR1-645.0 Effective: August 1, 2012...
- Page 2 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice. DCN No. ____________ ©...
- Page 3 Open Resevoir Water Temperature Control Units Page 3...
- Page 4 Shipping Info Unpacking and Inspection You should inspect the Open Resevoir temperature control unit for possible shipping damage. Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event of Shipping Damage According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and place of shipment.
- Page 5 Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department. Credit Returns Prior to the return of any material authorization must be given by the manufacturer. A RMA number will be assigned for the equipment to be returned. Reason for requesting the return must be given.
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Page 6: Table Of Contents
Chaper 2: Functional Description ........ 17 Introduction ................... 17 Necessary Documents ..............18 Models Covered ................18 Standard TCU Series Features ............. 18 Available Options ................19 Chapter 3: Installation ........... 22 Installation Location Considerations ..........22 Process Approach Temperature Considerations......22 External Piping Sizing Considerations .......... - Page 7 Chapter 6: Unit Maintenance ........40 Preventive Maintenance ..............40 Corrective Maintenance ..............41 Restoring the Controller to Factory Setup ........43 Electrical Connections ..............43 Safety Devices ................44 Cleaning and Storage ................45 Chapter 7: Troubleshooting ......... 47 Technical Assistance ................
- Page 8 Charts and Figures Typical Open Reservoir Water Temperature Control Unit and Specifications TCU Series Full Amp Loads Typical Piping Schematic Pump Curves; 60 Hz and 50 Hz Pressure Drops Typical Electrical Wiring Schematic Typical Eurotherm 3216 Graphic and Button Control Panels...
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Page 9: Chapter 1: Safety
Chapter 1: Safety Open Resevoir temperature control units are designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. To avoid possible personnel injury or equipment damage when installing, operating, or maintaining this equipment, use good judgment and follow these safe practices: ... -
Page 10: How To Use This Manual
How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining the Open Resevoir temperature control unit. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective maintenance. No other maintenance should be undertaken without first contacting a service engineer. - Page 11 Temperature control unit Safety Tags Hazard Alert Description/Explanation Preventative Maintenance Symbol High Voltage Hazard. The electrical Every six months inspect all electrical enclosure is supplied with 3-phase electrical connections for secure attachment. For power. Use caution when using or further information see the maintaining this product.
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Page 12: Warnings And Precautions
Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international regulations. -
Page 13: General Responsibility
Each individual must take responsibility for observing the prescribed safety rules as outlined. All warning and danger signs must be observed and obeyed. All actual or potential danger areas must be reported to your immediate supervisor. General Responsibility No mater who you are, safety is important. Owners, operators and maintenance personnel must realize that every day, safety is a vital part of their jobs. -
Page 14: Maintenance Responsibility
Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the area; If your temperature control unit has been inoperative or unattended, check all settings before starting. At the beginning of your shift and after breaks, verify that the controls and other auxiliary equipment are functioning properly. -
Page 15: Reporting A Safety Defect
Carefully test the condition of lifting cables, chains, ropes, slings, and hooks before using them to lift a load. Be sure that all non-current carrying parts are correctly connected to earth ground with an electrical conductor that complies with current codes. Install in accordance with national and local codes. - Page 16 -Notes- Page 16 Open Resevoir Water Temperature Control Units...
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Page 17: Chaper 2: Functional Description
Chaper 2: Functional Description Introduction Open Resevoir water temperature control units are reliable, accurate, and easy-to-use process temperature control units. They are self-contained, portable, and shipped ready to use. The water temperature control unit is designed to circulate water through your process and to precisely, automatically, and reliably maintain it at a specified temperature. -
Page 18: Necessary Documents
The Customer Parts List included in the information packet. Models Covered This manual provides operation, installation, and maintenance instructions for the TCU Series water temperature control unit. Model numbers are listed on the serial tag. A model number followed by Q indicates a specially constructed unit, and not all information in this manual may apply. -
Page 19: Available Options
Available Options Temperature Control systems are available with options to tailor the unit to your requirements. Some are factory installed; some can be retro-fitted in the field. Consult your ACS Group sales representative for more information. Available options include: ... -
Page 20: Typical Open Reservoir Water Temperature Control Unit And Specifications
36.5 9 kW heater 2.25 3.75 340/ 155/ 7½ 5.63 Figure 2 TCU Series Unit Full-Load Amps Model Full-load amps at 460 volts 9 kW heater 12 kW heater 18 kW heater 24 kW heater 0.75 hp 0.56 kW 12.7 amps 16.5 amps... - Page 21 - Notes - Open Resevoir Water Temperature Control Units Page 21...
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Page 22: Chapter 3: Installation
Low external piping pressure drop is needed for best operation. Note: Use a backup wrench to support TCU Series system piping when making process piping connections. All external valves, fittings, and hoses must be rated at a minimum of 150 psig and 180°F (1,034.25 kPa/10.34 bars and 82ºC). -
Page 23: Piping Considerations For High Mobility Installations
Water treatment is vital in any piping system. In some cases, raw water may be used in the system without problems; in other cases, it can result in large deposits of scale and corrosion. The ACS Group offers a complete line of water treatment equipment. Contact your sales representative for water testing and treatment options. -
Page 24: Typical Electrical Wiring Schematic
This is the outlet for the tempered water leading to the process being controlled. FROM PROCESS — 1½” NPT Water from the process re-enters the TCU Series system to be tempered and re-circulated back into the process. Making Cooling Water Connections Water In —... -
Page 25: Typical Piping Schematic
Figure 3 Typical Piping Schematic Open Resevoir Water Temperature Control Units Page 25... -
Page 26: Pump Curves; 60 Hz And 50 Hz
Figure 4 Pump Curves; 60 Hz Figure 5 Pressure Drops Model Pressure drop flow and loss 9 kW htr flow gpm flow lpm loss psi loss kPa 0.75 hp 0.56 kW 12.7 amps 0.0 psi 0.0 kPa 1.00 hp 0.75 kW 13.1 amps... -
Page 27: Making Electrical Connections
Check serial tag voltage and amperage requirements and make sure your electrical service conforms before making any electrical connections. Total running amps for TCU Series systems are listed on the nameplate. Customer connections can be run to the supply terminals from either side of the unit. - Page 28 Bring properly sized power leads and ground from a fused disconnect (installed by your electrician) to the unit. Provide external overcurrent protection to the unit, using circuit breakers or fuses. If you use fuses, make sure that they are dual-element time-delay fuses, sized according to your electrical code.
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Page 29: Identifying Controls And Features
4 Identifying Controls and Features Identifying Mechanical Controls and Features To and From Process Probes One (1) Type-K Thermocouple is included with your TCU temperature control unit. One is located downstream from the heater to sense To Process temperature. Safety Thermostat The safety thermostat mounted on the side of the heater tank protects against thermal runaway. - Page 30 Pump Starter TCU Series high quality IEC-rated pump motor starters are industrial grade motor controls with overload protection and manual reset. Page 30...
- Page 31 115 VAC control voltage. The 115 VAC circuit is protected by primary fusing and secondary grounding. Heater Contactor Your TCU Series unit uses high-quality IEC-rated industrial-grade electromechanical contactors for heater controls. Cooling With units equipped with the optional heat exchanger, the controller automatically regulates cooling by opening and closing the solenoid valve or modulating valve.
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Page 32: The Microprocessor Controller
The Microprocessor Controller The controller is an easy-to-operate microprocessor-based PID control device. When the process reaches the set point, the PID control cycles the cooling valve and/or immersion heater to maintain the proper leaving water temperature. The controller has been fully factory tested. Set the desired process temperature set point and the control does the rest. -
Page 33: Using Graphic Panel Buttons
Press to select a new parameter. If held down it will continuously scroll through the parameters. Do not change any of the control settings without consulting the ACS Group Service Department. The ACS Group warranty does not cover temperature control unit failures from tampering with controller settings! Down Key Each press of the... -
Page 34: Alarms
AIR PURGE Button Optional Press the button to purge the system of air. The AIR PURGE indicator lights during the air purge cycle. PURGE VALVE ON QUICK COOL Button Optional Press the button to open the cooling valve and QUICK COOL quickly cool the process. -
Page 35: Chapter 5: Startup And Operation
Chapter 5: Startup and Operation Introduction The checklist below outlines start-up procedures for TCU Series water temperature control units. This list assumes that installation information located in this manual has been read and followed. Startup Checklist Check the shipping papers against the serial tag to make sure that system size, type, and voltage is correct for the process under control. -
Page 36: Starting The Temperature Control Unit
Starting the Temperature Control Unit You can also use these steps to AUTO-TUNE the Controller, and operate the Unit with the Controller. The Auto-Tune function lets you fine-tune the control PID to process requirements. Activate the Auto-Tune function whenever the process under control changes. Don't be alarmed by control response. -
Page 37: Sequence Of Operation
FROM PROCESS TCU systems provide temperature control on processes by directly heating the process water and injecting cooling water into the heat exchanger (if option was selected). When the unit is energized, reservoir will be filled through the auto-fill solenoid valve. -
Page 38: Checking Motor Rotation Direction
Checking Motor Rotation Direction Check for correct pump rotation direction by looking at the top of the motor. Press the button and the button, and note the direction that the motor turns. START STOP Rotation should be clockwise when viewed from the motor end. Make sure that a qualified electrician performs the following steps. - Page 39 -Notes- Open Resevoir Water Temperature Control Units Page 39...
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Page 40: Chapter 6: Unit Maintenance
Chapter 6: Unit Maintenance Never attempt to service a unit until a qualified electrician has opened and locked out the main disconnect using OSHA 1910.147 standards. The water supply should be turned off and internal pressure should be relieved before you remove panels. All electrical connections must be done by a qualified electrician. -
Page 41: Periodic Checks
Periodic Checks Every Six Months Inspect all electrical connections for secure attachment and for safe and secure ground connections. Inspect the power cable, especially at the entrance point to the unit. Also inspect the heater contactors for loose wire connections and unusual wear or debris, as this may be a sign of premature failure. - Page 42 It is also fitted with high temperature flexible components for maximum heat resistance. These same components remain flexible even at low temperatures. Thus, the standard seal is a fine combination of heat resistant and wear resistant components. Unfortunately, even under normal use, the seal will eventually wear and require replacement.
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Page 43: Restoring The Controller To Factory Setup
Sluggish operation, excessive leakage, and/or noise indicate cleaning is necessary. Inspect the components for excessive wear while the valve is disassembled. Rebuild kits are available from the ACS Group Parts Department. Restoring the Controller to Factory Setup If the preset parameters on the controller have been tampered with and it no longer properly controls temperature, you can restore the controller to factory setup parameters. -
Page 44: Safety Devices
Safety Devices Make sure that only qualified electricians test safety devices! Safety devices should be tested for function every six (6) months. Perform the following procedures for testing: Motor Overload Disconnect main power. Open the electrical enclosure and rotate the manual button on the motor overload to the tripped TEST position. -
Page 45: Cleaning And Storage
Cleaning and Storage Inspect the unit daily for leaks. Wipe down the unit periodically to remove dirt and dust buildup, especially the motor casing. Drain and flush the unit every six (6) months to remove sediment buildup. Completely drain the unit and carefully blow out the piping with pressurized air before placing the unit in storage. - Page 46 - Notes - Page 46 Open Resevoir Water Temperature Control Units...
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Page 47: Chapter 7: Troubleshooting
Chapter 7: Troubleshooting Condition Possible cause Solution Check main disconnect, fuses, No power. wiring, and power lead to unit. Voltage must be within plus or Wrong voltage supplied to unit. minus 10% of nameplate rating. Unit does not turn on. Defective on/off switch. - Page 48 Check unit by connecting ¾” line directly from delivery to return Faulty TCU. line. Run unit to determine if TCU controls set point temperature. Drain is plugged or excessive Clear drain line or eliminate back pressure is in drain line.
- Page 49 Condition Possible cause Solution Visually inspect coil and Defective heater contactor. contacts; repair/replace defective contactors. Check resistance on all three (3) legs of the heater with an ohm Defective immersion heater. meter. If not all equal, contact factory for replacement heater. Check the heater output with an ohm meter to ground.
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Page 50: Service Notes
Service Notes Page 50 Open Resevoir Water Temperature Control Units... - Page 51 Service Notes Open Resevoir Water Temperature Control Units Page 51...
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Page 52: Technical Assistance
North, Central and South America +1 ( 262 ) 641-8600 or +1 (847) 273-7700 Monday–Friday, 8am–5pm CST Asia/Australia +86 512 8717 1919 Facilities: ACS offers facilities around the world to service you no matter where you are located. For more information, please visit us at www.acscorporate.com United States: Asia/Australia: ACS Schaumburg-Corporate Offices ACS Suzhou 1100 E.
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