Thermolator TW-1 and TW-2 - Conair...Both the TW-1 and TW-2 models are available in single or dual-zone configurations, using resistance heating and direct injection or closed circuit

Thermolator®

TW-1 and TW-2

Instant Access Parts and Service

(800) 458-1960(814) 437-6861

www.conairnet.com

The Conair Group, Inc.One Conair DrivePittsburgh, PA 15202Phone: (412) 312-6000Fax: (412)-312-6320

Water Temperature Control Units

UGH015/0902

Installation

Operation

Maintenance

Troubleshooting

It’s a good idea to record the model and serial number(s) ofyour equipment and the date you received it in the UserGuide. Our service department uses this information, alongwith the manual number, to provide help for the specificequipment you installed.

Please keep this User Guide and all manuals, engineeringprints and parts lists together for documentation of yourequipment.

Date:

Manual Number: UGH015/0902

Serial number(s):

Model number(s):

DISCLAIMER: The Conair Group, Inc., shall not be liable for errorscontained in this User Guide or for incidental, consequential dam-ages in connection with the furnishing, performance or use of thisinformation. Conair makes no warranty of any kind with regard tothis information, including, but not limited to the implied warrantiesof merchantability and fitness for a particular purpose.

Please record yourequipment’s model and

serial number(s) andthe date you received itin the spaces provided.

Copyright 2002 All rights reservedTHE CONAIR GROUP, INC.

UGH015/0902 Thermolator TW-1 and TW-2

TABLE OFCONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . .1-1Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . .1-2How the Guide is Organized . . . . . . . . . . . . . . . . . . . . . . .1-2Your Responsibility as a User . . . . . . . . . . . . . . . . . . . . . .1-2ATTENTION: Read this so no one gets hurt . . . . . . . . . . .1-3

DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1What is the Thermolator TW Series? . . . . . . . . . . . . . . . . .2-2Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2How it Works: Direct Injection . . . . . . . . . . . . . . . . . . . . .2-3How it Works: Closed Circuit . . . . . . . . . . . . . . . . . . . . . .2-4How it Works: Isolated Circuit . . . . . . . . . . . . . . . . . . . . . .2-5Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6Features and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

INSTALLATION . . . . . . . . . . . . . . . . . . . .3-1Unpacking the Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-3Connecting Process and Water Supply Lines . . . . . . . . . . .3-4Optional Purge Valve Hookups . . . . . . . . . . . . . . . . . . . . .3-5Connecting the Main Power Supply . . . . . . . . . . . . . . . . . .3-6Testing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8Changing Temperature Units . . . . . . . . . . . . . . . . . . . . . . .3-9Enabling and Disabling Passcode Protection . . . . . . . . . .3-10Selecting the Temperature Control Point (TW-2) . . . . . . . . .3-12Entering Temperature Deviation Parameters . . . . . . . . . . .3-14Activating SPI Communication . . . . . . . . . . . . . . . . . . . .3-15Installing the Auto Start Feature (TW-2) . . . . . . . . . . . . . . .3-16

OPERATION . . . . . . . . . . . . . . . . . . . . . .4-1TW-1 Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2TW-2 Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3Positioning the Control Panel . . . . . . . . . . . . . . . . . . . . . . .4-4Entering Passcodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5Starting the Thermolator . . . . . . . . . . . . . . . . . . . . . . . . . .4-6Stopping the Thermolator . . . . . . . . . . . . . . . . . . . . . . . . . .4-7Using the TW-1 Purge Feature . . . . . . . . . . . . . . . . . . . . . .4-8Using the TW-2 Purge Feature . . . . . . . . . . . . . . . . . . . . . .4-9Performing an Auto Tune . . . . . . . . . . . . . . . . . . . . . . . . .4-10

MAINTENANCE . . . . . . . . . . . . . . . . . . . .5-1Preventative Maintenance Schedule . . . . . . . . . . . . . . . . . .5-2Accessing the Thermolator Enclosure . . . . . . . . . . . . . . . .5-3Checking Reservoir Fluid Levels (IC) . . . . . . . . . . . . . . . . .5-4Performing System Tests . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

i

Thermolator TW-1 and TW-2 UGH015/0902

TABLE OFCONTENTS

MAINTENANCE . . . . . . . . . . . . . . .(continued)Key/Display Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6Input Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8Disabling and Enabling Output Monitors . . . . . . . . . . . . . .5-9Calibrating Temperature Sensors . . . . . . . . . . . . . . . . . . .5-10Logging Operating Hours . . . . . . . . . . . . . . . . . . . . . . . .5-12Pulse Mode Description . . . . . . . . . . . . . . . . . . . . . . . . . .5-13Pulse Mode Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14Pulse Mode Limits & Defaults . . . . . . . . . . . . . . . . . . . . .5-14Deviation Alarm/Inhibition Delay . . . . . . . . . . . . . . . . . .5-15Vent Timer Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

TROUBLESHOOTING . . . . . . . . . . . . . . . .6-1Before Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2A Few Words of Caution . . . . . . . . . . . . . . . . . . . . . . . . . .6-2How to Identify the Cause of a Problem . . . . . . . . . . . . . .6-3Shut Down Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4Warning Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8System Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11Thermolator Will Not Power Up . . . . . . . . . . . . . . . . . . .6-12Checking and Replacing Fuses . . . . . . . . . . . . . . . . . . . . .6-13Resetting Overloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14Replacing Pump Overload . . . . . . . . . . . . . . . . . . . . . . . .6-14Replacing the Motherboard . . . . . . . . . . . . . . . . . . . . . . .6-15Replacing the Heater Contactor . . . . . . . . . . . . . . . . . . . .6-16Checking Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . .6-17Replacing Thermocouples . . . . . . . . . . . . . . . . . . . . . . . .6-17Repairing Cooling Valves . . . . . . . . . . . . . . . . . . . . . . . . .6-18Repairing Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . .6-19Repairing Motorized Valves . . . . . . . . . . . . . . . . . . . . . . .6-20Replacing Heater Elements . . . . . . . . . . . . . . . . . . . . . . .6-20Removing the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22Disassembling and assembling 3/4 to 2 HP Pumps . . . . . .6-23Disassembling and assembling 3 to 7.5 HP Pumps . . . . . .6-24

APPENDIXCustomer Service Information . . . . . . . . . . . . . . . . . . . . . .A-1Warranty/Guarantee Information . . . . . . . . . . . . . . . . . . . .A-2Pump Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1Thermolator SPI Commands and Status Words . . . . . . . . .C-1

PARTS/DIAGRAMSTW-1 Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .PD-2TW-2 Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .PD-3

ii

1-1UGH015/0902 Thermolator TW-1 and TW-2

●● Purpose of the User Guide . . . .1-2●● How the Guide is Organized . . .1-2●● Your Responsibilities as a User 1-2●● ATTENTION: Read this so

no one gets hurt . . . . . . . . . . . .1-3

INTRODUCTION

Thermolator TW-1 and TW-2 UGH015/09021-2 INTRODUCTION

This User Guide describes the Conair Thermolator® TW-1 andTW-2 water temperature controllers and explains step-by-stephow to install, operate, maintain and repair this equipment.

Before installing this product, please take a few moments toread the User Guide and review the diagrams and safety infor-mation in the instruction packet. You also should review man-uals covering associated equipment in your system. Thisreview won’t take long, and it could save you valuable instal-lation and operating time later.

Symbols have been used to help organize the User Guide andcall your attention to important information regarding safeinstallation and operation.

Symbols within triangles warn of conditions that couldbe hazardous to users or could damage equipment.Read and take precautions before proceeding.Numbers within shaded squares indicate tasks or stepsto be performed by the user.

A diamond indicates the equipment’s response to anaction performed by the user.

An open box marks items in a checklist.

A shaded circle marks items in a list.

You must be familiar with all safety procedures concerninginstallation, operation and maintenance of this equipment.Responsible safety procedures include:

● Thorough review of this User Guide, paying particularattention to hazard warnings, appendices and related dia-grams.

● Thorough review of the equipment itself, with carefulattention to voltage requirements, intended uses andwarning labels.

● Thorough review of instruction manuals for associatedequipment.

● Step-by-step adherence to instructions outlined in thisUser Guide.

PURPOSE OFTHE USERGUIDE

HOW THEGUIDE ISORGANIZED

1◆

❒

●

YOURRESPONSIBILITYAS A USER

UGH015/0902 Thermolator TW-1 and TW-2 INTRODUCTION 1-3

We design equipment with the user’s safety in mind. You canavoid the potential hazards identified on this machine byfollowing the procedures outlined below and elsewhere in theUser Guide.

ATTENTION:READ THIS SO NOONE GETS HURT

WARNING: Improper installation,operation or servicing may result inequipment damage or personal injury.This equipment should be installed, adjusted,and serviced by qualified technical personnelwho are familiar with the construction, opera-tion and potential hazards of this type of equip-ment.

All wiring, disconnects and fuses should beinstalled by qualified electrical technicians inaccordance with electrical codes in your region.

Always maintain a safe ground. A properlysized conductive ground wire from the incomingpower supply must be connected to the chassisground terminal inside the electrical enclosure.Improper grounding can result in personalinjury and erratic machine operation.

Do not operate the equipment at power levelsother than what is specified on the the equip-ment serial tag and data plate.

WARNING: Electrical shock hazardThis equipment is powered by three-phasemain voltage, as specified on the machine seri-al tag and data plate.

Always disconnect and lock out the incomingmain power source before opening the electri-cal enclosure or performing non-standard oper-ating procedures, such as troubleshooting ormaintenance. Only qualified personnel shouldperform procedures that require access to theelectrical enclosure while power is on.

CAUTION: Hot surfacesSurface temperatures inside the Thermolatorcan exceed 250°F (121°C). Always allow theunit to cool to below 100°F (38°C) before open-ing, servicing or disassembling the unit.

WARNING: Hazardous substanceThe electrical contactors in theThermolator have mercury contactors.Mercury is considered a hazardous sub-stance and must be dealt with according-ly. See Material Safety Data Sheet(#7439-97). This sheet explains thepotential hazards, how to avoid them andhow to clean up and dispose of the mer-cury if it spills.

ATTENTION:READ THIS SO NOONE GETS HURT

Thermolator TW-1 and TW-2 UGH015/09021-4 INTRODUCTION


●● What is the Thermolator TW Series? . . . . . . . . . . . . . . .2-2

●● Typical Applications . . . . . . . . .2-2●● How it Works:

Direct Injection (DI) Models . . .2-3●● How it Works:

Closed Circuit (CC) Models . . .2-4●● How it Works:

Isolated Circuit (IC) Models . . .2-5●● Specifications . . . . . . . . . . . . . .2-6●● Features and Options . . . . . . . .2-8

DESCRIPTION

The Thermolator TW models circulate water at a temperaturehigher than the available water supply, to add or remove heatas needed to maintain a uniform temperature setpoint in theprocess. The TW-2 offers an enhanced TW-2 control, withadditional diagnostic features and autostart capabilities.

Both the TW-1 and TW-2 models are available in single ordual-zone configurations, using resistance heating and directinjection or closed circuit cooling. Dual-zone models can con-trol at two different temperatures at different locations in theprocess. Two-zone models have common cooling water mani-folds and electrical connections.

The best model for your application depends on the processtemperature you need to maintain and the quality of the cool-ing water supply.

Direct injection (DI) models control the temperature bydischarging heated process water and adding cooling waterdirectly from the water supply. DI models are designed for:● Process temperatures up to 250°F (121°C).● Use with chiller water or properly treated and filtered tower

or city water.

Closed circuit (CC) models add cooling water to the processloop only during the initial filling or when make-up water isneeded. CC models are recommended for: ● Process temperatures up to 250°F (121°C).● Use with contaminated cooling water.

Isolated circuit (IC) models separate the cooling water fromthe process fluid, which is held in a reservoir. IC models arerecommended for:● Process temperatures up to 180°F (82°C).● Use with contaminated cooling water.● When process and cooling fluids are different.

WHAT IS THETHERMOLATOR?

Thermolator TW-1 and TW-2 UGH015/09022-2 DESCRIPTION

TYPICALAPPLICATIONS

IMPORTANT: Do not usedeionized water or glycolmixtures containing additivesin a Thermolator. Softenedwater or glycol mixtures withadditives, such as automo-tive fluids, can damage theThermolator. Glycol/waterprocess loop mixtures shoulduse industrial-grade ethyleneglycol only.

Direct injection models maintain the process temperatureby electrically heating and injecting cool water supplied tothe Thermolator by a chiller, tower or other water source.

HOW IT WORKS:DIRECT INJECTION

UGH015/0902 Thermolator TW-1 and TW-2 DESCRIPTION 2-3

A

B

The temperature of the process fluid is measuredas it leaves the unit’s heater tank. The fluid thenflows through the “To Process” line to the moldor process. The fluid returns to the unit through the“From Process” line for reheating or cooling.

1A

B

C

If the processtemperature isbelow the set-point, the heaterelements insidethe heater tankare energized.

EF

4 The pump moves water from the mixingtank to the heater tank. Pressure is measured before and after the pump .NOTE: Some higher kW models have anadditional heater in the mixing tank

E F

The temperature of the processfluid is measured as it flows intothe mixing tank through the“From Process” line .

2B

If the average temperature isabove the setpoint value, the cool-ing valve opens. Cool waterenters the bottom of the mixingtank via the “Cooling In” line .Warm water flows out through the“Cooling Out” line .

C

D

3b3a

D

HOW IT WORKS:CLOSED CIRCUIT


A

B

The temperature of the processfluid is measured as it leavesthe unit’s heater tank. The fluidthen flows through the “ToProcess” line to the mold orprocess. The fluid returns to theunit through the “FromProcess” line for reheating

1

A

B

CD

3b If the process temperatureis below the setpoint, theheater elements inside theheater tank are energized.

EF4 The pump moves water from the

mixing tank to the heater tank.Pressure is measured beforeand after the pump .E F

The temperature ofthe process fluid ismeasured as it flowsinto the cooling tankthrough the “FromProcess” line .

2

B

3a If the temperature is abovethe setpoint value, the coolingvalve opens. Cool waterenters the cooling pipingand circulates through a tubeheat exchanger to cool theprocess fluid. The coolingvalve allows warm fluid toescape through the “CoolingOut” line .

C

D

Closed Circuit models maintain the process temperature byelectrically heating and indirectly cooling fluid in theprocess circuit. Cooling water supplied by a chiller, toweror other water source, is mixed with the process fluid onlyduring the initial filling or when water is needed to makeup process fluid loss.

HOW IT WORKS:ISOLATED


Isolated Circuit models maintain the process temperatureby electrically heating and indirectly cooling fluid in theprocess circuit. The process fluid, which is stored in areservoir, is isolated from cooling water supplied by achiller, tower or other source.

A

B

The temperature of theprocess fluid is measuredas it leaves the unit’sheater tank. The fluid thenflows through the “ToProcess” line to the moldor process. The fluidreturns to the unit throughthe “From Process” linefor reheating or cooling.

1

A

B

C D

If the process temperatureis below the setpoint, theheater elements inside theheater tank are energized.

E4 The pump moves waterfrom the mixing tank tothe heater tank.Pressure is measuredafter the pump .E

The temperature ofthe process fluid ismeasured as it flowsinto the cooling tankthrough the “FromProcess” line .

2

B

If the temperature isabove the setpointvalue, the cooling valveopens. Cool waterenters the cooling pipingand circulates through atube heat exchanger tocool the process fluid.

C

G

The vent line allows warmprocess fluid to expand to thereservoir . The reservoirsupplies process fluid througha make-up line as needed.

G

3b

3a

SPECIFICATIONS


CABINET STYLE REFERENCEHeater Voltage Selection Single Zone Dual ZoneDirect Injection (DI)9, 12, 18 or 24 kW 208, 230, 460, 575 A B36 kW 208 or 230 C D36 kW 460 or 575 A B48 kW 208, 230, 460, 575 C DClosed Circuit (CC)9 or 12 kW 208, 230, 460, 575 A B18 or 24 kW 208, 230, 460, 575 C DIsolated Circuit (IC)9, 12, 18 or 24 kW 208, 230, 460, 575 C D

A B

C D

Dimensions and performance characteristics vary according tothe model, voltage and components selected. See the cabinetstyle reference chart to determine dimensional information foryour specific model. Additional technical information can befound in the Appendix of this User Guide.

Hei

ght

WidthSingle Zone

Width2- Zone

Depth

WidthSingle Zone

Width2- Zone

Hei

ght

Depth

NOTE: Dual zone modelshave common wiring andcooling water plumbing.

WATER CONNECTIONSAll modelsNPT inches (female)

From process 1.25Cooling water in/out 0.75

SPECIFICATIONS


TW-1 TW-2

Zones(1or 2)

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 TW1-DI or TW2-DI TW1-CC or TW2-CC TW1-IC or TW2-ICMinimum Setpoint Temperature °F {°C} 32 {0} 32 {0} 32 {0}

Maximum Setpoint Temperature °F {°C} 250 {121} 250 {121} 180 {82}Minimum Operating Temperature °F {°C} Approximately 20° {11°} above the cooling water inlet temperature*Standard Cooling Valve Size inches {mm} 1/4 {6.35} 3/4 {19.05} 3/4 {19.05}Available pump sizes 0.75, 1, 2, 3, 5 or 7.5 Hp {0.56, 0.75, 1.49, 2.24, 3.73 or 5.59 kW}Available heater sizes 9, 12, 18, 24, 36 or 48 kW 9, 12, 18 or 24 kW

PUMP PERFORMANCE - Consult your Conair representative for pump performance characteristics at other operating points.Pump 3/4 HP {0.56 kW} 1 HP {0.75 kW} 2 HP {1.49 kW} 3 HP {2.24 kW} 5 HP {3.73 kW} 7.5 HP {5.59 kW}

Nominal Flow gpm {lpm} 40 {151} 45 {170} 55 {208} 80 {303} 100 {379} 115 {435}Pressure@ Nominal Flow psi {kg/cm2} 17 {1.2} 18 {1.3} 31 {2.2} 35 {2.5} 43 {3} 51 {3.6}

TOTAL FULL LOAD AMPS PER ZONE All voltages are 3 phase, 60 Hz.Heater 9 kW 12 kW 18 kW 24 kW 36 kW 48 kW

Voltage 208V 230V 460V 575V 208V 230V 460V 575V 208V 230V 460V 575V 208V 230V 460V 575VPump

0.75 HP {0.56 kW} 28.9 26.2 13.1 10.5 37.3 33.8 16.9 13.5 54.0 48.8 24.4 19.5 70.7 64.0 32 25.61 HP {0.75 kW} 29.4 26.6 13.3 10.6 37.8 34.2 17.1 13.7 54.4 49.2 24.6 19.7 71.2 64.4 32.2 25.82 HP {1.49 kW} 31.8 28.8 14.4 11.5 40.2 36.4 18.2 14.6 56.8 51.4 25.7 20.6 73.6 66.6 33.3 26.63 HP {2.24 kW} 34.7 31.4 15.7 12.6 43.1 39.0 19.5 15.6 59.7 54.0 27.0 21.6 76.5 69.2 34.6 27.75 HP {3.73 kW} 38.5 34.8 17.4 13.9 46.9 42.4 21.2 17.0 63.4 57.4 28.7 23 80.2 72.6 36.3 29.07.5 HP {5.59 kW} 45.7 41.4 20.7 16.6 54.1 49.0 24.5 19.6 70.7 64.0 32.0 25.6 87.5 79.2 39.6 31.7

SHIPPING WEIGHT RANGES lbs {kg} Weights vary depending on cabinet size and cooling type (DI, CC or IC).Single Zone Dual Zone

Pump Min Max Min Max0.75 HP {0.56 kW} 240 {109} 300 {136} 480 {218} 600 {272}1 HP {0.75 kW} 240 {109} 300 {136} 480 {218} 600 {272}2 HP {1.49 kW} 250 {113} 310 {141} 500 {226} 620 {282}3 HP {2.24 kW} 260 {118} 320 {145} 520 {236} 640 {290}5 HP {3.73 kW} 270 {122} 330 {150} 540 {244} 660 {300}7.5 HP {5.59 kW} 280 {127} 340 {154} 560 {254} 680 {308}

DIMENSIONS in. {mm}Cabinet Style A B C D

Height 28.0 {710} 28.0 {710} 43.0 {1090} 43.0 {1090}Depth 22.5 {570} 22.5 {570} 31.5 {800} 31.5 {800}Width 13.75 {350} 27.5 {700} 14.0 {355} 28.0 {710}

208V 230V 460V 575V 208V 230V 460V 575V

104.0 94.0 47.0 37.6 137.0 124.0 62.1 49.7104.3 94.4 47.2 37.8 137.7 124.6 62.3 49.6106.7 96.6 48.3 38.6 140 126.8 63.4 50.7109.6 99.2 49.6 39.7 143 129.4 64.7 51.8113.4 102.6 51.3 41.0 146.7 132.8 66.4 53.1120.7 109.2 54.6 43.7 154 139.4 69.7 55.8

MODEL DESIGNATIONS

TOTAL FULL LOAD AMPS PER ZONE All voltages are 3 phase, 60 Hz.Heater 0 heaters

Voltage 208V 230V 460V 575VPump

0.75 HP {0.56 kW} 3.9 3.6 2.3 1.51 HP {0.75 kW} 4.4 4.0 2.5 1.62 HP {1.49 kW} 6.8 6.2 3.6 2.53 HP {2.24 kW} 9.7 8.8 4.9 3.65 HP {3.73 kW} 13.5 12.2 6.6 4.97.5 HP {5.59 kW} 20.7 18.8 9.9 7.6

NOTE: Thermolatorscan be ordered without heaters forcertain applications.

High efficiency pumpsfrom 3/4 to 7.5 Hp. Siliconcarbide seals are standard.

Pump seal flush linecontinuously cleans thepump seal for extended life.

Incoloy heatersminimize chemical andhigh temperature damage

Built-in sediment trapsettles contaminants awayfrom the pump seals.

Motor drip coverprotects motor windingsfrom moisture damage.

Two-piece cast construction

Alarm packages The Thermolator control includes an outputrelay that can be connected to an optionalexternal alarm package to call attention toalarm conditions.

Motorized Cooling Valve Slow open/close cycle time eliminates ther-mal shock and water hammer from yourprocess circuit.

Compressed Air Mold PurgeQuickly evacuates fluid from the processcircuit, allowing for faster, cleaner discon-nection of the temperature controller frommolds and hoses.

Stacking RackSave floor space by stacking Thermolatorstwo-high. The stacking rack can be usedonly with single-zone models in 28-inchhigh cabinets.

OPTIONS


FEATURES ANDOPTIONS


●● Unpacking the boxes . . . . . . . . .3-2●● Preparing for Installation . . . . . .3-3●● Connecting Process and

Water Supply Lines . . . . . . . . .3-4●● Optional purge valve hookups .3-5●● Connecting the Main Power . . .3-6●● Testing the Installation . . . . . . .3-7●● Initial Setup . . . . . . . . . . . . . . . .3-8●● Changing Temperature Units . .3-9●● Enabling and Disabling

Passcode Protection . . . . . . .3-10●● Selecting the Temperature

Control Point . . . . . . . . . . . . .3-12●● Temperature Deviation

Alarm Parameters . . . . . . . . .3-14●● Activating SPI

Communications . . . . . . . . . .3-15●● Installing the Auto Start

Feature . . . . . . . . . . . . . . . . . .3-16

INSTALLATION

UNPACKING THEBOXES

Thermolator TW-1 and TW-2 UGH015/09023-2 INSTALLATION

Carefully remove the Thermolator and components from their shipping containers.

Remove all packing material, protectivepaper, tape and plastic. Check inside the electrical enclo-sure and behind the side panels for accessories or hard-ware that may have been placed there for shipping.

Carefully inspect all components to make sureno damage occurred during shipping, and that you haveall the necessary hardware. If damage is found, notify thefreight company immediately.

Take a moment to record serial numbers andspecifications in the blanks provided on the back of theUser Guide’s title page. The information will be helpful ifyou ever need service or parts.

You are now ready to begin installation.Complete the preparation steps on the next page.

Remote control cord(TW-2 only)

Thermolator

1

2

3

4

5

Thermolator TW models come fully assembled. If they werespecified at the time of the order, the optional purge valve ormotorized cooling valve is factory-installed.

Motorized cooling valve(optional)

Compressed air mold purge(optional)

UGH015/0902 Thermolator TW-1 and TW-2 INSTALLATION 3-3

The Thermolator is easy to install, if you plan the location andprepare the area properly.

Position the Thermolator as close to the process machine as possible.

Make sure the installation area provides:❒❒ A three-phase power source supplying the correctcurrent for your Thermolator model. Check the serial tagon the side of the electrical enclosure for the requiredvoltage, phase, frequency, full load amps, disconnect fusesize and minimum wire connection size. Field wiringshould be completed by qualified personnel to the plannedlocation for the Thermolator. All electrical wiring shouldcomply with your region’s electrical codes.❒❒ A clean, well-ventilated environment. The room temperature should not exceed 120° F (48° C)with 95% non-condensing humidity and should not fallbelow 32° F (0° C).❒❒ Minimum clearance for safe operation andmaintenance. The diagram at right shows mini-mum clearance for operation. You also needenough clearance in the rear for water hookups.For maintenance, you should move theThermolator toprovide at least 36 inches on any side ofthe Thermolator. ❒❒ A source of water for cooling. City, tower or chiller water may be used,as long as the supply pressure is at least 25 psi and notmore than 85 psi.

Install plumbing for process and cooling lines.You will need two 11/4-inch NPT male fittings for theprocess inlet and outlet and two 3/4-inch NPT male fit-tings for the cooling inlet and outlet. Larger line sizes areacceptable as long as they are reduced at the Thermolatorconnections. Smaller line sizes are not recommended.

PREPARING FORINSTALLATION1

2

Process machine

Thermolator

Alternatelocations

3

12 inches(305 mm)

12 inches(305 mm)

20 inches(508 mm)

The Thermolator process inlets and outlets must be connectedto the plumbing that will circulate the temperature-controlledwater or fluid through the process. Cooling water inlets andoutlets are connected to the cooling water supply.

Remove the shipping pipe plug from the femaleconnections on the back of the Thermolator.

Install pipe to the rear of the Thermolator.Use male 11/4-inch NPT piping for process connectionsand male 3/4 inch NPT piping for water connections. Pipeand pipe threads must be clean and new. Clean threadswith solvent, removing all oil, grease and dirt. Allow thethreads to dry before proceeding.

Coat the pipe threads with thread sealant.Follow the sealant manufacturer’s directions.

Connect the male pipe to the appropriatefemale connection on the back of the unit. Startby hand until the threads engage, then use a pipe wrenchto tighten the connection only enough to prevent leaks.Do not over-tighten!

CONNECTINGPROCESS ANDWATER SUPPLYLINES


1

2

3

4

Tools for installation:r Pipe wrench large enough

for a 2-inch piper Premium quality Teflon

thread sealant

NOTE: We recommendthat you install anexternal ball valve onthe cooling water inletof the Thermolator. Thisvalve is required whenthe purge valve optionis installed.

From process

Toprocess

From process

Toprocess

Cooling water out

Cooling water in

Cooling water in

DIRECT INJECTION CLOSED CIRCUITISOLATED CIRCUIT

Cooling water out

A purge valve is available as an option on Direct Injection andClosed Circuit units only. This valve quickly evacuates fluidfrom the process circuit, allowing faster disconnection of thetemperature controller from molds and hoses. An optionalmanual purge button controls this valve on TW-1 models. TheTW-2 models have a purge button on the TW-2 control panel.

If this option is ordered with the Thermolator, purge controlwiring and installation of the valve on the process line outletof the unit is completed at the factory. You still must connectprocess and cooling water inlets and outlets, as well as a sup-ply of non-lubricated compressed air.

Remove the shipping pipe plug from thefrom the female connections on the back of theThermolator.

Install an external ball valve on the cooling water inlet of the Thermolator. This valve is requiredwhen a purge valve is used.

Install pipe to the rear of the Thermolator.Use male 11/4-inch NPT piping for process connectionsand male 3/4 inch NPT piping for water connections. Pipeand pipe threads must be clean and new. Clean threadswith solvent, removing all oil, grease and dirt. Allow thethreads to dry before proceeding.

Coat the pipe threads with thread sealant.Follow the sealant manufacturer’s directions.

Connect the male pipe to the appropriate female connection on the back of the unit. Connect cool-ing water lines as indicated on the previous page. Connectprocess lines as indicated below. Start by hand until thethreads engage, then use a pipe wrench to tighten the con-nection only enough to prevent leaks. Do not over-tight-en!

Connect the purgevalve to the compressed airsupply. The air pressure shouldnot exceed 100 psi.


OPTIONALPURGE VALVEHOOKUPS

INSTALLATION 3-5

From process

Toprocess

Compressed airfitting

1

2

3

4

5

6


Before beginning, note the electrical specifications on thenameplate mounted to the side of the unit. The electricalhookup must match these specifications with +/- 10% maxi-mum voltage variance. An improper power supply could dam-age the unit as well as seriously injure an operator.

The electrical hookup also should run through a fused discon-nect sized for the nameplate amperage and conforming toArticle 250 of the National Electrical Code.

Open the unit’s electrical enclosure.

Insert the main power wire through the knockout hole in the right side of the enclosure.

Secure the power wire with a rubbercompression fitting or strain relief.

Connect the power wires to the terminals. Connect the three hotwires to L1, L2, and L3on the terminal block.

Connect the groundwire to the coppergrounding mount. If youhave installed a discon-nect device, follow themanufacturer’s wiring instructions.

12

3

4

5

CONNECTINGTHE MAINPOWER SUPPLY

3-6 INSTALLATION

WARNING: Electrical shock hazardThis equipment is powered by three-phase mainvoltage. Always disconnect and lock out the mainpower source before performing any workinvolving electrical connections. All wiring,disconnects and fusing should conform to yourregion’s electrical codes and should be installedonly by qualified personnel.

IMPORTANT: Always referto the wiring diagrams thatcame with your temperaturecontrol unit before makingelectrical connections. Thediagrams show the mostaccurate electrical compo-nent information.

IMPORTANT! Before initiatingpower to the unit:❒ Check the system for leaks.❒ Verify that the voltage, phase,

frequency, amperage, disconnectfuse and minimum wire size meet thespecifications stated on the name-plate mounted on the side of the unit.

❒ Verify that resistance to ground oneach phase is at least 1 meg ohm.


Turn on the cooling water supply and check for leaks. If any leaks appear, stop the test and fix theproblem before continuing. The cooling water must be atleast 25 PSI or the unit will not function. The LOWWATER PRESSURE light will come on when power isapplied. The light goes off when the pressure is correct.

Apply power to the unit.◆ Indicator lights on the control panel blink green, then

red, to test operation of the LEDs.◆ Setpoint and actual windows will display for

three seconds, followed by the software version. Thewindows then display the factory default setpoint of100° F and the actual temperature.

Check the rotation of the pump. Remove the top access panel and the pump motor dripcover. Verify that the pump rotation matches the directionindicated on the rotation sticker on top of the pump.

NOTE: If the rotation is incorrect, stop the test anddisconnect power to the unit. Open the electricalenclosure and switch any two of the three powersource wires on the terminal block. Return to Step 2and check rotation again.

Replace the drip cover and top access panel.Press the RUN key to start the unit. If everything is working correctly:◆ The RUN/STOP light turns green.◆ The unit initiates a venting sequence. Cooling and

venting valves are active for the first half of thesequence. The pump is active for the final half of thesequence. Indicator lights energize when the device isactive.

◆ Normal operation begins. The heater turns on if theactual temperature is below setpoint. The cooling valveopens if the actual temperature is above setpoint.

The test is over. Proceed to Initial Setup if the unit operatesnormally; refer to the TROUBLESHOOTING section if it does not.

TESTING THEINSTALLATION

1

2

3

45

WARNING: Only qualified personnelshould perform this procedure.Parts of this test require opening the unit while it isenergized. Only qualified personnel who havebeen trained in the use of electrical testing devicesand in avoiding the safety hazards involved insafely troubleshooting this type of equipmentshould perform this test procedure.


INITIAL SETUP

The factory-set parameters and operating modes will satisfymost applications. But you can change some settings andenable or disable features as needed.

You can modify the parameters for high and low process tem-perature deviation warnings from the control panel. SeeSETTING SETPOINT DEVIATION PARAMETERS.

Dip switches on the motherboard inside the TW-1 and TW-2electrical enclosure allow you to:

❒ Select the units of measure for tem-perature displays.

❒ Enable password protection.❒ Enable the Auto Tune.❒ Enable the Auto Start feature.❒ Enable the Test Mode.❒ Select the source point of tempera-

ture control.

To change the dip switch settings, see the appropriate topicon the following pages.

8 7 6 5 4 3 2 1

Dipswitch ConfigurationNo. OFF ON1 Display units in °F Display units °C2 Auto Tune disabled Auto Tune enabled3 Passcode protect Password reset/modify4 * Auto Start disabled Auto Start enabled5 * Control point protect Control point source select6 Test Mode disabled Test mode enabled7 † Controller type selection Controller type selection8 † Controller type selection Controller type selection

* Available only on TW-2 models.† Switches 7 and 8 must be ON for Direct Injection and Closed Circuit

models. Switches 7 and 8 must be OFF for Isolated Circuit models. Donot change these settings.

WARNING: Electric shock hazardThis equipment is powered by high voltage. Alwaysdisconnect and lock out the main power sourcebefore opening the unit or the electrical enclosure tomodify factory settings. Failure to disconnect andlock out the main power source can result in severepersonal injury.

NOTE: All dip switch illustra-tions in this manual showswitches 7 and 8 set to ON.If you have an IsolatedCircuit model, these switch-es should be set to OFF.Do not change the factorysettings of these dip switch-


CHANGINGTEMPERATUREUNITS

The temperature units are factory-set as degrees Celsius ordegrees Fahrenheit, as specified when the unit was ordered.

When the Thermolator is on, the indicator lights to the right ofthe Actual temperature display on the control panel will showwhich temperature unit has been set.

To change this setting, move Dip Switch 1 on the control circuit board.

Disconnect and lock out main power to theThermolator.

Open the electrical enclosure.

Change Dip Switch 1 to:OFF for °F ON for °C

Close the electrical enclosure amd restoreand restore main power to begin operating.

8 7 6 5 4 3 2 1

1

23

8 7 6 5 4 3 2 1

4

INSTALLATION 3-9


NOTE: All dip switch illustra-tions in this manual showswitches 7 and 8 set to ON.If you have an IsolatedCircuit model, these switch-es should be set to OFF.


The TW-1 and TW-2 provide the ability to protect systemparameters from unauthorized changes during normal operat-ing mode. When system passcode protection is enabled, thefollowing parameters cannot be changed unless you enter thecorrect passcode:

● The Process Setpoint● High Deviation Alarm Setpoint● Low Deviation Alarm Setpoint● Baud Rate selection for serial communications● Address selection for serial communications

When the unit is turned on for the first time, passcode protec-tion is disabled. To enable passcode protection:

Disconnect and lock out main power to the unit.


Set dip switch 3 to ON and switches 5 and 6 toOFF.

Close the electrical enclosure and restore power to the unit.

Press any button when thecontrol displays“Pas rSt”(Passcode Reset).The control willdisplay the lastpasscode used.

Select a new passcode using the ▲▲ and ▼▼setpoint adjustment buttons. Stop pressing the setpointbuttons when the passcode you want appears in the set-point display window. Selecting “OFF” as the passcodewill disable the passcode feature.

ENABLING ANDDISABLINGPASSCODEPROTECTION

3-10 INSTALLATION


1

23

4

8 7 6 5 4 3 2 1

5

6



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 newpasscode will not be saved.

Turn off power to the unit. Disconnect and lock out the main power supply.


Set dip switch 3 to OFF.

Close the electrical enclosure and restore power to the unit. A passcode now is required to changesystem parameters.

INSTALLATION 3-11

7

8

8 7 6 5 4 3 2 19

10

11

ENABLING ANDDISABLINGPASSCODEPROTECTIONCONT’D

Disabling Passcode ProtectionTo disable passcodeprotection and allowuniversal access to system parameters:

Follow Steps 1 through 5 in theprevious sectionon enabling pass-code protection.

Hold down the ▼▼ setpoint adjustment buttonto select “OFF” as the new passcode.

Follow steps 7 through 11, above.

1

3

2


TW-1 models control the process temperature based upon theaverage of the temperatures recorded at the supply (toprocess) and return (from process) thermocouples.

TW-2 models allow you to select how the unit will measureand control the process temperature. The control point can beselected as the supply, the return or the average of the the twotemperatures.

To select the control point source on TW-2 models:

Disconnect and lockout power to the unit.


Set dip switches 3 and 6 to the OFF position.

Set dip switch 5 to the ON position.


Press any button when the control displays “Cnt Pt”. The con-troller displays“Sel CnP” andflashes the LED forthe current controlpoint.

Select a new control point using the Display button. Stop pressing the select button until the indicator light next to the control point you want illuminates.

3-12 INSTALLATION

123

4

5

6


8 7 6 5 4 3 2 1

SELECTING THETEMPERATURECONTROL POINT(TW-2 ONLY)

7



SELECTING THETEMPERATURECONTROL POINT(TW-2 ONLY)

INSTALLATION 3-13

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.

Turn off power to the unit. Disconnect and lock out the main power supply.


Set dip switch 5 to OFF.

Close the electrical enclosure and restore power to the unit. The TW-2 will now control theprocess temperature based on actual temperatures record-ed at the new control point source.

8

9

10

11

8 7 6 5 4 3 2 1

12


You can establish a normal operating range around the processtemperature setpoint using the high and low deviation parame-ters. If the process temperature exceeds the high deviationlimit, or falls below the low deviation limit for longer than theset delay time, the Thermolator alerts you to the unacceptabletemperature variation with an alarm light, and optional audibleor strobe.

These temperature deviation limits will adjust automaticallyrelative to the process temperature setpoint.

The factory default setting for both the high and low deviationparameters is 25°F. These parameters are adjustable to estab-lish a narrower or wider acceptable temperature band for nor-mal operation.

To change the temperature deviation settings:

Press the Setpoint Selectbutton to select the deviation para-meter you want to change.

Use the ▲ and ▼ setpoint buttons to enter the deviation tem-perature. The setting is stored inmemory even when the power isturned off. The recommended set-ting is ± 2-10°F.

ENTERINGTEMPERTUREDEVIATIONALARMPARAMETERS

1

2

NOTE: If you enabled passcode protection, you must enterthe passcode to change this parameter. Too enter the pass-code:

Hold down the Setpoint Select button for 5 seconds. Whenthe control displays “ 1 PaS”, use the setpoint adjustment but-tons to enter the passcode. Press the Setpoint Select buttonagain. If the correct passcode was entered the controller willdisplay ACC PAS for 3 seconds. If the passcode was incor-rect, the controller will display rEJ PAS (rejected passcode).

Access to system parameters remain until power is cycled orthe RUN or STOP button is pressed.


TW-1 and TW-2 Thermolators provide SPI compatible supportfor RS-485 serial communications with a host machine. UseSPI communication to change or monitor the:

● Process temperature setpoint● High and low temperature deviation alarms● Process status (run and alarm conditions)● Machine 1 status● Machine 2 status● Actual temperature to process● Actual temperature from process

To use the SPI communication option, you must connect theThermolator to the host machine and set the communicationbaud rate and node address using the setpoint select andadjustment buttons on the control panel.

Connect the host machine to the unit.Plug the male DB9 connector into the serial communica-tions port on the Thermolator.

Apply power to the Thermolator.Enter the passcode, if necessary.Hold the Setpoint Select button for 5 seconds. When thecontrol displays 1 PaS, use the setpoint adjustment but-tons to enter the passcode.

Enter the node address.Press the Setpoint Select button to chooseAddress. Then press the setpoint ▲ or ▼arrow until the address you want appears inthe setpoint display. The address may be setto any number from 32 to 254 (a hexadeci-mal integer between 20 and FE), as long asthat number has not been assigned to anothermachine connected to the same network.

Set the baud rate to 12, 24, 48 or 96.The Thermolator must be set to send andreceive data at the same baud rate as the hostmachine. Press the setpoint ▲ or ▼ arrowuntil the baud rate you want appears in thesetpoint display window.12 = 1200 bps 48 = 4800 bps24 = 2400 bps 96 = 9600 bps

The green SPI status light on the control panel should flashwhen the unit is communicating. The LED will turn red, indi-cating an alarm, if SPI communication is not properly set up.

1

23

4

ACTIVATING SPICOMMUNICATION

5

NOTE: To disable SPI, usethe setpoint ▲ or ▼ arrow toselect Address. Press the ▼arrow until OFF is displayed inthe sepoint window.

See the APPENDIX for additionalSPI programming information.

If you have a TW-2 model, you can automatically start andstop the Thermolator from a remote switching or timingdevice that has power contacts rated 110VAC, such as theprocess machine control.

Wiring the device to the Thermolator is accomplished througha dry contact to the appropriate terminals on the motherboard.After wiring the device to the unit, Auto Start must beenabled by configuring a dip switch on the motherboard.

Disconnect and lockout power to the unit.


Punch a small hole in the left side of theelectrical enclosure. The hole must be large enough toaccommodate conduit for the power contact wires fromyour switching or timing device.

Insert the two power leads from the devicethrough the conduit into the electrical enclosure.

Connect the 110VAC device contact wires to the Auto Start terminals. Make sure terminals are screwedtight.


INSTALLING THEAUTO STARTFEATURE(TW-2 ONLY)

3-16 INSTALLATION

123

4

AC

IN

4

AC

IN +

3A

C O

UT

2A

C O

UT

+ 1 F1

LL

S/W

PS

LL

S/W

PS

AU

TOS

TAR

TA

UTO

STA

RT

HP

S/L

PS

HP

S/L

PS

OP

SO

PS

FS

TAT

FS

TAT

6 5 4 3 2 1 4 3 2 1

5


IMPORTANT: Alwaysrefer to the wiring diagramsthat came with your tempera-ture control unit before mak-ing electrical connections. Thediagrams show the mostaccurate electrical componentinformation.

Device contacts

Set dip switch 4 to the ON position.

Close the electrical enclosure and restorepower to the unit.

When Auto Start is enabled:◆ The Auto Start indicator light flashes to indicate that the

Thermolator can start at any time. The Thermolator willstart whenever the remote switching or timing device sendsa signal to start processing.

◆ The Auto Start indicator light is on whenever theThermolator is under the control of the remote device.

To disable Auto Start:Repeat steps 1,2 and 7, setting dip switch 4 to the OFF insteadof the ON position.

INSTALLING THEAUTO STARTFEATURE(TW-2 ONLY)


6

NOTE: All dip switch illus-trations in this manual showswitches 7 and 8 set to ON.If you have an IsolatedCircuit model, these switch-es should be set to OFF.

8 7 6 5 4 3 2 1

7


●● TW-1 Control Features . . . . . . . .4-2●● TW-2 Control Features . . . . . . . .4-3●● Positioning the Control Panel . .4-4●● Entering Passcodes . . . . . . . . . .4-5●● Starting the Thermolator . . . . . .4-6●● Stopping the Thermolator . . . . .4-7●● Using the TW-1 Purge Feature .4-8●● Using the TW-2 Purge Feature .4-9●● Performing an Auto Tune . . . .4-10

OPERATION

All normal operating functions can be controlled from theTW-1 control panel. If you have the optional manual moldpurge, the control switch is located on the side of theThermolator electrical enclosure.

TW-1 CONTROLFEATURES

Thermolator TW-1 and TW-2 UGH015/09024-2 OPERATION

Setpoint adjustment buttonsPress ▲ or ▼ to enter the processtemperature setpoint, SPI parametersand passcodes. Press ▲ to increase a value. Press ▼ to decrease a value. TIP: Press and hold the button forfaster scrolling speed.

NOTE: Passcode protection prevents accidental or unauthorized changes to all operating parameters. If passcode protection has been enabled, youmust enter the correct passcode tochange the process temperature set-

Actual values displayThe green window displays the temperatureat the middle of the mold. This temperatureis calculated as an average of the tempera-tures of the supply water and return water.The lights indicate whether the temperatureis in degrees Fahrenheit or Celsius. See theINSTALLATION section for instructions on howto change the temperature units.

Setpoint displayThe Setpoint display shows thesetpoints entered for fluid temper-ature, high and low temperaturedeviation alarms, the SPI baudrate, and the SPI address.Setpoint and Actual value displaywindows also display some alarmcodes and setup instructions.

Run/Stop Press RUN button tostart normal operation.Press STOP to stop thetemperature control unit.

= Running (green)= Stopped (red)= Alarm (red, flashing)

Status lightsThe lights indicate the oper-ating status of the listedcomponents. Except in TestMode, the lights indicate:

= Off or inactive= On or active (green)= Alarm condition (red)

Test Mode is used for test-ing displays, keys andinput/output functions.When test mode is enabled,normal operation is dis-abled.

= Test Mode off= Test Mode on (red);

AlarmPress to acknowledge thealarm light and silence theoptional audible alarm. Thealarm light will flash until thecause of the alarm conditionis fixed. See Troubleshootingfor alarm descriptions andremedies.

Setpoint Select buttonPress repeatedly until the green lightappears next to the parameter you want toprogram or view. NOTE: Default settings for the deviation setpoints are:High = setpoint + 25°F Low = setpoint - 25°FA warning alarm occurs (indicator light red)whenever the actual temperature is outsidethis setpoint range for more than the setdelay. Recommended setting: ± 2-10°F.

TW-2 CONTROLFEATURES

UGH015/0902 Thermolator TW-1 and TW-2 OPERATION 4-3

Purge ValveThe light indicates the operating status of the purge valve. Except inTest Mode and Auto Start, the light indicates:

= Off or inactive= On or active

Display Select buttonPress repeatedly until the green lightappears next to the temperature you want to view.

All normal operating functions can be controlled from theTW-2 TW-2 control panel, including the optional mold purge.

Status lightsThe lights indicate the oper-ating status of the listedcomponents. Except in TestMode and Auto Start, thelights indicate:

= Off or inactive= On or active (green)= Alarm condition (red)

Test Mode is used for testingdisplays, keys and input/out-put functions. When testmode is enabled, normaloperation is disabled.

= Test Mode off= Test Mode on (red);

unit disabled

Auto Start allows you to startand stop the unit from aremote switching or timing device, such as theprocessing machine control.This feature can only benenabled by configuring a dipswitch on the control mother-board.

= Disabled; Auto Startnot available

= Enabled (flashing green);unit can start any time

= On and under control ofthe remote device

Actual values displayThe green window displays the temperatureat the middle of the mold. This temperatureis calculated as an average of the tempera-tures of the supply water and return water.The lights indicate whether the temperatureis in degrees Fahrenheit or Celsius. See theINSTALLATION section for instructions on howto change the temperature units.

Setpoint displayThe Setpoint display shows thesetpoints entered for fluid temper-ature, high and low temperaturedeviation alarms, the SPI baudrate, and the SPI address.Setpoint and Actual value displaywindows also display some alarmcodes and setup instructions.

Run/Stop Press RUN button tostart normal operation.Press STOP to stop thetemperature control unit.

= Running (green)= Stopped (red)= Alarm (red, flashing)

Setpoint adjustment buttonsPress ▲ or ▼ to enter the processtemperature setpoint, SPI parametersand passcodes. Press ▲ to increase a value. Press ▼ to decrease a value. TIP: Press and hold the button forfaster scrolling speed.

AlarmPress to acknowledge thealarm light and silence theoptional audible alarm. Thealarm light will flash until thecause of the alarm conditionis fixed. See Troubleshootingfor alarm descriptions andremedies.

Setpoint Select buttonPress repeatedly until the green lightappears next to the parameter youwant to program or view. NOTE: Default settings for the deviation setpoints are:High = setpoint + 25°F Low = setpoint - 25°FA warning alarm occurs (indicator lightred) whenever the actual temperatureis outside this setpoint range for morethan the set delay.Recommended setting: ± 2-10°F.


POSITIONINGTHE CONTROLPANEL

The TW-2 control panel can be mounted up to 50 feet fromthe unit, using a remote control cable and the magnets on theback of the panel.

Do not stretch the cable. The cable is available in 30 and 50foot lengths so that you can order the appropriate cable foryour installation.

To detach the TW-2 control panel:Grasp the black control panelhandles and pull upward.

Use the magnetic back to mountthe control panel in the remotelocation. Connect the remote-mounted control to the unit withthe cable provided.

CAUTION: Improper handling of the controlpanel can damage the unit.

DO NOT mount the detached TW-2 control panelto a hot surface.


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 baudrate.

If passcode protection is enabled, you must enter the correctpasscode to change these parameters. To enter the passcode:

Press and hold the Setpoint Select button for 5 seconds. The control will display 1 PaS to indicate apasscode is needed.

Press the Select ▲ button until the correct passcode appears in the display.

Press again to enter the passcode.If the passcode is correct, the control displays ACC PASfor 3 seconds. If the passcode is incorrect, the control dis-plays rEJ PAS (rejected passcode) for 3 seconds.

Press Setpoint to select the parameter you want to change.

You have access to the system parameters until:● The power is cycled off and on.● The RUN or STOP button is pressed.

NOTE: Pressing the STOP or RUN key while you areentering a passcode will abort the passcode entrysequence.

ENTERINGPASSCODES

1

2

3

4


Before starting the Thermolator, verify that the system hasbeen installed correctly for your application. See theINSTALLATION section.

If Passcode Protection has been enabled, you must enter thecorrect passcode before you can change or enter any of theoperating parameters, including the temperature setpoint.

Turn on the water supply to the Thermolator.The supply must be at least 25 psi. Check for leaks in thecooling water and process fluid lines before continuing.

Turn on main power to the Thermolator.The control initiates a brief self test. ◆ Indicator lights blink green, then red.◆ Setpoint and actual windows will display for

three seconds, followed by the software version. Thewindows then display the factory default setpoint of100° F and the actual temperature.

Enter the passcode,if necessary. Hold the SetpointSelect button for 5 seconds. When the control displays 1 PaS, use the set-point adjustment buttons toenter the passcode. Press theSetpoint Select button again.

Enter the temperature setpoint. Press the SetpointSelect button until the greenlight appears next toTemperature. Press ▲ toincrease or ▼ to decrease thetemperature setting.

Press to start normal operation.◆ The RUN/STOP light turns green.◆ The unit initiates a 60-second venting sequence.

Cooling and venting valves are active for 60 seconds.The pump is active for the final 30 seconds.

◆ Normal operation begins. The heater turns on when theactual temperature is below setpoint. The cooling valveturns on if the actual temperature is above the setpoint.

If the Alarm light turns on, press to silence the option-al audible alarm. Then see the TROUBLESHOOTING section.

STARTING THETHERMOLATOR

1

2

3

Run

IMPORTANT: If you areoperating the Thermolatorfor the first time sinceinstallation, you should perform an Auto Tune aftertwo hours of normal opera-tion. You should performthe Auto Tune periodicallyto ensure that the controlcorrectly calculates howmuch heat and coolingshould be applied to main-tain the process setpoint.See “Performing an AutoTune.”

5

4


STOPPING THETHERMOLATOR

You must shut down the Thermolator whenever you:● Change the water hookups.● Shut down the process machine.● Purge the process circuit of the water or fluid.● Run the unit’s diagnostic tests.● Perform routine or preventative maintenance.● See an alarm condition that requires troubleshooting.● Relocate, ship or store the unit.

To shut down the unit for purging the process lines, diagnostictesting, routine maintenance or troubleshooting, press the Stopbutton. Then refer to the appropriate topic or section in thisUser Guide.

To shut down the unit to change water hookups:

Press and drain the unit of all water or fluid.Drain the unit using the two drainplugs on the back of the unit.

Once the unit is cool, remove the water hookups.

To shut down the unit for relocation or storage:

Press and drain the unit of all fluid.Drain the unit using the two drain plugs.

Disconnect the power supply and all waterfeeds.

Position the control panel to rest flush with the unit.

In shipment or storage, the Thermolator can withstand anenvironment between -40°F (-40°C) and 150°F (65°C) with95% relative humidity non-condensing.

WARNING: Electrical shock and hot surface hazardsBefore 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).

Stop1

2

Stop1

23


The TW-1 direct injection and closed circuit models can beordered with optional mold purge, which clears the processlines of fluid using compressed air. The purge is operated by amanual switch on the left side of the unit.

IMPORTANT: Before purging the process lines, be surethat the cooling water source feed is closed. If the feed isopen and the air line has a higher pressure than the coolingwater, air may be injected into the cooling water system. Ifthe cooling water pressure is higher than the air line, coolingwater may be injected into the air line.

Press to shut down the Thermolator.◆ The RUN/STOP LED turns red.

Shut off the cooling water supply to the unit.

Turn the manual purge switch to the “ON”position to start purging.◆ The Purge Valve LED lights.◆ The Vent and Cool outputs are activated.◆ The STOP and RUN buttons are deactivated during the

purge or when the cool delay off timer is active.The time required to clear the process lines of fluid willvary according to the length of the process piping and thesize of the tooling.

Turn the purge switch to the “OFF” position to stop purging.◆ The Vent and Cool solenoids remain energized for 5

seconds after the purge is terminated.

USING THE TW-1 PURGEFEATURE

Stop1

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4

NOTE: The purge operation will terminate immediately if theunit detects a blown fuse in the Vent or Cool output. The unitwill alarm and shut down.

See the TROUBLESHOOTING section for instructions on how toclear the alarm and fix the problem.


The TW-2 direct injection and closed circuit models can beordered with optional mold purge, which clears the processlines of fluid using compressed air. The purge is operated by abutton on the control panel.

IMPORTANT: Before purging the process lines, be surethat the cooling water source feed is closed. If the feed isopen and the air line has a higher pressure than the coolingwater, air may be injected into the cooling water system. Ifthe cooling water pressure is higher than the air line, coolingwater may be injected into the air line.

Press to shut down the Thermolator.◆ The RUN/STOP light turns red.

Shut off the cooling water supply to the unit.

Press to open the valve and start purging.◆ The Purge Valve LED lights.◆ The Vent and Cool outputs are activated.◆ The STOP and RUN buttons are deactivated during the

purge or when the cool delay off timer is active.The time required to clear the process lines of fluid willvary according to the length of the process piping and thesize of the tooling.

Press to close the valve and stop purging.◆ The Vent and Cool solenoids remain energized for 5

seconds after the purge is terminated.

USING THE TW-2 PURGEFEATURE

Stop1

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4

NOTE: The purge operation will terminate immediately if theunit detects a blown fuse in the Vent or Cool output. The unitwill alarm and shut down.

See the TROUBLESHOOTING section for instructions on how toclear the alarm and fix the problem.

You should perform an Auto Tune after the first two hours ofoperation and whenever process variables change (changes incooling water pressure, piping or molds; large ambientswings; new setpoint temperature) to ensure that the controlcontinues to obtain good approximations of the PID constantsused to compensate for the thermal lag of the system.

To ensure a successful Auto Tune, verify that:❒ The Auto Tune feature has been enabled. Auto Tune is

enabled or disabled via dip switch 2 on the motherboard.❒ The process value is stable. A fluctuating process value

will fool the software into making inaccurate tuning deci-sions. The software waits 5 minutes for the process value tostabilize before it starts the Auto Tune process. If theprocess value still fluctuates after 5 minutes, the Auto Tuneterminates and the control displays the “At ti” error.

❒ The control is in STOP mode and the process value is inambient temperature. This allows the software to obtaingood approximations of process parameters, which are crit-ical for performing an accurate tune. If this requirement isnot met, then a good tune cannot be guaranteed.

❒ The setpoint/process deviation is at least 25° F. If theabsolute value of setpoint - process temperature is notgreater than or equal to 25° F, the Auto Tune will terminate.The control will display an “At dEV” error.

Press to shut down the Thermolator.

Disconnect and lock out main power to the unit.

Enable Auto Tune.Open the electrical enclo-sure. Set dip switch 2 to ON.Close the electrical enclosureand restore power to the unit.

Restore power to the unit.

PERFORMING ANAUTO TUNE


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Stop

Set the setpoint to desired value.

Press and (the Setpoint Select button) simultaneously to begin the Auto Tune. The pump ener-gizes, the Actual display flashes “At” and the currentprocess temperature to indicate that an Auto Tune isunderway.

If Auto Tune is successful, the controller automaticallystarts controlling using the new PID parameters. If you press the STOP button or a fault occurs during theAuto Tune, the control enters stop mode and Auto Tuningimmediately terminates. The Actual display stops flashing“At.” If a fault occurred, the control displays the appropri-ate error message.

PERFORMING ANAUTO TUNE


Run

ERROR MESSAGE ERROR DESCRIPTION

Insufficient setpoint/process deviation.If the absolute value of (setpoint - processvalue) is less than 25° F. The Auto Tune can-not be started until the temperature difference is at least 25° F.

Auto Tune timed out. Auto Tune will timeout if a stable process value cannot beobtained 5 minutes into the tune, or if thetuning process takes longer than 30 minutes.If this error occurs, verify that you followedevery requirement under “To ensure a suc-cessful Auto Tune” and perform a secondtune.

Invalid PID constants were generated.The most likely causes of this error is a tunestarted inappropriately or an external element(i.e., loose thermocouple) that upset theprocess while tuning was in progress. Verifythat you followed every requirement under“To ensure a successful Auto Tune” and per-

d E vA t

t IA t

b a dA t

56


●● Maintenance Schedule . . . . . . .5-2●● Accessing the Thermolator

Enclosure . . . . . . . . . . . . . . . .5-3●● Checking Reservoir

Fluid Levels . . . . . . . . . . . . . . .5-4●● Performing System Tests . . . . .5-5●● Key/Display Test . . . . . . . . . . . .5-6●● Input Test . . . . . . . . . . . . . . . . . .5-7●● Output Test . . . . . . . . . . . . . . . .5-8●● Disabling or Enabling

Output Monitors . . . . . . . . . . . .5-9●● Calibrating Temperature

Sensors . . . . . . . . . . . . . . . . . .5-10●● Logging Operating Hours . . . .5-12●● Pulse Mode Description . . . . . .5-13●● Pulse Mode Setup . . . . . . . . . .5-14●● Pulse Mode Limits &

Defaults . . . . . . . . . . . . . . . . . .5-14●● Deviation Alarm/Inhibition

Delay . . . . . . . . . . . . . . . . . . .5-15●● Vent Timer Adjustment . . . . . .5-16

MAINTENANCE

Thermolator TW-1 and TW-2 UGH015/09025-2 MAINTENANCE

PREVENTATIVEMAINTENANCESCHEDULE

Thermolator TW-1 and TW-2 water temperature controllersare essentially maintenance-free. However, to maintain thebest performance, we recommend the following maintenanceschedule.

●● Whenever process variables change❒❒ Perform an Auto Tune.

The Auto Tune ensures that the control continues toobtain good approximations of the PID constants usedto compensate for the thermal lag of the system. Youshould perform an Auto Tune after the first two hours ofoperation and whenever the process changes, such asafter a mold change; installation of different pipe sizes;or change in process setpoint. See the PERFORMING ANAUTO TUNE in the OPERATION section.

●● Daily❒❒ Check for leaks in cooling and process lines.

Before and during operation, you should inspect theunit and all plumbing lines for leaks. If a leak develops,stop the Thermolator and repair it.

❒❒ Keep the unit and the area around it clean.Check for and remove lint, dust or other obstructions onthe unit, especially around air intake areas. Keep thefloor around the unit dry.

❒❒ Check the process fluid level (IC models). Isolated circuit models have an internal reservoir thatcontains the process fluid. Check the level indicator onthe back of the unit to make sure the reservoir containsan adequate amount of process fluid. Refill as needed.

●● Monthly, or as often as needed.❒❒ Inspect the fluid reservoir (IC models only).

Check the level switches in the process fluid reservoir for debris or deposits that could interfere with proper operation. Flush and clean the reservoir, if necessary.

●● Quarterly (every 3 months)❒❒ Inspect power cords, wires and electrical

connections. Check for loose or frayed wires, burned contacts, andsigns of overheated wires. Check exterior power cordsto the main power source and from the electrical box tothe pump and heating elements. Check the ground wireand thermocouple connections. Replace any wire thatappears damaged or has worn or cracked insulation.

PREVENTATIVEMAINTENANCESCHEDULE

UGH015/0902 Thermolator TW-1 and TW-2 MAINTENANCE 5-3

●● Annually (every 12 months)❒❒ Test and calibrate the unit’s control systems.

The Thermolator’s Test Mode checks the operationof displays, control buttons, inputs and outputs. You

can also calibrate the supply and return thermocouples.See PERFORMING SYSTEM TESTS in this section.

WARNING: Electrical shock and hot surface hazardsBefore 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 than100° F (38° C)

To access the Thermolator enclosure:

Remove the top access panel by lifting straight up. Removethe side panels by lifting straight up.

ACCESSING THETHERMOLATORENCLOSURE

The isolated, or totally closed circuit models separate the cool-ing water from the process fluid, which is held in a reservoirinside the unit. This reservoir should be kept at about three-quarters full of the process fluid.

You can check the fluid level in the reservoir using the sightglass on the back of theThermolator.

To fill the reservoir:

Disconnect and lockout power, and remove thetop panel of the Thermolator.

Locate the reservoir near the top of the unit.

Locate the fill port at the top of the reservoir.

Refill the reservoir. Monitor the level using thesight glass on the back of the unit. Because IC units canuse pure water or glycol mixtures, make sure you areadding the correct fluid for your application.

Replace the top panel of the Thermolator.

CHECKING THERESERVOIRFLUID LEVEL(IC MODELS ONLY)


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5

IMPORTANT: Do not use deionized water or gly-col mixtures containing additives in aThermolator. Softened water or glycol mixtureswith additives, such as automotive fluids, candamage the Thermolator. Glycol/water processloop mixtures should use industrial-grade ethyl-

Sight glass

The TW-1 and TW-2 Thermolators provide a Test Mode thattests displays and keys on the control panel, as well as inputsand outputs. The Test Mode also allows calibration of the sup-ply and return line thermocouples.

System tests and calibration should be performed annually.

To enable Test Mode:

Press to shut down the Thermolator.

Disconnect and lock out main power to the unit, then open the electrical enclosure.

Set dip switches 3 and 5 to OFF.

Set dip switch 6 to ON.


◆ The control displays “tSt.”◆ The Test Mode LED lights.

Press any button to display the first test menu.Test mode provides the following menus:● Key/Display Test● Input Test● Output Test● Calibration● Total Operating Hours● Output Monitor Enable/Disable

After performing each test, hold the Setpoint for 3 seconds to index to the next test menu. The proce-dure for each test is described on the following pages.

PERFORMINGSYSTEM TESTS


Stop

8 7 6 5 4 3 2 1

12

3

45

6

7

IMPORTANT: All normaloperating functions are disabled while Test Mode isenabled. To return to normaloperation, you must disableTest Mode.

To disable Test Mode,repeat steps 2 through 5,setting dip switch 6 to OFFinstead of ON.

The Key/Display Test verifies the function of displays, LEDsand buttons on the control panel.

Enable Test Mode.

Press any key.

If necessary, index to the Key/Display menu.

Press and hold the Setpoint key for 3 seconds toindex to each test menu until the controller displays“dSP”.

Press any key to clear all displays.

Repeatedly press any key to test displays.With each key press, a new segment of all six 8-segmentLEDs and a select group of LED indicator lights will illu-minate.

Exit the test and enter the next test.Press and hold the Setpoint key for 5 seconds to exitand index to the next test.

KEY/DISPLAYTEST


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6

The Input Test verifies the function of inputs available on thevarious models of TW-1 or TW-2. Not all inputs are used onall models. The performance evaluation of the inputs is basedon the voltage sensing device (VSD).

Connect all inputs to the system.

Press any key to display the first test menus.

Select the Input Test menu.Press and hold the Setpoint key for 3 seconds toindex to each test menu until the controller displays“InP”.

Repeatedly press and release any key to test.With each key press and release, the left display will indi-cate the number of the input being tested (v1, v2, v3,etc.). The right display indicates either “1” for voltagepresent or “O” for an absence of voltage.

Only inputs that are actually used by the particular modelwill be tested.


INPUT TEST


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5

OUTPUT TEST


The Output Test verifies the function of outputs available onthe various models of TW-1 or TW-2. Not all outputs are usedon all models. The performance evaluation of the inputs isbased on the output monitors (OM).

Connect all outputs to the system.

Enable Test Mode.


Select the Output Test menu.

Press and hold the Setpoint key for 3 seconds toindex to each test menu until the controller displays“oUt”.

Repeatedly press and release any key to test.With each key press and release, the left display will indi-cate the number of the output being tested (oS1= OM1;oS2 = OM2; etc.). The right display indicates either “1”for a good output or “O” for a failed output.

Only outputs that are actually used by the particularmodel will be tested.


IMPORTANT: Testing each output requires the fir-ing of the associated solid state relay. Make sure anoutput device is connected to the controller, other-wise the test result will be erroneous.

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6

All output monitors on the Thermolator can be enabled or dis-abled permanently through the OM Enable/Disable Menu inTest Mode.

You need to use this feature if you have replaced the mother-board, or if dip switches 7 and 8 have been changed erro-neously. This will enable any required output monitors thatwere disabled and give fuse failures.

Enable Test Mode.Press any key to display the first test menus.

Select the OM Enable/Disable menu.Press and hold the Setpoint key for 3 seconds toindex to each test menu until the controller indicates“oS1” in the actual display and the status of the selectedoutput in the Select display.

Press the Setpoint ▲▲ or ▼▼ key to change thestatus. Each press of the key changes the output statusfrom ON to OFF or OFF to ON.

Press the Setpoint to select the next output.Repeat Step 4 to change the status of the output, or pressany key to continue indexing through the outputs.

Save changes and exit the output menu.Press and hold the Select key for 3 seconds to savethe changes and exit.

DISABLING ORENABLINGOUTPUTMONITORS


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3

4

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6

OUTPUT MONITOR SELECTION GUIDEMODEL TYPE DI CC IC OM1 Pump ON ON ONOM2 Heat ON ON ONOM3 Cool ON ON ONOM4 Vent OFF ON OFFOM5 Purge (TW-2 option only) ON ON OFF

The TW-1 and TW-2 Thermolators use type “K” thermocou-ples to sense the temperature in the return and supply processlines. These thermocouples should be calibrated annually, orwhen a new thermocouple is installed, to ensure correct opera-tion.

The Thermolator’s Calibration Mode provides zero and spancalibration of both the supply and return line thermocouples.You access the Calibration Mode while in Test Mode.

Enable Test Mode.See PERFORMING SYSTEM TESTS.

Press any button to display the first test menu.

Select the Calibration Mode menu.Press and hold the Setpoint key for 3 seconds toindex to each test menu until the controller indicates“SC.L” in the Actual display.

Release the Setpoint key.You are now in calibration mode. Each press and releaseof this key will exit the current calibration and start thenext calibration. The table below lists the calibrations thatwill be performed.

Using the thermocouple calibrator, apply the appropriate temperature to the control input.

CALIBRATINGTEMPERATURESENSORS


Special Tools Needed:❒ type K thermocouple

calibrator 1

23

4

5

SETPOINT ACTUALCALIBRATION DISPLAY DISPLAY

Zero Calibrate Supply Sensor 32°F (0°C) SC.LZero Calibrate Return Sensor 32°F (0°C) rC.LSpan Calibrate Supply Sensor 510°F (266°C) SC.HSpan Calibrate Return Sensor 510°F (266°C) rC.H

Press the up ▲▲ key to begin calibrating.The controller displays the name of the current calibration(examples: 32 SC.L; 32 rC.L; 510 SC.H; or 510 rC.H).

Wait until the control displays ‘don’ or ‘bad’.A “don” message in the Setpoint display indicates the cal-ibration was successful. A “bad” message in the Setpointdisplay indicates a bad calibration.

Press Select to start the next calibration.Pressing and releasing the Select key at the end of acalibration tells the controller to perform the next calibra-tion.

Exit Calibration Mode.Press and hold the Select key for 3 seconds to exit theCalibration Mode.

You can now proceed to the next test in Test Mode, or disableTest Mode and resume normal operation.

CALIBRATINGTEMPERATURESENSORS


7

NOTE: The original calibration value stored inEEProm can be restored for the current calibrationby pressing the STOP key at any time.

8

TO DISABLE TEST MODE, complete steps 2through 5 in “Performing System Tests”, setting dipswitch 6 to OFF instead of ON.

9

6

You can see the total numbers of operation by accessing theTotal Operating Hours Log in Test Mode.

Enable Test Mode.


Index through test menus to the operating log.Press and hold the Setpoint key for 3 seconds toindex to each test menu until the Actual display indicates“Log”. The Setpoint display indicates the total number ofoperating hours in 100-hour units.

Exit the Operating Hours Log.Press and hold the Select key for 3 seconds to exitand index to the next test.

You can now proceed to another menu in Test Mode, or dis-able Test Mode and resume normal operation.

LOGGINGOPERATINGHOURS


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4

TO DISABLE TEST MODE, complete steps 2 through 5in “Performing System Tests”, setting dip switch 6 toOFF instead of ON.

The Thermolator Direct Injection Model has a Pulse Mode inwhich software pulses the cool and vent valves at a predeter-mined rate under normal control and autotune when all of thefollowing conditions are met.

● The Control Point temperature is less than 245°F.● The setpoint is greater than the control point tem-

perature by more than 5°F.

Pulse Mode is used to relieve excess pressure that can buildup from thermal expansion of water in the process loop. ThePulse Time and Pulse Cycle Time parameters are adjustableunder Test Mode. Pulse Time is the time in which the cool andvent valves shall be activated within the pulse cycle. PulseCycle Time determines the cycle time for each pulse to berepeated. The cycle time can be set to ‘OFF’ to disable PulseMode.

PULSE MODEDESCRIPTION


PULSE MODESETUP


IMPORTANT: If theParameter Select button isnot pressed after a new valueis entered, then the newlyentered value is not saved tonon-volatile memory.

PULSE MODELIMITS ANDDEFAULTS

Parameter

Pulse Cycle Time

Pulse Time

Low Limit

Off, 0.1 minute

0.5 seconds

High Limit

15.0 minutes

5 seconds

Default Value

Off

1 second

When the Pulse Cycle Time is set to Off the Pulse Mode isdisabled.

Pulse Mode Setup establishes the characteristics of the pulsein Thermolator Direct Injection Model’s Pulse Mode.

To access the Pulse Mode Setup:

Follow Steps 1 through 7 in Test mode until “P.Cy” displays on the Actual screen. This is the PulseCycle Time parameter.

Release the Parameter Select button.The left display shows the Pulse Cycle Time value.

Use the UP and DOWN Arrow buttons to set a new Pulse Cycle Time value.

Momentarily press and release the ParameterSelect button to save the newly entered Pulse Cycle Timevalue into non-volatile memory. P.tI displays on theActual display. This is the Pulse CTime parameter.

Use the UP and DOWN Arrow buttons to set a new Pulse Time value.

Momentarily press and release the ParameterSelect button to save the newly entered Pulse Time valueto non-volatile memory.

Press and hold the Parameter Select button to exit Pulse Mode Setup and to enter the next service on themenu.

1

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3

4

5

6

7

The table lists the limits and defaults for the pulse mode para-meters.

The deviation alarm inhibition timer starts when the unitbegins running (for a unit with venting, the timer starts afterventing) or after the setpoint is changed. Whenever theprocess value is within the alarm band, the alarm inhibitionshall be canceled. The deviation alarm delay timer only startsafter the alarm inhibition is over.

Follow these steps to access the deviation alarminhibition/delay parameters:

Follow Steps 1 through 7 in Test Mode until “A.In” is displayed on the right display. This is the AlarmInhibition Time item.

Release the Parameter Select button.The left display shows the Alarm Inhibition Time value.

Use the UP and DOWN Arrow buttons to set a new Alarm Inhibition Time value.

Momentarily press and release the ParameterSelect button to save the new Alarm Inhibition Timevalue into non-volatile memory. The Actual displayscrolls to the ‘A.dY’ (Alarm Delay Time) item.

Use the UP and DOWN Arrows to set a new Alarm Delay Time value.

Press and release the Parameter Select button to save the new setting into non-volatile memory.

Press and hold the Parameter Select button to exit Alarm Delay/Alarm Inhibition, and enter the next ser-vice on the menu.

The table lists the limits and defaults for the AlarmInhibition/Alarm Delay parameters. The values are adjustablein 0.5 minute increments.

DEVIATIONALARMINHIBITION /DELAY


Parameter

Alarm Inhibition Time

Alarm Delay Time

Low Limit

1.0 minute

0.5 minutes

High Limit

15.0 minutes

5.0 minutes

Default Value

10.0 minutes

1.0 minutes

1

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3

4

5

6

7

When the unit starts, i.e. Run key is pressed or AutostartSwitch input is closed and Autostart Dip Switch is in theenabled state, the Vent sequence is initiated.

The venting sequence is divided into two phases. In the firstphase the cool and vent outputs energize for half the set vent-ing sequence time. This is followed by a second phase inwhich the cool, vent, and pump outputs are energized for theremainer of the venting sequence time. If the process tempera-ture is above 200ºF, the vent sequence will be skipped.

To access the Vent Timer setup:

Follow steps 1 through 7 in the Test modeuntil“vEn” shows on the Actual display.

Use the Up and Down arrow to set the desired vent cycle duration (0.1 to 10.0 minutes,adjustable in 0.1 minute increments).

Press and hold the Select button.The software saves the newly entered vent cycle durationinto non-volatile memory, and returns to the initial dis-play test menu (dSP).

Shut off and lock out the power supply to the Thermolator.

Return the Test Mode dip switch 6 to the OFFposition.

Reapply power to the unit.

VENT TIMERADJUSTMENT


1

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●● Before Beginning . . . . . . . . . . . . . . . .6-2●● A Few Words of Caution . . . . . . . . . .6-2●● Identifying the Cause

of a Problem . . . . . . . . . . . . . . . . . .6-3●● Shut Down Alarms . . . . . . . . . . . . . . .6-4●● Warning Alarms . . . . . . . . . . . . . . . . .6-8●● Other Warnings . . . . . . . . . . . . . . . .6-10●● System Alarms . . . . . . . . . . . . . . . . .6-11●● Thermolator will not Power Up . . . .6-12●● Checking and Replacing Fuses . . .6-13●● Resetting Overloads . . . . . . . . . . . .6-14●● Replacing Pump Overload . . . . . . .6-14●● Replacing the Motherboard . . . . . . .6-15●● Replacing the Heater

Contactor . . . . . . . . . . . . . . . . . . .6-16●● Checking Thermocouples . . . . . . . .6-17●● Replacing Thermocouples . . . . . . .6-17●● Repairing Cooling Valves . . . . . . . .6-18●● Repairing Solenoid Valves . . . . . . .6-19●● Repairing Motorized Valves . . . . . .6-20●● Replacing Heater Elements . . . . . . .6-20●● Removing the Pump . . . . . . . . . . . .6-22●● Disassembling and Assembling

3/4 - 2 HP Pumps . . . . . . . . . . . . . .6-23●● Disassembling and Assembling

3 - 7.5 HP Pumps . . . . . . . . . . . . . .6-24

TROUBLESHOOTING

You can avoid most problems by following the recommendedinstallation, operation and maintenance procedures outlined inthis User Guide. If you do have a problem, this section willhelp you determine what caused it and tell you how to fix it.

Before you begin troubleshooting:❏ Find the wiring, plumbing or other diagrams

that were shipped with your equipment. These diagramsare the best reference for correcting a problem. The dia-grams also will note any custom features, such as specialwiring, control or plumbing options, not covered in thisUser Guide.

❏ Verify that you have manuals for other equip-ment in the process line. Solving problems may requiretroubleshooting malfunctions or incorrect operating proce-dures on other pieces of equipment.

❏ If an alarm is present, note any indicator lights and messages shown on the control panel. These indicatorswill help you discover the cause of the problem morequickly.

The Thermolator is equipped with many safety devices. Donot remove or defeat them. Improper corrective action canlead to hazardous conditions, and should never be attemptedto sustain production.

Thermolator TW-1 and TW-2 UGH015/09026-2 TROUBLESHOOTING

BEFOREBEGINNING

A FEW WORDSOF CAUTION

WARNING: This machines should be adjust-ed and serviced only by qualified technical per-sonnel who are familiar with construction andoperation of this type of equipment.

WARNING: Hot surfaces and liquidsAllow the Thermolator to cool to below 100°F (38°C) before servicing the unit.

DANGER: Voltage hazard.Troubleshooting the electrical system of thisequipment requires use of precision electronicmeasuring equipment, and may require accessto the electrical enclosure while power is on.Exposure to potentially fatal voltage levels maybe unavoidable. These troubleshooting proce-dures should be performed only by qualifiedelectrical technicians who know how to use thisprecision electronic equipment and who under-stand the hazards involved.

UGH015/0902 Thermolator TW-1 and TW-2 TROUBLESHOOTING 6-3

A status light that turns fromgreen to red indicates analarm condition.

Most Thermolator malfunctions are indicated by an illuminat-ed alarm light and error codes displayed on the control panel.

A problem can trigger three types of alarms:●● Shut Down Alarms: The Thermolator detected a problem

that caused it to shut down automatically to prevent equip-ment damage or personal injury.

●● Warning Alarms: The Thermolator continues to operate,but warns of a problem that could lead to a condition thatwill shut down the unit.

●● System Errors: The system error codes indicate a non-recoverable problem with the microprocessor control.

When the Thermolator control detects a problem, the redAlarm light is activated and the RUN/STOP light changesfrom green to flashing red.

When an Alarm condition occurs:

Press to silence any optional audible orvisual alarm. The RUN/STOP light changes from flashingred to steady red.

Note any indicator lights or error messages to help determine the cause of the problem.

Find the alarm or error code in the diagnostics tables in the Troubleshooting section of this manual.

If the unit is still operating, press to clearthe alarm and shut down the Thermolator to correct theproblem.

Press to resume normal operation afterthe problem is corrected.

IDENTIFYING THECAUSE OF APROBLEM

1

2

3

Stop

WARNING:Disconnect and lockoutthe main power sourcebefore opening theThermolator or its electri-cal enclosure for servic-ing. Disconnect air andwater supply lines asneeded.

4

Run5


SHUT DOWNALARMS

Alarm

The cooling waterpressure is less than25 psi.

Note: The unit will re-start automaticallyafter a two-seconddelay if the waterpressure returns to atleast 25 psi.

The pump motoroverload hastripped. The contact is open.

WARNING:Only qualified electri-cal service personnelshould examine andcorrect problems thatrequire opening theunit's electrical enclosure or checkingelectrical current todiagnose the cause ofa problem.

Possible causeThe water supply pres-sure is below 25 psi.

The pressure switchfailed.

The cooling valve failed.

The incorrect voltage issupplied to the pumpmotor.

The required water flowis greater than thepump’s capacity.

The motor overloadisfaulty or set incorrectly.

The pump is not workingproperly.

Solution

Verify that the water supply ison and delivering water at apressure of at least 25 psi.Check for closed valve orfaulty pump in the supply cir-cuit.Watch gauges while turningcooling water on and off. Ifpressure vents automatically,check vent or cooling valve.

Check the cooling valve. SeeRepairing Solenoid Valves orMotorized Cooling Valves.

Supply voltage should matchthe rating on the pump nameplate. If voltage is correct,check wiring connections.

r Review pump sizing for the application.

r Decrease the process waterflow.

Disconnect the power and openthe electrical enclosure. Verifythat the overload is set to trip atthe proper amperage, whichshould not exceed the FLA.Manually trip and reset theoverload. If the problem contin-ues, replace the overload. SeeResetting and ReplacingOverloads.

Replace the pump if supplyvoltage, wiring and overloadsettings are correct, but thepump continues to draw exces-sive current.

The Thermolator has detected a problem that could lead to equip-ment damage or personal injury if it is not corrected.u The Alarm LED lights and the STOP/RUN LED flashes red.u The Thermolator automatically shuts down.u The control displays a red LED or alarm code indicating the

source of the problem.

Low Water Pressure

Pump


Alarm

The actual tempera-ture of water supplied to theprocess exceeds the260° F safety switchlimit.

WARNING:Only qualified electri-cal service personnelshould examine andcorrect problems thatrequire opening theunit's electricalenclosure or checkingelectrical current todiagnose the cause ofa problem.

The actual tempera-ture of water supplied to theprocess exceeds theprogrammed 260° Fsafety limit.

WARNING:Only qualified electri-cal service personnelshould examine andcorrect problems thatrequire opening theunit's electrical enclosure or checkingelectrical current todiagnose the cause ofa problem.

Possible causeWater stopped flowingthrough the unit orbetween the supply andreturn.

The optional electro-mechanical safety switchis improperly set or defective.

The heater contactor hasfailed.

Water stopped flowingthrough the unit orbetween the supply andreturn.

The heater contactorfailed.

Solution

r Verify that the unit is run-ning and that the pump isworking.

r Check for closed or defec-tive cooling or vent valvesand plugged lines. SeeRepairing Solenoid Valves.

Check the switch setting. Asetting that is too low willcause nuisance trips. Check theswitch and replace if defective.See Checking and ReplacingSwitches.

Replace the contactor if defective. See Replacing the Heater Contactor.

r Verify that the unit is run-ning and that the pump isworking.

r Check for closed or defec-tive cooling or vent valvesand plugged lines. SeeRepairing Solenoid Valves.

Replace the contactor if defective. See Replacing the Heater Contactor.

High Temp. Safety

SHUT DOWNALARMS

The Thermolator has detected a problem that could lead to equip-ment damage or personal injury if it is not corrected.u The Alarm LED lights and the STOP/RUN LED flashes red.u The Thermolator automatically shuts down.u The control displays a red LED or alarm code indicating the


SAFHi


Alarm

Actual temperatureof water supplied tothe process is belowthe programmed 20° F safety limit.

The thermocouplein the processreturn line failed.

The thermocouplein the process supply line failed.

Possible causeThe cooling valve is stuckopen.

The heater failed.

The thermocouple isloose.

The thermocouple failed.

The thermocouple loose.

The thermocouple failed.

SolutionDisassemble the cooling valveand check for particles block-ing the valve seat. Check thevalve seat for excessive wear.Replace parts as required usinga valve repair kit. SeeRepairing Solenoid Valves.

Check for a bad heatingelement, or a heater contactorthat failed in the open position.See Replacing the HeaterContactor and ReplacingHeater Elements.

Check for a loose thermocou-ple or loose wire connectionsto the thermocouple.

Check the thermocouple andreplace if necessary. SeeChecking and ReplacingThermocouples.

Check for a loose thermocou-ple or loose wire connectionsto the thermocouple.

Check the thermocouple andreplace if necessary. SeeChecking and ReplacingThermocouples.

SAFLo

ErrPbr

SHUT DOWNALARMS

The Thermolator has detected a problem that could lead to equip-ment damage or personal injury if it is not corrected.◆ The Alarm LED lights and the STOP/RUN LED flashes red.◆ The Thermolator automatically shuts down.◆ The control displays a red LED or alarm code indicating the


ErrPbS


SHUT DOWNALARMS

The Thermolator has detected a problem that could lead to equip-ment damage or personal injury if it is not corrected.◆ The Alarm LED lights and the STOP/RUN LED flashes red.◆ The Thermolator automatically shuts down.◆ The control displays a red LED or alarm code indicating the

source of the problem..

Alarm

The incomingpower is out ofphase. A leg mayhave failed or isdisconnected.

NOTE: This alarmis available only onTW-2(TW-2) models.

Pump fuse.

Heater fuse.

Cooling valve fuse.

Vent valve fuse.

Purge valve fuse.

Possible causeThe pump is rotating inthe wrong direction.

One of the main supplywire leads has disconnect-ed.

The indicated device hasblown a fuse.

The incorrect device isbeing used for this fuselocation.

The motherboard outputSSR at the designatedfuse failed.

SolutionCheck pump rotation againstthe arrow stamped on thepump. If the pump is rotatingin the wrong direction, discon-nect and lockout the mainpower source. Open the elec-trical enclosure, and reverse any two leads on the incomingpower connection.

Disconnect power and openthe electrical enclosure. Checkfor loose connections in mainsupply and on motherboard.

Disconnect and lockout themain power. Open the electri-cal enclosure. Check for loosewires and incorrectly installedjumpers or terminal blocksassociated with the fuse error.Replace the fuse, if necessary.See Checking and ReplacingFuses.

Replace the fuse, then enterTest Mode. Turn off the OutputMonitor associated with thefuse location and test outputs.See Performing System Testsand Disabling or EnablingOutput Monitors in theMAINTENANCE section.

Replace the motherboard. SeeChecking and Replacing theMotherboard.

ErrPHS

002FUS

003FUS

004FUS

005FUS

006FUS


WARNINGALARMS

Alarm

The Thermolatorwill not heat to thesetpoint temperature,or takes too long toreach the setpointtemperature. Theactual temperature offluid supplied to theprocess is lower thanthe setpoint devia-tion allows.

WARNING:The Thermolator shouldbe tested and repairedonly by qualified techni-cians equipped with thecorrect tools and trainedin the maintenance andrepair of electrical sys-tems and industrialappliances.

Possible causeThe cooling valve is stuckopen or leaking water?.

A heater element fail.

A heater contactor failed.

The low deviation tem-perature is set too low.

The Thermolator isincorrectly sized for theapplication.

SolutionDisassemble the cooling valveand check for particles block-ing the valve seat. Check thevalve seat for excessive wear.Replace as required using avalve repair kit. See RepairingSolenoid Valves.

With the unit powered down:Check for loose connections.Check resistance between thephases on the output side ofthe heater contactor. Readingsshould be within 0.25 ohms ofeach other. Replace the heater,if necessary. See ReplacingHeater Elements.

With power on and theHeater LED lit: Check theamp draw on each of the threephases to the heater. All shouldmatch the FLA listed for theheater on the unit nameplate.Replace the heater contactor ifthere is a voltage imbalancegreater than 10%. SeeReplacing the HeaterContactor.

Increase the low deviation set-ting. The recommended settingis 2°F to 10°F.

Review specifications andselection guidelines that applyto heater and pump sizes intemperature control units.

Low Deviation

The Thermolator has detected a problem that could lead to a shutdown condition if it is not corrected.◆ The Alarm LED lights.◆ The Thermolator continues operating.◆ The control displays a red LED or alarm code indicating the



WARNINGALARMS

Alarm

The Thermolatorwill not cool down,or takes too long tocool down. The actu-al temperature offluid supplied to theprocess is higherthan the setpointdeviation allows.

WARNING:The Thermolator shouldbe tested and repairedonly by qualified techni-cians equipped with thecorrect tools and trainedin the maintenance andrepair of electrical sys-tems and industrialappliances.

Possible causeWater stopped flowingbetween the supply andreturn.

The cooling valve failed.

The temperature differ-ence between the coolingwater supply and the set-point is too small.

A heater contactor failed.

The cooling valve is thewrong size.

The high deviation tem-perature is set too low.

SolutionCheck for a plugged pipe orclosed valve.

Check the cooling valve. SeeRepairing Solenoid Valves orMotorized Cooling Valves.

The temperature differenceshould be at least 25° F toachieve proper cooling. Increasethe process setpoint, decreasethe cooling water supply tem-perature. or increase coolingwater supply pressure.

With power on and the HeaterLED lit: Check the amp drawon each of the three phase legsto the heater. All should matchthe FLA listed for the heater onthe unit nameplate. Replace theheater contactor if there is avoltage imbalance greater than10%. See Replacing the HeaterContactor.

Check the cooling load (Btu/hr)for which the valve was speci-fied.

Increase the high deviation set-point. The recommended settingis 2°F to 10°F .

High Deviation

The Thermolator has detected a problem that could lead to a shutdown condition if it is not corrected.◆ The Alarm LED lights.◆ The Thermolator continues operating.◆ The control displays a red LED or alarm code indicating the


OTHERWARNINGS


The Thermolator has detected a problem that could lead to a prob-lem if it is not corrected.

◆ The Thermolator continues operating.◆ The control displays a red LED indicating the source of the

problem.

Alarm

The SPI communica-tion link has failed.

DIP Switch Error

Possible causeThe unit is not connectedto a host machine.

The network address andbaud rate are incorrect.

Something is wrong withthe cable.

The controller type DIPswitches (7 and 8) inad-vertently changed sincethe last power upsequence.

SolutionIf the Thermolator is not con-nected to a host device, set theSPI address to OFF using theSetpoint adjustment buttons onthe control panel.

❒ Check the network address.The address may be set toany number from 32 to 254(a hexadecimal integerbetween 20 and FE), as longas that number has not beenassigned to another machineconnected to the same net-work.

❒ Make sure the baud rate(9600, 4800, 2400, or 1200)matches the host machine.

Check the communicationcable condition and connec-tions. The cable must conformto SPI standards. Check forloose connections on themotherboard.

Power down the controller andreset the controller type DIPswitches (7 and 8) to the previ-ous settings. Refer to page 3-8of this User Guide for detailson the proper DIP switch set-tings.

SPI Communication

tyPSET

SYSTEMALARMS


Alarm

RAM hardwarefailure.

ROM, checksumfailure.

COP failures.

Illegal Opcode.

throughSoftware cannot

CauseElectrical noise or failedCPU on the motherboardcaused system write teststo fail during power up.

The CPU and/or PROMchip (U1 or U2) is notmaking good contact withits socket, or the PROMchip has failed.

A failed CPU, failed moth-erboard, software bug orelectrical noise caused aninternal software error.

The CPU tried to executean illegal software instruc-tion due to electrical noiseor a failed motherboard.

A failed CPU, failed moth-erboard, software bug orelectrical noise caused aninternal software error.

The memory has exceededits usable life or there is asoftware bug. This erroroccurs only after changeshave been made to non-volatile memory eitherthrough the operator panelor SPI.

SolutionMake sure all connections onthe motherboard are solid.Operate unit in a noise freeenvironment. If error persists,contact Conair service.

Make sure the CPU and PROMchips are seated correctly in thesockets. If error persists, contactConair service.

Cycle power to the unit. If theproblem persists, contact Conairservice technicians. You mayneed to replace the mother-board.

Make sure all connections tothe motherboard are solid andthat the unit is operating in anoise free environment. If errorpersists, contact Conair service.

Cycle power to the unit. If theproblem persists, contact Conairservice technicians. You mayneed to replace the mother-board.

Cycle power to the unit.Contact Conair service if anoperating parameter such as thesetpoint is not being saved or ifthis error persists.

The Thermolator has detected a non-recoverable error involv-ing he microprocessor control.◆ The Alarm LED lights and the STOP/RUN LED flashes red.◆ The Thermolator shuts down or will not start.◆ The control displays an error code indicating the source of

the problem.

001ERR

003ERR

002ERR

004ERR

006ERR

005ERR

015ERR

014ERR

016ERR

If you apply power to the Thermolator and the control panel doesnot light, you have a problem with the main power circuit or theunit’s microprocessor board.

WARNING: Electrical Shock HazardDisconnect and lockout the main power supplybefore proceeding.


THERMOLATORWILL NOTPOWER UP

SymptomApplying powerdoes not turn onthe Thermolator orlight the controlpanel.

The control panel islit, but theThermolator willnot operate whenRUN is pressed.

Possible causePower is not reaching theThermolator

The unit blown a fuse.

The incorrect voltage isreaching theThermolator.

The unit is in Test Mode.

Solution❒ Verify that the main power

supply and any customer-installed electrical discon-nect or emergency stopdevices are in the ON posi-tion.

❒ Verify correct electrical con-nections between the unitand the control, andbetween the unit and thepower supply. Replace anydamaged wires or cables.

Check Fuse 1 on the mother-board and any fuses or breakersassociated with customer-installed disconnect devices.Replace or reset as required.Identify the cause of the groundfault and correct it. See Check-ing and Replacing Fuses.

Check the electrical require-ments on the unit nameplate.Verify correct main supplyvoltage to the unit and the sec-ondary voltage supply from thetransformer to unit compo-nents. Replace the transformer,if necessary.

If the Test Mode LED is lit,you must disable Test Mode onthe motherboard before resum-ing operation. See PerformingSystem Tests in theMAINTENANCE section.


CHECKING ANDREPLACINGFUSES

IMPORTANT: Alwaysrefer to the wiring dia-grams that came withyour Thermolator tolocate specific electricalcomponents. Illustrationsin the User Guide areintended to be represen-tative only.

This procedure covers the factory-installed fuses on the unit’smotherboard. If you have installed an electrical disconnect oremergency stop switch, additional fuses and/or breakers mayhave been used elsewhere in the in the main power circuit.

To replace a blown fuse:

Disconnect and lockout the main power.

Open the electrical enclosure door.Turn the screw on the front panel counterclockwise toopen.

Replace the fuse. The fuses are located on the mother-board and are labeled and identified on the orange shield.

Close the electrical enclosure and restart the unit.

If fuse continues to fail:❒ Verify that the unit is receiving the correct voltage.

Check the voltage, phasing and amperage ratings on theunit’s nameplate.

❒ Verify that the unit’s transformer is operating correctly.Check for proper voltage (120V ±10%) to the voltagesensing device for the fuse location.

❒ Check all wiring referencing the fusing location forloose connections, damage or improper grounding.Verify that the correct device is being used for this fuselocation. See Disabling or Enabling Output Monitorsin the MAINTENANCE section.

12

3

4

12345678

CONFIGURATIONDIP SWITCH

OFF

ON

4321

4321

UNLDR 1/ VENT 2 SOL +UNLDR 1/ VENT 2 SOL UNLDR 2/ COOL 1 SOL +UNLDR 2/ COOL 1 SOL

F5

F4

F2

PUMPPUMP

PUMP OLPUMP OL

654321

4321

654321

F3

4321

F6

PMP AUXPMP AUX

1FS/ COMP AUX1FS/ COMP AUX

PUMPDOWNPUMPDOWN

HEAT/COMPHEAT/COMP

HTS/COMP OLHTS/COMP OL

NC

NCNO

C110V

ALARM

LLS/PURGE 3SOL LLS/PURGE 3SOL +

PURGE 4SOL PURGE 4 SOL +

3 PHASE INPUT

TCPL'SSUP RET

AC

IN

4

AC

IN +

3A

C O

UT

2A

C O

UT

+ 1 F1

LL

S/W

PS

LL

S/W

PS

AU

TOS

TAR

TA

UTO

STA

RT

HP

S/L

PS

HP

S/L

PS

OP

SO

PS

FS

TAT

FS

TAT

L1

L2

L3

6 5 4 3 2 1 4 3 2 1

Y R R Y

1 2 3 4 5 6 7 8 1 2 3 4

(-2)

CO

NT

RO

LO

PE

R P

NL

CA

BL

E

+ 1

20 O

hm

+ T

R

TR

G

ND

G

ND

+ T

R

TR

1

20 O

hm

Fuse 1Controlpower

Fuse 5Vent valve

Fuse 4Cooling valveFuse 2Pump

Fuse 3Heater

Fuse 6Purge valve

WARNING:Shock Hazard

Only qualified service per-sonnel familiar with electri-cal testing and industrialequipment should examineand correct problems thatrequire opening the unitwith power on to diagnosethe cause of a problem.


Open the electrical enclosure door. Turn the screw on the front panel counterclockwise toopen.

Locate the pump overload module attached tothe pump motor starter.

Disconnect the three power leads from theoverload module to the pump motor. Note the placement

of each lead and label as needed.

Disconnect auxiliary wiring on the overload module.

Remove the overload module.Loosen the three screws that connectthe overload module to the motor con-tactor. Pull the overload module downto release it from the starter.

Reverse these steps to install the new overload module.

Set the module reset mode to MAN (manual).

Set the proper FLA trip point.Do not exceed the FLA for the pumpmotor.


RESETTINGOVERLOADS

8

9

The pump motor overload is located inside the unit’s electri-cal enclosure.


Open the electrical enclosure door. Turn thescrew on the front panel counterclockwise to open.

Check the overload.If the red button is out, the over-load has tripped. Press the bluebutton to reset the overload.Verify that the overload trippoint does not exceed the FLAfor the pump.

12

3

Motor contactor

Motor overload

REPLACINGPUMP

12

3

4

5

6

7


REPLACING THEMOTHERBOARD

IMPORTANT: Alwaysrefer to the wiring dia-grams that came withyour Thermolator tolocate specific electricalcomponents. Illustrationsin the User Guide areintended to be represen-

Disconnect and lockout the main power supply.


Mark or label each wire connected to the motherboard.The orange shield is labeledwith the connection informa-tion. You must label the wiresto ensure they are connected tothe correct terminals on thenew motherboard.

Disconnect the wires from the motherboard bypulling the terminal blocks up.

Loosen the screws hold-ing the orange shield.

Remove the mother-board and shield from theelectrical enclosure as a unit.

Remove the mother-board from the shield andreplace with the new mother-board.

Reattach the shield and new motherboard in the elec-trical enclosure. Tighten thescrews.

Reconnect the terminal blocks and wires to the newboard. Make sure you alignthe terminal blocks with the correct pins on the board.Push the terminal blocks onto the pins, taking care not tobend any pins.

Set dip switches 7 and 8 to the correct unit type.Set ON for DI and CC models; set off for IC models.

Program output monitors on the new board. See Disabling or Enabling Output Monitors in theMAINTENANCE section.

12

3

4

5

6

12345678


OFF

ON

4321

4321


F5

F4

F2

PUMPPUMP

PUMP OLPUMP OL

654321

4321

654321

F3

4321

F6

PMP AUXPMP AUX


PUMPDOWNPUMPDOWN

HEAT/COMPHEAT/COMP


NC

NCNO

C110V

ALARM



3 PHASE INPUT

TCPL'SSUP RET

AC

IN

4

AC

IN +

3A

C O

UT

2A

C O

UT

+ 1 F1

LL

S/W

PS

LL

S/W

PS

AU

TOS

TAR

TA

UTO

STA

RT

HP

S/L

PS

HP

S/L

PS

OP

SO

PS

FS

TAT

FS

TAT

L1

L2

L3

6 5 4 3 2 1 4 3 2 1

Y R R Y

1 2 3 4 5 6 7 8 1 2 3 4

(-2)

CO

NT

RO

LO

PE

R P

NL

CA

BL

E

+ 1

20 O

hm

+ T

R

TR

G

ND

G

ND

+ T

R

TR

1

20 O

hm

1 2 3 4 5 6 7 8

4321

4321

654321

4321

654321

4321

6 5 4 3 2 1 4 3 2 1

1 2 3 4 5 6 7 8 1 2 3 4


OFF

ON


F5

F4

F2

PUMPPUMP

PUMP OLPUMP OL

F3

F6

PMP AUXPMP AUX


PUMPDOWNPUMPDOWN

HEAT/COMPHEAT/COMP


NC

NCNO

C110V

ALARM



3 PHASE INPUT

TCPL'SSUP RET

AC

IN

4

AC

IN +

3A

C O

UT

2A

C O

UT

+ 1 F1

LL

S/W

PS

LL

S/W

PS

AU

TOS

TAR

TA

UTO

STA

RT

HP

S/L

PS

HP

S/L

PS

OP

SO

PS

FS

TAT

FS

TAT

L1

L2

L3

Y R R Y

(-2)

CO

NT

RO

LO

PE

R P

NL

CA

BL

E

+ 1

20 O

hm

+ T

R

TR

G

ND

G

ND

+ T

R

TR

1

20 O

hm

7

8

9

10

11

Thermolators use mercury displacement heater contactors. Theheater contactors should be replaced if:● You have checked the amp draw on each of the three-phase

legs and discovered a voltage imbalance greater than 10%.● You have checked the continuity and found that ohms at the

coil equal zero.

To replace the heater contactor:



Disconnect the wires from the heater contactorMake sure you label the wires to ensure you can connectthem correctly to the newcontactor.

Remove the contactorby removing the screws thathold it in place.

Discard old contactorusing the proper disposalprocedure. See MaterialSafety Data Sheet.

Reverse this procedure to install the new contactor.Make sure the wires areconnected correctly.


12

3

4

5

WARNING: Hazardous SubstanceThermolators use mercury displacement contactors.Mercury is considered a hazardous substance and mustbe dealt with accordingly. See the Material Safety Datafor information on the how to avoid the potential haz-ards and how to clean up and dispose of mercury if itspills.


WARNING: Electrical Shock HazardOnly qualified service personnel who have been

trained on electrical testing and the procedures foravoiding the hazards should diagnose or correct prob-lems that require opening the unit with power on.

6

REPLACING THEHEATERCONTACTOR

Heater contactor


The Thermolator uses two type ‘K’ thermocouples to monitor supply and return process temperatures. One ther-mocouple is installed in the wall of the heater tank at the “toprocess” outlet. The other thermocouple is installed in the wallof the cooling tank at the “from process” inlet.

To check a thermocouple after a probe error:


Open the electrical enclosure door. Turn thescrew on the front panel counterclockwise to open.

Unplug the appropriate thermocouple from the motherboard and install a jumper on the leads. Referto the wiring diagrams that came with your unit.

Restart the Thermolator.◆ If error message disappears, replace the thermocouple.◆ If error message does not disappear, replace the moth-

erboard. See Replacing the Motherboard.

To replace a thermocouple:


Shut off the cooling water infeed and drain the unit. Drain all water using the drain plugs located in thebottom of the unit.

Remove the unit’s top panel and open the electrical enclosure.

Remove the thermocouple.Loosen the compression nut to slidethe thermocouple out of the casing.Disconnect the thermocouple wiresat the motherboard.

Install the new thermocouple.Insert the tip of the new thermocou-ple at least 1 inch into the tank.tighten the compression nut. Threadthe leads through the raceway lead-ing to the electrical enclosure.Attach the thermocouple leads to themotherboard.

12

3

4

CHECKINGTHERMOCOUPLES

12

3

4

5

REPLACINGTHERMOCOUPLES

Thermocouple

Nut

WARNING:Hot surfaces

Allow the Thermolator to coolto below 100°F (38°C) beforeservicing the unit.


Every Thermolator has a solenoid valve assembly that con-trols the cooling water out flow. Closed circuit (CC) units alsohave a vent valve assembly. Solenoid valves also are found onthe optional purge valve.

Shut off the cooling water infeed.

Drain the unit of all water through the reliefvalve port in the rear ofthe unit. Use a 1/4 inchallen key.

Remove the cooling water out feed. Forclosed and isolated cir-cuit models, alsoremove the coolingwater in feed.

Disconnect and lockout main power.

Remove the top and side panels of theThermolator. Lift the toppanel straight up, then liftthe side panels up.

Remove the cooling valve from the coolingwater out line.

Disassemble the cooling valve.See Repairing Solenoid Valves and RepairingMotorized Valves.

Inspect and clean or repair the valve body assembly. Remove foreign particles and replace damagedparts as necessary.

REPAIRINGCOOLINGVALVES

Cooling water in

1

3

WARNING: Electrical shock and hot surface hazardsBefore attempting maintenance of any kind on the Thermolator, you must stop the unit; disconnect and lockout the main power supply;and allow the unit to cool to 100°F (38°C)


Coolingwater out

Cooling water out

Cooling water in

6

7

8

2

4

5


Reassemble the valve and other components.Reassemble in reverse order. Seal all pipe fittingswith pipe sealant. Check that all flows are in the correctdirection. Check for leaks before resuming operation.

REPAIRINGSOLENOIDVALVESNameplate

Cover*

Yoke*

Housing*7/8" Dia. Hole

for 1/2" Conduit

Solenoid Base Sub-Assembly

0.9375-26 UNS-2AThread

Core (AC) Tapped Hole in Core 0.250-28 UNF-2B

0.38 Minimum Full Thread

or Retaining Clip*

Retaining Cap*

Sleeve*Grounding Wire (Not present on all constructions)

Insulating Washer

Sleeve*

SpringWasher*

Housing*with Nameplate*

*Indicates Parts Supplied in Solenoid Enclosure Kit

Alternate Construction withNameplate on Housing

Coil

Insulating Washer

9

*Indicates Parts Supplied in Solenoid Enclosure Kit Cover*

Yoke*

7/8" Dia. Hole for 1/2" Conduit

Solenoid Base Sub-Assembly

0.9375-26 UNS-2AThreadCore (AC) Tapped Hole in Core

0.250-28 UNF-2B 0.38 Minimum Full Thread

or Retaining Clip*

Sleeve*Grounding Wire (Not present on all constructions)

Sleeve*Coil

Disassemble valves following the steps in Repairing CoolingValves. Reassemble the valve and other components. inreverse order of disassembly. Seal all pipe fittings with pipesealant. Check that all flows are in the correct direction.Check for leaks before resuming operation.

REPAIRINGMOTORIZEDVALVES


WARNING: Electrical shock and hot surface hazardsBefore 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 than100°F (38°C)

REPLACINGHEATERELEMENTS


Remove the top panel of the Thermolator.

Remove the heater cap.Use a 1/4-inch open-endwrench to remove the threebolts that hold the cap to theheater tank.

Remove the heaterwiring harness. Label thewiring layout of the heater ter-minals; wires are labeled 2T1,2T2, 2T3 and GND.

123

4

Heatercap

Actuator

Complete valvewith actuatorlinkage kitinstalled

Valve stem andplug assembly

Mounting nut

Hex coupler

Packing cartridgewith packing nut

Spring retainerSpring compression screwScrew

Valve bodyValve repair kit

Wrench

The Valve Repair kitincludes Valve Stem andPlug Assembly andPacking Cartridge withPacking Nut.

Unscrew the locking screws on the wiring harness andremove the wires.

Shut off the cooling water in feed.

Drain the Thermolator using the drain plugs located at the rear of the unit.

Remove the four bolts that hold the heater element in place. Use a 15/16-inch socket with 1/2-inchdrive.

Lift the heating element out of the heater tube.Lift the element straight up.

56

HEATER TERMINAL CONNECTIONS

7



The wiring layout will be one of the following: REPLACINGHEATERELEMENTSCONT’D

Heater cap

Heater element

Heater gasket

Lift the heating element out of the heatertube. Lift the element straight up.

Replace the heater gasket if it is worn.

Reverse these steps to install the new heaterelement and reassemble the unit.

9

10

8

11

REMOVINGTHE PUMP



Shut off the cooling water in feed.

Drain the unit of all fluid. Remove therelief valve at the rearof the unit using a 1/4-inch allen key.

Remove the top and side panels..

Remove the seal flush line. Use a 1/2-inch open-end wrench to remove theflush line from the connec-tion on the pump adapter.

Remove the pump assembly bolts. Use a 9/16-inch open-end box wrenchto remove the bolts holdingthe pump to the volute. Thebolt in the rear will requirea 9/16-inch crows foot wrench.

Lift the pump assembly straight up to remove. The pumpcan now be replaced or disas-sembled for repair. Extra longleads so the motor can beremoved with disconnecting thewires.

Reverse the steps to reassemble the unit.

NOTE: Before restarting, close all drain openings usingsealant on the threads and reprime the pump. Do not startuntil the pump is completely filled with water.

12

3

4

5

6

7

8

Cooling water in


Coolingwater out

Cooling water out

Cooling water in

WARNING: Electrical shock and hot surface hazardsBefore 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 than100°F (38°C)

Pump seal flush line

Pumpassembly

bolts

Volute


DISASSEMBLINGAND ASSEMBLING3/4 - 2 HP PUMPS

To replace a failed seal, you must disassemble the pump.Remove the impeller nut.Insert a screwdriver in one of the impeller waterway pas-sages and back off the impeller nut.

Remove the impeller by inserting a screw-driver in the slot of the motor shaft. Unscrew the impellerwhile holding the shaft against the rotation.

Remove the seal, gasket case, adapter and flinger.

Clean the gasket and flange faces, seal seat cavity and shaft. The shaft shoulder that fits against theimpeller must be clean.

Replace the flinger. Lubricate the seal seat cavity of the adapter and theflinger with soapy water solution before pressing theflinger squarely into the cavity. Do not chip or scratch thelapped seat face.

Remount the adapter to the motor, making sure the motor shaft does not dislocate or chip the seat ofthe seal.

Replace the remaining seal components. Apply a soapy water solution to the motor shaft and therubber bellows of the rotating seal. Be sure the rotatingseal face stays in the holding collar during installation.Do not chip or scratch the lapped seat faces.

Reassemble the remaining components, hold-ing the shaft against rotation. Remove any burrs caused bythe screwdriver on the impeller.

Reattach the pump to the volute case. Replace any damaged gasket or O-ring between the pumpassembly and volute case. Check for free rotation afterassembly is completed.

Pump motor

Flinger*Pump adapter

Gasket, case*

Seal*Impeller

D washer*

Impeller nut*

*Indicates Parts Supplied in the Seal Repair Kit

1

2

3

4

5

6

7

8

9

NOTE: Before restarting,close all drain openings usingsealant on the threads andrefill the unit with fluid. Do notstart the the pump when theunit is dry.


To replace a failed seal, you must disassemble the pump.Remove the impeller retaining assembly. Insert ascrewdriver in one of the impeller waterway passages tohold the impeller steady while removing the retainer.

Remove the impeller being careful not to loseany parts. If the impeller is difficult to remove, you mayneed to use a bearing puller.

Remove the seal, adapter, shaft and flinger.

Clean the gasket and flange faces, seal seat cavity, shaft sleeve and motor shaft. Replace the shaftsleeve if it is damaged or worn.

Replace the flinger. Lubricate the seal seat cavity of the adapter and theflinger with soapy water solution before pressing theflinger squarely into the cavity. Do not chip or scratch thelapped seat face.

Remount the adapter to the motor.Make sure the motor shaft does not dislocate or chip theseat of the seal.

Replace the remaining seal components. Apply a soapy water solution to the motor shaft and therubber bellows of the rotating seal. Slide the rotatingmember of the seal over the shaft sleeve. Replace the sealspring and seal retainer, making sure the rotating seal facestays in the holding collar during installation. Do not chipor scratch the lapped seat faces.

Place the key in the key seat and slide the impeller on the shaft. Replace the impeller retaining nut.Remove any burrs caused by the screwdriver on theimpeller.

1

2

3

Pump motor

Flinger*

Pump adapter

Gasket, case*

Seal*

Impeller

O-ring, shaft*

Impellerretainer*

*Indicates Parts Supplied in Repair Kit

Shaft* sleeve

Sealretainer*

Key*

Wear ring

4

5

6

7

8

DISASSEMBLINGAND ASSEMBLING3 - 7.5 HP PUMPS


DISASSEMBLINGAND ASSEMBLING3 - 7.5 HP PUMPS

Reattach the pump tothe volute. Make sure youreplace any damaged gasket orO-ring between the pumpassembly and volute case.Check for free rotation afterassembly is completed.

NOTE: Before restarting, close all drain openings usingsealant on the threads and and refill the unit with fluid.Do not start the the pump when the unit is dry.

9

IMS0002/0296 SERVICE INFORMATION APPENDIX A-1

Conair has made the largest investment in customer support inthe plastics industry. Our service experts are available to helpwith any problem you might have installing and operatingyour equipment. Your Conair sales representative also canhelp analyze the nature of your problem, assuring that it didnot result from misapplication or improper use.

To contact Customer Service personnel, call:

From outside the United States, call: 814-437-6861

You can commission Conair service personnel to provide on-site service by contacting the Customer Service Department.Standard rates include an on-site hourly rate, with a one-dayminimum plus expenses.

If you do have a problem, please complete thefollowing checklist before calling Conair:

❒ Make sure you have all model, serial and parts listnumbers for your particular equipment. Servicepersonnel will need this information to assist you.

❒ Make sure power is supplied to the equipment.

❒ Make sure that all connectors and wires withinand between control systems and related components have been installed correctly.

❒ Check the troubleshooting guide of this manualfor a solution.

❒ Thoroughly examine the instruction manual(s)for associated equipment, especially controls.Each manual may have its own troubleshootingguide to help you.

❒ Check that the equipment has been operated asdescribed in this manual.

❒ Check accompanying schematic drawings for information on special considerations.

BEFORE YOUCALL ...

HOW TOCONTACTCUSTOMERSERVICE

Additional manuals andprints for your Conairequipment may beordered through theCustomer Service orParts Departments fora nominal fee.

WE’RE HERETO HELP

WARRANTY INFORMATION IMS0003/0796APPENDIX A-2

EQUIPMENTGUARANTEE

PERFORMANCEWARRANTY

WARRANTYLIMITATIONS

Conair guarantees the machinery and equipment on this order,for a period as defined in the quotation from date of shipment,against defects in material and workmanship under the normaluse and service for which it was recommended (except forparts that are typically replaced after normal usage, such asfilters, liner plates, etc.). Conair’s guarantee is limited toreplacing, at our option, the part or parts determined by us tobe defective after examination. The customer assumes the costof transportation of the part or parts to and from the factory.

Conair warrants that this equipment will perform at or abovethe ratings stated in specific quotations covering the equip-ment or as detailed in engineering specifications, provided theequipment is applied, installed, operated and maintained in therecommended manner as outlined in our quotation or specifi-cations.

Should performance not meet warranted levels, Conair at itsdiscretion will exercise one of the following options:

● Inspect the equipment and perform alterations oradjustments to satisfy performance claims. (Chargesfor such inspections and corrections will be waivedunless failure to meet warranty is due to misapplica-tion, improper installation, poor maintenance practicesor improper operation.)

● Replace the original equipment with other Conairequipment that will meet original performance claimsat no extra cost to the customer.

● Refund the invoiced cost to the customer. Credit issubject to prior notice by the customer at which time aReturn Goods Authorization Number (RGA) will beissued by Conair’s Service Department. Returnedequipment must be well crated and in proper operatingcondition, including all parts. Returns must be prepaid.

Purchaser must notify Conair in writing of any claim and pro-vide a customer receipt and other evidence that a claim isbeing made.

Except for the Equipment Guarantee and PerformanceWarranty stated above, Conair disclaims all other war-ranties with respect to the equipment, express orimplied, arising by operation of law, course of dealing,usage of trade or otherwise, including but not limited tothe implied warranties of merchantability and fitness fora particular purpose.

UGH015/0902 Thermolator TW-1 and TW-2 APPENDIX B-1

PUMPCURVES

APPENDIX C-1UGH015/0902 THERMOLATOR SPI COMMANDS

The SPI commands supported by Conair Thermolator® moldtemperature controllers are listed in the following tables.

The standard required commands and three optional com-mands are listed in the SPI Command Pairs table, along withthe Select and Poll command pairs in hexadecimal format.Select commands set or change Thermolator functions. Pollcommands retrieve information from the Thermolator.

See SPI Status Words for status words and BIT positions forProcess Status, Machine 1 Status and Machine 2 status.

For more information on the SPI protocol, you can obtain theSPI Communication Protocol Manual by contacting:

The Society of the Plastics Industry, Inc.1801 K Street, NWSuite 600KWashington DC 20006(202) 974-5200 Fax: (202) 296-7005www.plasticsindustry.org

SPI Command PairsMold temperature controllers Device ID: hex 20

Commands Select PollEcho 0x20 0x20- Select stores 4 bytes of information at the Thermolator; Poll retrieves it. 0x21 0x20Version 0x20- Retrieves 4 bytes of SPI version information. 0x22Setpoint Process Temperature 0x20 0x20- Sets and retrieves the process temperature setpoint. 0x31 0x30Alarm, High Temperature Deviation* 0x20 0x20- Sets the alarm band temperature; retrieves setpoint + alarm band value. 0x33 0x32Alarm, Low Temperature Deviation* 0x20 0x20- Sets the alarm band temperature; retrieves setpoint + alarm band value. 0x35 0x34Process Status 0x20- Retrieves run status and alarm conditions. 0x40Status, Machine 1 0x20- Retrieves run status and alarm conditions. 0x42Status, Machine 2 0x20- Retrieves run status and alarm conditions. 0x44Mode, Machine 0x20 0x20- Start/stops the Thermolator; acknowledges alarms; retrieves run status 0x49 0x48Temperature, to Process 0x20- Retrieves the actual temperature of fluid leaving to the Thermolator. 0x70Temperature, from Process 0x20- Retrieves the actual temperature of fluid returning to the Thermolator. 0x72* NOTE: Both High and Low Temperature Deviation commands set thesame variable. Use only one of these commands to avoid problems.

SPI COMMANDSSUPPORTED BYTHE CONAIRTHERMOLATOR®

THERMOLATOR SPI COMMAND UGH015/0902C-2 APPENDIX

SPI STATUS WORDSStatus, ProcessPoll: 0x20 0x40

SPI STATUS WORD

Word BIT position 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0EEprom 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. Hi temp safety *Output monitor failure SET SET *Low water pressure SET SET SET *High deviation alarm SET SET SET *Low deviation alarm SET SET SET *Prog. Lo temp safety *Pump overload SET SET *Low water level SET SET *Test Mode *Phase error *

NOTES:* The SPI I/O list defines the Processing bit as being cleared if the unit is not processing; otherwise it is SET.Elsewhere on the chart:● If a bit is not shown to be SET, it is cleared.● The System Alarm bit is SET if an alarm is present. It is the logical OR of Process alarm and Machine alarm.● Processing, System Alarm, Process Alarm and Machine Alarm bits are repeated for Process Status, Machine 1

Status and Machine 2 Status.

Ope

n

Ope

n

Res

erve

d

Res

erve

d

Res

erve

d

Res

erve

d

Ala

rm, L

ow fl

ow

Res

erve

d

Ala

rm, L

ow p

ress

ure

cond

ition

Ala

rm, H

igh

pres

sure

con

ditio

n

Ala

rm, L

ow te

mpe

ratu

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evia

tion

Ala

rm, H

igh

tem

pera

ture

dev

iatio

n

Ala

rm, M

achi

ne

Ala

rm, P

roce

ss

Ala

rm, S

yste

m

Proc

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ng

UGH015/0902 THERMOLATOR SPI COMMANDS APPENDIX C-3

Status, Machine 1Poll: 0x20 0x42

SPI STATUS WORD

Word BIT position 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0EEprom 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 SET *Prog. Hi temp safety SET SET SET *Output monitor failure SET SET *Low water pressure SET SET SET *High deviation alarm *Low deviation alarm *Prog. Lo temp safety SET SET SET *Pump overload SET SET *Low water flow SET SET *Low water level SET SET *Test Mode *Phase error SET SET SET *



SPI STATUS WORDS

Ope

n

Ala

rm, P

hase

Ala

rm, L

ow c

urre

nt

Ala

rm, H

igh

curr

ent

Ala

rm, L

ow v

olts

Ala

rm, H

igh

volts

Res

erve

d

Res

erve

d

Ala

rm, L

ow p

ress

ure

safe

ty li

mit

Ala

rm, H

igh

pres

sure

saf

ety

limit

Ala

rm, L

ow te

mpe

ratu

re s

afet

y lim

it

Ala

rm, H

igh

tem

pera

ture

saf

ety

limit

Ala

rm, M

achi

ne

Ala

rm, P

roce

ss

Ala

rm, S

yste

m

Proc

essi

ng

THERMOLATOR SPI COMMAND UGH015/0902C-4 APPENDIX

Status, Machine 2Poll: 0x20 0x44

SPI STATUS WORD

Word BIT position 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0EEprom 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 SET *E/M Hi temp safety *Prog. Hi temp safety *Output monitor failure SET SET *Low water pressure *High deviation alarm *Low deviation alarm *Prog. Lo temp safety *Pump overload SET SET *Low water level SET SET *Test Mode *Phase error *



SPI STATUS WORDS

Ope

n

Ope

n

Res

erve

d

Res

erve

d

Res

erve

d

Res

erve

d

Res

erve

d

Res

erve

d

Res

erve

d

Res

erve

d

Faul

t, C

AL

Faul

t, Se

nsor

Ala

rm, M

achi

ne

Ala

rm, P

roce

ss

Ala

rm, S

yste

m

Proc

essi

ng

PD-1UGH015/0902 Thermolator TW-1 and TW-2

●● TW-1 Circuit Board . . . . . . . . .PD-2●● TW-2 Circuit Board . . . . . . . . .PD-3

PARTS/DIAGRAMS

TW-1 CIRCUIT BOARD UGH015/0902PD-2

UGH015/0902 TW-2 CIRCUIT BOARD PD-3

Documents

Thermolator TW-1 and TW-2 - Conair...Both the TW-1 and TW-2 models are available in single or dual-zone configurations, using resistance heating and direct injection or closed circuit