User Guide - ACS Group
Contents
1. 7o ol WIRE entes I amp SO rp 0 ici I Wer NY NY ORO CP OL m Q A Q 9 1 O SSS OHHH ey Eure 9 T C IFMR O Q BRD gt He a O 1TR eL O IMC 5 TIBEF Q C Q C Q io Q jm Ah D m JOUOU eng spe ste e ia e jl 1M JE 2141214124 ROLES a ale 809 d GP D WTRI 605 Chapter 4 Installation 25 of 44 N I DOR po 0 O 4 0 UL SC To TU T0 7 A OL CoC TM AAAY Chapter 5 Identifying Controls and Features 5 1 Mechanical Controls and Features To Process Probe One 1 type K thermocouple probe is incl2. 40 CHAPTER 9 APPENDIX icis essais uds nuu x 43 1661 1051 5516131 0 TS Sa 43 F arts Departmehl x patte ana E axo quac tiu pauca ot es 43 Sales and Contracting Department sessi nnn nns 43 miel cm SS RS SEL 43 WTRI 935 iv Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your granulator The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the equipment We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the granulator These instructions are intended to supplement sta
3. Pressure switch circuit is open WTRI 605 Possible cause No power Wrong voltage supplied to unit Defective on off switch Control circuit fuse blown Defective control transformer Broken or loose wire in pump motor control circuit Pump motor contactor holding coil is open Low water pressure light on Water supply to unit is turned off Pump overload light on Pump running in reverse Foreign matter in the system System has minimal back pressure and is operating at the far end of the pump curve Foreign matter obstructing system Restricted water flow System has high back pressure and is operating at the end of the pump curve a low flow condition Insufficient cooling or makeup water pressure Switch is broken Chapter 8 Troubleshooting Check main disconnect fuses wiring and power lead to unit Voltage must be within plus or minus 1096 of nameplate rating Replace Replace Check transformer Locate and repair Repair or replace Check for at least 16 psig 110 32 kPa 1 1 bars water pressure on WATER IN Open water supply Reset and test each leg for balanced amp draws Verify proper rotation If not clockwise reverse any two incoming power leads Clean the system As long as there is satisfactory process temperature control there is no problem Clean the system Check for closed valves etc Be sure all lines are properly sized As long as there is
4. Make sure that only qualified electricians test safety devices Safety devices should be tested for function every six 6 months Perform the following procedures for testing Pressure Switch With the unit running program a set point of 30 F 1 C Allow the process temperature to drop under 100 F 38 C When the process temperature reaches that point turn off the water supply The pump should stop and the Low Water Pressure indicator should illuminate Turn the water supply on to reset the pressure switch Safety Thermostat Disconnect main power Open the electrical enclosure and disconnect the neutral lead on the safety thermostat from the terminal strip Protect the stripped lead to prevent short circuits Close the enclosure reconnect main power and push the START button The heater should not turn on and the Over Temperature indicator should illuminate Disconnect main power before reconnecting the thermostat lead 7 6 Cleaning and Storage Inspect the unit daily for leaks Wipe down the unit periodically to remove dirt and dust buildup especially the motor casing e Drain and flush the unit every six 6 months to remove sediment buildup Completely drain the unit and carefully blow out the piping with pressurized air before placing the unit in storage 39 of 39 WTRI 605 Chapter 7 Maintenance Chapter 8 Troubleshooting Unit does not turn on Unit does not run Low pump pressure High pump pressure
5. means to get less back between cooling WATER IN and OUT lines pressure in the WATER OUT line Heater contactor has welded Replace contactor shut Foreign material under valve Manually open valve to clear Rajavel seat seat of material Reduce WATER IN water High system pressure pressure Unit under sized for application Unit runs continuously cooling or Call sales representative heating and cannot attain set Check heater output point 4 of 41 WTRI 605 Chapter 8 Troubleshooting Condition Possible cause Solution Visually inspect coil and Defective heater contactor contacts repair replace defective contactors Check resistance on all three 3 legs of the heater with an ohm meter If not all equal contact factory for replacement heater Check the heater output with an ohm meter to ground It should Controller heat output open read in the mega ohm range Infinite or zero readings indicate a defective output Set process temperature to Heater contactor is not l maximum and check for control energizing but HEAT LED is on voltage at heater contactor Immersion heater elements Remove heater and clean dirty elements Check heater tank for scorched discolored paint Check resistance on all three 3 legs of the heater with an ohm Immersion heater element is meter Replace heater as burned out required Check for balanced amp draws and supply voltage If not present replace immersi
6. power cord that can be un plugged unplug it If the unit is permanently wired to a power main make sure that a fused power disconnect is installed to allow the disconnect to be locked in the OFF position Open and lock out the disconnect installed in the control enclosure 4 2 Installation Requirements Mini Micro Series systems are portable and can be installed almost anywhere As with all equipment installations follow all applicable codes and regulations M The recommended ambient temperature range for Mini Micro Series installations is from 14 F 10 C to a maximum operating ambient temperature of 131 F 55 C Recommended ambient storage temperature range 1s from 13 F to 149 F 25 C to 65 C If storing the unit below freezing temperatures make sure the unit has an anti freeze mixture circulated inside M Provide a minimum of twelve inches 12 or about 30 cm clearance on all sides of the cabinet to allow circulation of cooling air M Locate the unit as close to the process as practical 4 3 Process Approach Temperature Considerations If the differential between COOLING WATER IN and TO PROCESS temperatures 15 less than 10 F 7 C consult our Sales Department for advice on how to control low approach applications WTRI 605 Chapter 4 Installation 16 of 44 4 4 External Piping Sizing Considerations I All external hose and piping should be adequately sized to assure minimum external pressure drop M Low extern
7. satisfactory process temperature control there is no problem Check for 16 psig 172 38 kPa 1 72 bars water pressure on WATER IN Replace switch if needed 40 of 40 Condiion 05651010080560 50110 Undersized connectors water Increase size of connectors unit and mold and shorten connecting lines instead of series flow Temperature fluctuations rapid lime buildup Clean mold cycling from hot to cold Quick disconnect fitting with Remove and replace fitting or check valve valve Lime buildup in unit piping Clean or replace Check unit by connecting 74 line directly from delivery to return line Run unit to determine if TCU Controller controls set point temperature COOLING WATER OUT Drain l Clear drain line or eliminate is plugged or excessive back ae back pressure condition pressure is in drain line Test solenoid valve by pressing Faulty solenoid valve VENT button and listen for valve operation Replace if faulty a Cool output relay Replace output relay Set process temperature to minimum and check for mag netism on solenoid coil top Also check for voltage at the coil TEIE TE Check coil resistance If MQ Solenoid coil circuit is open l range replace solenoid coil Faulty Controller Solenoid valve is not operating Unit overheats or does not cool but OUT2 LED is on Insufficient pressure differential Find a
8. when the motor is rewired to the unit A phase sensor does not always indicate proper rotation if motor wire leads are reversed at installation Consult the elementary wiring diagram for more information Heaters Heaters may need to be cleaned chemically or mechanically to remove deposits and dirt that reduce heat transfer and cause hot spots Hot spots cause premature heater failure Install a new gasket when reassembling Make sure a qualified electrician disconnects and reconnects heater wires Solenoid Valves M Clean annually more often if using high mineral content water or on high service level units I Sluggish operation excessive leakage and or noise indicate cleaning is necessary Inspect the components for excessive wear while the valve 1s disassembled Rebuild kits are available from the ACS Group Parts Department 7 3 Restoring the Controller Factory Setup If the preset parameters on the controller have been tampered with and it no longer properly controls temperature you can restore the controller to factory setup parameters 1 4 Electrical Connections Make sure that a qualified electrician inspects all electrical components and connections every six 6 months for secure attachment and ground connections Inspect all wiring for fraying or damage especially power lines where they enter the unit All wiring connections must be clean amp tight 38 of 38 WTRI 605 Chapter 7 Maintenance 7 5 Safety Devices
9. A To Process Cooling Water Out T3 n VEMM REM CU ELO Tm From Process Cooling Water Inlet Shipping Lr E 460 230 hp KW gpm 7 psig kPa in cm in cm in cm lbs Kg 3kWh et wel 17 44 0 9 24 0 23 58 0 110 50 Figure 2 TrueTemp Mini Series Unit Full Load Amps Full load amps at 460 volts hp kW 6 kW heater 9 kW heater 0 SkWheater 0 5hp 10 37 KW 8 5 amps 12 3 amps 0 75 hp 0 56 kW 12 7 amps WTRI 605 Chapter 2 Functional Description 11 of 44 WTRI 605 Chapter 2 Functional Description 12 of 44 Chapter 3 Shipping Information 3 1 Unpacking and Inspection You should inspect your Mini Micro Series temperature control unit for possible shipping damage If the container and packing materials are in reusable condition save them for reshipment if necessary Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In case of breakage damage shortage or incorrect shipment refer to the following sections 3 2 Inthe Event of Shipping Damages Important According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment M Notify the transportation company s local agent if you discove
10. CE button to silence the alarm You should investigate the alarm condition and restore the unit to normal operation before continuing with the temperature control cycle AIR PURGE Optional Press the AIR PURGE switch to initiate the purge It is a momentary switch and must be pressed to keep the purge valve open Releasing the switch closes the cooling vent and compressed air solenoid valves QUICK COOL Switch Optional Press the QUICK COOL switch to open the cooling valve and quickly cool the process WTRI 605 Chapter 5 Identifying Controls and Features 30 of 44 5 6 Alarms Audible Visual General Fault Alarm Optional The audible visual general fault alarm sounds if any fault triggers such as low water pressure over temperature or pump overload A signal from any of the safety devices activates a horn and flashing strobe B Push the ALARM SILENCE switch to silence the alarm The optional mechanical high temperature safety alarm is interlocked with the heater When triggered the heater cuts out and the pump continues to run 5 7 Controller Factory Setup The controller is set up and tested at the factory for optimum operation and doesn t need to be adjusted If the controller does not work properly or you suspect someone has accidentally changed some settings you can do two things First perform the Auto Tune Procedure described in the following section If that doesn t work restore the controller to the original factory s
11. Mini amp Micro Series Water Temperature Control Units Part Number 882 12039 00 Bulletin Number WTR1 605 Effective August 1 2012 an ACS company Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No O Copyright 2012 All rights reserved WTRI 935 1 Table of Contents CHAPTER 15 SAFETY usse ea tesessexvetiu qnia xsPTeEit E D rS USE 5 151 Howto USE This MANUAL ST 5 Safety Symbols Used in 10019 cise 5 122 3111765 ANG precautions tel eee era eer debes emen in dete etm rotas 7 CHAPTER 2 FUNCTIONAL DESCRIPTION 8 2 1 Models Covered in This Manual ccccccceeceeeeeeeeeeeeeeeeaeeeeeeeeeeeeeeeseeeseeeaeeeseeeaeeeaees 8 2 2 60613113656 010 Gang i ete Fra pt e edge ides Fori 8 2 9 Necessary DOCUMENTS otio con iae Saas 9 24 moie uc itam a Mie Sd 9 2 5 AVallablepDUOLisie tte CR Em eh deu rv av Ra e Rb ni Bs 10 CHAPTER 3 SHIPPING INFORMATION 13 9 1 UNPACKING aria Inspection D
12. TER IN line you MUST install an expansion tank of at least 2 gallon about 2 liters capacity Failure to do so can result in system overpressure from thermal expansion Install the tank configured as shown below Check the expansion tank frequently to make sure it is not flooded 19 of 44 WTRI 605 E TCU E Non reliexing PA device 4 10 COOLING WATER OUT 74 NPT The cooling water return outlet leading back to the cooling tower chiller or drain Net supply pressure must be between 16 psig and 40 psig 172 38 kPa 1 72 bars and 517 13 kPa 5 17 bars Net supply below 15 psig 103 43 kPa 1 03 bars may allow water to flash to steam cavitate the impeller and damage the pump which prevents the unit from cooling properly Operation above 40 psig 517 13 kPa 5 17 bars may cause premature opening of the relief valve from pump pressure and pressure surges Pressure Relief 74 The pressure relief valve 15 located at the back of the unit It is recommended to run a hose or pipe to the floor This hosing or piping reduces the chance of scalding nearby personnel if the relief valve should trip Making System Purge Connections Mini Micro Series systems equipped with the System Purge option have a compressed air inlet marked MOLD PURGE See Below Connect to a clean dry 100 psig 689 50 kPa 6 90 bars air line Install your own shut off valve to prevent process liquid from backing up into the plant air pi
13. al piping pressure drop is needed for best operation Use a backup wrench to support water temperature control system piping N O 1 CE when making process piping connections All external valves fittings and hoses must be rated at a minimum of 150 psig and 250 F 1 034 25 kPa 10 34 bars and 121 C 4 5 Piping Considerations for Permanent Installations It is recommended that an optional or customer installed strainer on the COOLING WATER IN inlet The unit must have at least 16 psig 110 32 kPa 1 1 bars water supply pressure to prevent pump cavitation that can be caused by the water flashing to steam To avoid damage to the pump or other components make sure that maximum supply pressure does not exceed 55 psig 275 8 kPa 2 8 bars Keep restrictions to a minimum by using proper inlet pipe sizing If the water supply piping is larger than 74 reduce the size at the unit The table below contains the pipe sizes that are used in the unit Pipe sizes for hp and hp 0 37 kW and 0 56 kW units Location Size in inches NPT Process delivery Ya Process return YA Water supply Ta Drain YA Common black pipe is recommended for permanent installations Mini Micro Series water circuit piping 1s non ferrous stainless steel and brass and reacts electro chemically with ferrous metallic materials such as iron Some water contains dissolved minerals that greatly accelerate the reaction between dissimilar metals Non ferrou
14. and seal flush lines as standard The pump is a stamped stainless steel bronze fitted close coupled centrifugal type It features a split case design to facilitate replacement of the seal It has a high output capacity with excellent discharge pressure helping it facilitate turbulence to maximize heat transfer and 15 well suited for the conditions under which it was designed to operate WTRI 605 Chapter 5 Identifying Controls and Features 26 of 44 Heaters The specially designed 3 6 or 9 kW three phase low watt density electrical immersion heaters heat the water and the controller regulates the temperature The standard heater has an incolloy sheath for best heat transfer and low fouling properties Solenoid Valves TrueTemp Mini Series systems use rugged industrial design solenoids with replaceable coils and or internal components The unit is equipped with a 4 direct acting solenoid valve Pump Starter Mini Micro Series high quality IEC rated Motor Circuit Protectors MCPs are industrial grade motor controls with overload protection and manual reset Transformer High quality industrial design transformers are specified to suit incoming voltage on the application and provide 115 VAC control voltage The 115 VAC circuit is protected by primary fusing and secondary grounding Heater Contactor Your temperature control unit uses high quality IEC rated industrial grade electromechanical contactors for heater controls Cooling The
15. ary disconnect A properly installed operated and maintained water temperature control system provides years of reliable operation Please read and follow the instructions in this manual to get the most satisfaction from your water temperature control system WTRI 605 Chapter 2 Functional Description 8 of 44 2 3 Necessary Documents The following documents are necessary for the operation installation and maintenance of your Mini Micro Series water temperature control units Additional copies are available from ACS Group Familiarize the appropriate personnel with these documents M M M M This manual The controller operation manual The electrical schematic and connection diagram placed inside the manual envelope The operation and installation manuals for accessories and options selected by the customer The Customer Parts List included in the information packet 2 4 Standard Features Compact rugged cabinet with easy access side panels Non ferrous construction Incoloy immersion heaters with IEC contactors NEMA 1 electrical enclosure CAL 9000 microprocessor controller with fuzzy logic includes status lights CE and CUL Independent high temperature safety thermostat Motor Circuit Protector for pump Ys cooling solenoid valve EPDM Carbon carbide pump seal Adjustable low supply water pressure switch factory set at 16 psig 110 kPa 1 1 bars 150 psig 1 034 kPa 10 3 bars pressure relief valve Choic
16. controller automatically regulates cooling by opening and closing the solenoid valve For direct injection the unit cools by removing the required amount of warm water from the system This process permits an equal amount of cool plant water to enter the system well ahead of the pump allowing it to blend with the system water The water supply temperature governs the minimum operating temperature of the unit Electricals The pump motor and the immersion heater operate on three phase 50 60 cycle nominal voltages with the control circuit operating at 115V single phase The control circuit voltage 15 provided by a single phase machine tool transformer with a grounded secondary The 115V control circuit and controller outputs are fuse protected The pump motor is controlled by a full voltage magnetic non reversing motor starter with fused branch circuit overcurrent and thermal overload protection Automatic Vent This feature automatically triggers the purging of air from the system before you start the unit The vent actuates the solenoid valve and forces trapped air and water out through the drain properly filling and priming the unit prior to startup Complete venting is necessary to prevent damage to the pump and heater The vent process is controlled through a timer If you have a large process you may need to complete the venting process by pressing the VENT button on the front mounted switch panel WTRI 605 Chapter 5 Identifying Contro
17. d FIRE EXTINGUISHER should be close at hand and ready for use 1f needed M Do not jump or bypass any electrical safety control M Do not restore power until you remove all tools test equipment etc and the hot oil temperature control unit and related equipment are fully reassembled M Do not restore power until all tools test equipment etc have been removed and the panels replaced M Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality WTRI 605 Chapter 1 Safety 7 of 44 Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual lists installation operation and maintenance instructions for all mini micro water temperature control units Model numbers are listed on the serial tag A model number followed by Q indicates a specially constructed unit and not all information in this manual may apply Make sure that you know the model number serial number and operating voltage of your unit if you contact us 2 2 General Description Mini Micro Series water temperature control units are reliable accurate and easy to use process temperature control units They are self contained portable and sh
18. e of 208 230 or 460 operating voltages 74 water supply and drain connections 74 process connections Automatic vent sequence Operating range of 32 F to 250 F 17 C to 121 C One 1 year parts and labor warranty at the factory three 3 year controller warranty WTRI 605 Chapter 2 Functional Description 9 of 44 2 5 WTRI 605 Available Options Mini Micro Series systems are available with options to tailor the unit to your requirements Some are factory installed some can be retro fitted in the field Consult your ACS Group sales representative for more information Available options include RS 232 or RS 485 communications Remote controller enclosure Heaters available in 3 kW 6 kW and 9 kW Quick Cool function Auto system water purge mold purge Y strainer Remote start stop control Casters available 1n lieu of rubber feet Audible and visual general fault alarm Rotary through the door disconnect switch Electrical operation available in 208 230 460 and 575 volts 60 Hz 200 380 and 415 volts 50 Hz UL CUL listed electrical subpanel 10 ft power cord Manual bypass Pressure regulator on water supply Chapter 2 Functional Description 10 of 44 Figure 1 Typical Control Unit and Specifications T E D x E Ray c mein oe zd k 44 a pH iol OT Ui m paar i b a Hl EK H He 4 i E WES pop ie NM 4 E 2 X E k E J R1 4 d E J eel ae
19. e process temperature you want by pressing and holding the and Y keys or Le lua A keys 271 SET POINT screen displays the set point temperature you want IV Watch the drain for any bubbles or erratic flow which indicates if the system has not been properly vented If the stream 1s steady the unit was properly vented and all air 15 out of the system M Operate the unit checking for anything unusual that could indicate improper operation You can stop the temperature control unit at any time by pressing the NO TICE ON OFF switch to the OFF O position NCAUTION 1 Your TrueTemp Mini Series system operates with hot water under pressure To reduce the risk of scalding Always wear work gloves and safety glasses when operating the unit Never operate the unit with panels or shields removed Pipe the relief valve to an open drain Never install a fitting or hose that is rated less than 150 psig and 250 F 1 034 25 kPa 10 34 bars and 121 C 2 To reduce the risk of electrical shock All electrical installation and repairs should be done by a qualified electrician Ground the unit in accordance with electrical codes Never attempt any repairs without first opening and locking out the main disconnect Never deactivate or neutralize any safety device WTRI 605 Chapter 6 Startup and Operation 33 of 44 6 5 WTRI 605 Sequence of Operation The simplicity of design and the highly engineered controller make t
20. eeseeeseeees 29 5 4 Using CAL Controls Controller Keys esseesseessessseeneennnnn nennen 29 5 5 Using CAL Controls Controller 0 5 cesses 30 SOME LII mm 31 5 7 Controller Factory Setup oem a ceeded esaisaue uus uin es ut edes 31 5 8 Operating the Unit with the 0 1 31 9 COMINUNICAUONS sess rc 31 CHAPTER 6 STARTUP AND OPERATION 32 ox MEM Irtigero Hello arcs DLE 32 WTRI 935 ii 0 2 Startup Checklist RU rai eode Ld 1 32 6 3 Starting the Temperature Control Unit cc cccccceecceeeee cess eeseeeseeeseeeseeeseeeseeeaes 33 6 4 Sequence Of Operation 34 6 5 Checking Motor Rotation Direction secs nennen nnns 34 6 6 Shutting down the Temperature Control Unit cece cece ecceeeceeeeeesseeeeeaeeeaeeneeees 35 CHAPTER 7 MAINTENANCE eene 36 7 1 Preventative MalnterianiCe i ie eH ES ate ve Yep Gal Ss 36 1 2 Corrective Maintenance 37 7 3 Restoring the Controller Factory Setup ceases 38 ZL Electcal CONNECLONS Gi tad e b vitat ned tds euge f su Re 38 9 Safety DEVICES c EE 39 7 6 CICA MING and Strage TEAR 39 CHAPTER 8 TROUBLESHOOTING
21. ef valve should be piped to an open unrestricted drain M TO PROCESS FROM PROCESS WATER IN WATER OUT and MOLD PURGE connections should be complete Only use components rated at a minimum of 150 psig and 250 F 1 034 25 kPa 10 34 bars and 121 C M All outer panels must be in place M All external process valving should be set for proper operation of the unit M Cooling and or makeup water between 16 psig and 55 psig 110 32 kPa 1 1 bars and 517 13 kPa 5 17 bars must be available for the unit to operate properly M Connect the main power to the unit disconnect switch and press the ON OFF switch to the ON position to check for proper pump rotation direction as described in Section 5 6 on Page 42 Pump rotation should be clockwise viewed from the motor end M Check your work and proceed to the Startup Procedure section on the following page WTRI 605 Chapter 6 Startup and Operation 32 of 44 6 3 Starting the Temperature Control Unit M Turn ON the water supply and push the ON OFF switch to the ON position M The unit automatically executes a one minute venting sequence to expel air trapped in the process piping AEC Inc recommends a longer venting sequence on larger process systems Press and hold the VENT button to force the cooling vent valve open and eliminate air trapped in the process piping in larger process systems The controller is OFF during the vent sequence M Set the microprocessor controller to th
22. erator injury or death Bring properly sized power leads and ground from a fused disconnect installed by your electrician to the unit Provide external overcurrent protection to the unit using circuit breakers or fuses If you use fuses make sure that they are dual element time delay fuses sized according to your electrical code Make sure that all electrical connections are tight WTR1 605 Chapter 4 Installation 21 of 44 1 Electrical connections must comply with all applicable electrical codes The temperature control unit must be grounded in accordance with NEC Article 250 Voltage must be within plus or minus ten percent 10 of the nameplate rating 4 Make sure your installer provides external protection WTRI 605 Chapter 4 Installation 22 of 44 Figure 3 Typical Electrical Wiring Schematic Drawing 1 WTRI1 605 Chapter 4 Installation 23 of 44 Figure 3 Typical Electrical Wiring Schematic Drawing 2 WTRI 605 Chapter 4 Installation 24 of 44 Typical Electrical Subpanel Layout Figure 4
23. essive temperatures We recommend that technicians use safety gloves while performing maintenance to protect hands from being exposed to these hot surfaces WTRI 605 Chapter 1 Safety 6 of 44 1 2 Warnings and precautions Our units are designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes To avoid possible personal injury or equipment damage when installing operating or maintaining this granulator use good judgment and follow these safe practices M Follow all SAFETY CODES M Only PROPERLY TRAINED personnel familiar with the information within this manual should work on this equipment M TrueTemp Mini Series cabinets and piping are hot and are a BURN HAZARD M Wear SAFETY GLASSES and WORK GLOVES M Disconnect and or lock out power before servicing or maintaining the hot oil temperature control unit M Use care when LOADING UNLOADING RIGGING or MOVING this equipment M Operate this equipment within design specifications M OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you M Make sure the hot oil temperature control unit and components are properly GROUNDED before you switch on power M When welding or brazing in or around this equipment be sure VENTILATION is ADEQUATE PROTECT adjacent materials from flame or sparks by shielding with sheet metal An approve
24. esult in death or serious injury CAUTION indicates a potentially hazardous situation or practice that if not avoided may result in minor or moderate injury or in property damage WTRI 605 Chapter 1 Safety 5 of 44 Hazard Alert Description Explanation Preventative Maintenance Symbol High Voltage Hazard The electrical Every six months inspect all electrical enclosure is supplied with 3 phase electrical connections for secure attachment For power Use caution when using or further information see the maintaining this product Maintenance Chapter in this manual A Hot Surface Hazard When the unit operates Every six months inspect all surfaces above 212F 100C the surface of the unit for signs of heat degradation If any may reach excessive temperatures Use appear remove panel and verify cause caution when using or maintaining this of degradation and repair product Mandatory Description Explanation Symbol Read Operators Manual This equipment must be operated and maintained by properly trained personnel The information contained within this manual must be read and understood prior to operating this equipment Lock Out This equipment is operated with 3 phase electrical power Therefore when performing any maintenance operations we recommend following the local standards for performing a lock out tag out procedure Wear Safety Gloves This equipment operates above 212F 100C and its surfaces may reach exc
25. ettings as described in the appendix 5 8 Operating the Unit with the Controller To change the process temperature set point e Press m together to decrease setpoint e Press and A together to increase setpoint The set point automatically updates 5 9 Communications A connection port on the electrical cabinet permits easy hook up to the host computer for RS 232C and RS 485 communications The connection port is a direct pin to pin extension from the back of the controller WTRI 605 Chapter 5 Identifying Controls and Features 31 of 44 Chapter 6 Startup and Operation 6 1 Introduction The checklist below outlines start up procedures for TrueTemp Mini Series water temperature control units This list assumes that installation information located in this manual has been read and followed 6 2 Startup Checklist M Check the shipping papers against the serial tag to make sure that system size type and voltage is correct for the process under control M Check the transformer primary voltage connections to be sure they are configured for the electrical power you are using The voltage at the main power connection must be within plus or minus ten percent 10 of the voltage listed on the serial tag Electrical connections must conform to all applicable codes Make sure that a qualified electrician checks all electrical connections M The safety thermostat is preset at the factory to trip at 265 F 129 C M The reli
26. ge warm water or energizing the immersion heater to maintain the process set temperature Checking Motor Rotation Direction Check for correct pump rotation direction by looking at the end of the motor Press the ON OFF switch from the OFF O position to the ON button and note the direction that the motor turns Rotation should be clockwise when viewed from the motor end Make sure that a qualified electrician performs the N O TI CE following steps To change rotation direction 1 Disconnect and lock out power at the customer supplied fused disconnect 2 Reverse any two incoming leads at the power terminal blocks 3 Do not switch leads at the motor or motor starters Chapter 6 Startup and Operation 34 of 44 6 6 Shutting down the Temperature Control Unit Cool the unit down by selecting a set point of zero 0 Let the unit stabilize at one temperature close to the incoming water temperature then press the ON OFF switch to the OFF O position Now press the VENT button to relieve any remaining pressure in the system Finally shut off the main power supply to the unit Make sure you provide a correctly sized and protected supply of electrical power to the unit Refer to National Electric Code NEC Article 430 24 through 430 26 M for proper feeder conductor and supply disconnect sizing a Maintain a safe ground and disconnect the power supply before servicing the unit A qualified electrician should make electrica
27. his is done by a special flushing system that uses water exiting the pump to constantly wash the seal area It is also fitted with high temperature flexible components for maximum heat resistance These same components remain flexible even at low temperatures Thus the standard seal 1s a fine combination of heat resistant and wear resistant components Unfortunately even under normal use the seal will eventually wear and require replacement A small puddle underneath the unit is a sign of rotary seal wear and if investigation confirms the pump as the source the seal should be replaced as soon as practical The water slinger 1s intended to provide temporary protection against this but a continued and substantial leak will ruin the motor bearing and cause further damage Under some conditions the pump may not start After turning off the power supply check the motor shaft to be certain it is free to turn By removing the drip cover on top of the motor you ll have access to the end of the shaft It has been slotted to make it easy to turn with a screwdriver If the shaft is free to turn next check that the motor overloads are set check for blown fuses and finally check the power supply on each leg to the motor A qualified electrician should check the motor and its circuit 37 of 37 WTRI 605 Chapter 7 Maintenance If the pump motor wiring is disconnected for removal from the unit make sure that you check the actual rotation direction
28. his unit almost self operating The ON OFF and VENT switches and the temperature controller buttons are all that is required to operate this unit After you complete all connections turn the water supply ON then turn control power ON The unit automatically vents for a preset time of one 1 minute If you need additional vent time press the VENT button on the control panel As the water comes in the water supply line the water must enter the pump up through the tank and out through the TO PROCESS line through the process back through the FROM PROCESS line and through the solenoid line and out the COOLING WATER OUT line M TCU systems provide temperature control on processes by directly heating the process water and injecting cooling water into the process water M When the unit is energized the pump starts and a one minute vent sequence opens the cooling vent valve to remove any air trapped in the process piping M Ifthe cooling water supply pressure is insufficient the low cooling water pressure cutout switch set at 16 psig 2 psig differential 110 32 kPa 1 10 bars 68 95 kPa 0 69 bars differential opens You need at least 16 psig 110 32 kPa 1 10 bars for the best cooling capacity and to prevent water boiling in the process circuit at high temperatures particularly at the pump suction M After venting the microprocessor controller monitors the TO PROCESS RTD Thermocouple probe cycling open the cooling vent valve to dischar
29. ints with plastic WTRI 605 Chapter 4 Installation 18 of 44 4 8 Making Process Water Connections Direct Injection For both types of systems the connections are basically the same On the back of each unit the connections are labeled appropriately Connect the TO PROCESS hookup to the entrance of the process and the FROM PROCESS hookup to the exit of the process Connect the COOLING WATER INLET SUPPLY to your plant water supply Connect the COOLING WATER OUT line to an open drain or to the return line of your central water system Make sure you carefully select the connecting lines and connectors between the N TI CE temperature control unit and the process to suit the needs and requirements of your application If your unit has a maximum operating temperature of 250 F 121 C the connecting lines and connectors should have a service rating of at least 250 F 121 C and 150 psig 1 034 25 kPa 10 34 bars TO PROCESS NPT This is the outlet for the tempered water leading to the process being controlled FROM PROCESS NPT Water from the process re enters the Mini Micro Series system to be tempered and re circulated back into the process 4 9 Making Cooling Water Connections Cooling Water InLET 3 4 NPT The cooling water supply inlet from a cooling tower a chiller or a city water supply If a non relieving device such as a regulator ball valve or check valve is installed on the WA
30. ipped ready to use Mini Micro Series water temperature control unit is designed to circulate water through your process and to precisely automatically and reliably maintain it at a specified temperature Standard unit operating range is from O F 17 C to 250 F 121 C The unit is suited for use with city water water from portable or central chillers or towers or well water These units are designed for rapid recirculation of a relatively small amount of water to provide close and uniform temperature relation between deliveries and return lines This performance of course depends on the configuration of your process and any restrictions within the mold The recirculation combined with the large immersion heater and cooling capability gives fast and accurate response to bring the water up to temperature or to changes in the settings when needed The Mini Micro Series water temperature control unit is a self contained system consisting of a centrifugal pump electric immersion heaters cool vent solenoid valve and electrical control including a PID microprocessor controller and thermocouple It is designed for use in process temperature control applications using water or a water glycol mix Any other use or fluid is prohibited Some standard safety devices include a mechanical over temperature safety thermostat a pressure relief valve motor overload protection a low pressure cut out switch branch fusing and non fused lockable rot
31. l connections and disconnect and lock out electricity using OSHA 29CFR 1910 147 standards when you need a service call WTRI 605 Chapter 6 Startup and Operation 35 of 44 Chapter 7 Maintenance NCAUTION Never attempt to service a unit until a qualified electrician has opened and locked out the main disconnect using OSHA 1910 147 standards The water supply should be turned off and internal pressure should be relieved before you remove panels All electrical connections must be done by a qualified electrician NWARNING Disconnect all power to the unit let the unit cool down and turn off the water prior to any servicing Failure to do so can result in SERIOUS INJURY OR DEATH 7 1 Preventative Maintenance Draining Drain the unit thoroughly if you are taking 1 out of service for a long period of time or you expose it to freezing Drain plugs are provided at the base of the heater tank and at the base of the pump 36 of 36 WTRI 605 Chapter 7 Maintenance Periodic Checks Every Six Months Inspect all electrical connections for secure attachment and for safe and secure ground connections Inspect heater contactors for loose wire connections or large amounts of carbon dust around contacts as it may indicate the end of the life of the contactor Inspect the power cable especially at the entrance point to the unit A qualified electrician should make this inspection Check for leaks especially under the pump a
32. ls and Features 27 of 44 Pressure Switch A pressure switch built into each unit keeps the system from starting until the water supply 15 turned On and subjected to the minimum water supply pressure This feature protects the pump seal and the heater from damage through attempted operation without water The pressure switch is set at approximately 16 psig 110 32 kPa 1 10 bars for 250 F 121 C units prior to leaving the factory 2 The Microprocessor Controller The CAL 9300 controller is an easy to operate microprocessor based PID control device When the process reaches the set point the PID control cycles the cooling valve and or immersion heater to maintain the proper leaving water temperature The controller is fully factory tested Set the process temperature set point you want and the controller does the rest Built in range of operation on the controller is 32 F to 250 F 0 C to 121 C Figure 5 Typical Graphic and Button Control Panels QUI 1 HEAI LN ALARM nut HFF COOL ON E ALARM SIGUE WTRI 605 Chapter 5 Identifying Controls and Features 28 of 44 5 3 Identifying Controller Panel Components Screen Displays Numeric LED During normal operation the LED on the controller displays the process temperature of the fluid in the heater tank It also displays parameter and pre set function values during setup Status Indicators OUT1 Indicator The OUT1 indicator is on when the f
33. luid temperature is below the set point and is being heated OUT2 Indicator The OUT2 indicator is on when fluid temperature is above the set point and is being cooled Display Indicators LED Indicator Under normal operation the LED indicator displays the temperature of the outgoing fluid To view the setpoint press the star key 5 4 Using CAL Controls Controller Keys Star Key Press and hold the Star key to view the setpoint Press the Star Key and the A together to increase the setpoint Press the Star Key and the together to decrease the setpoint ES UP Arrow Key Press the A UP Arrow key to scroll through the functions or increment or advance the values or settings on the LED screens Y Down Arrow Key Press the DOWN Arrow key to scroll through the functions decrement or reduce the values or settings on the LED screens WTRI 605 Chapter 5 Identifying Controls and Features 29 of 44 Do not change any of the control settings without consulting the ACS Group Service Department The warranty does not cover TCU failures from tampering with controller settings 5 5 Using CAL Controls Controller Keys ON OFF Switch Push the ON OFF rocker switch to the ON energize the unit and begin the temperature control cycle The switch will be illuminated whenever the unit is on VENT Switch Push the VENT switch for additional manual venting ALARM SILENCE Switch Optional Push the ALARM SILEN
34. n of this manual Have the order number and item number available Hold the items until you receive shipping instructions Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department Credit Returns Prior to the return of any material authorization must be given by the manufacturer A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given ALL returned material purchased from the manufacturer returned is subject to 15 75 00 minimum restocking charge ALL returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied No credit will be issued for material that is not within the manufacturer s warranty period and or in new and unused condition suitable for resale Warranty Returns Prior to the return of any material authorization must be given by the manufacturer A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied After inspecting the material a replacement or credit will be given at the manufacturer s discretion If the item is found to be defective in materials or workmanship and it was manufactured by our company purchased components are covered under their specific watran
35. ndard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the granulator safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your granulator provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics parts lists and available options A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death A DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury AWARNING WARNING indicates a potentially hazardous situation or practice that if not avoided could r
36. o Se Ui sires 13 3 2 Inthe Event of Shipping 095 n 13 3 3 If the Shipment is Not Complete 13 3 4 If the Shipment is Not Correct 14 3 5 Uncrating your Mini Micro Series SYStOM ccccceccceccceeeceecceeeseeeeeeeseeeseeeseeeseeeseeees 15 CHAPTER 4 INSTALLATION eere ee 16 del RET 16 4 2 Installation Requirements 16 4 3 Process Approach Temperature Considerations 16 4 4 External Piping Sizing Considerations seers 17 4 5 Piping Considerations for Permanent Installations eeseeeseesseeessse 17 4 6 Piping Considerations for High Mobility Installations eeeseeseeeeseessse 18 4 1 Process Water Considerations 18 4 8 Making Process Water Connections enne nnns 19 4 9 Making Cooling Water Connections 19 4 10 Making System Purge Connections ccccccccceceseeeceecceccceeceeeeseeeseeeaueceueceesaeesaess 20 4 11 Making Electrical Connections 21 CHAPTER 5 IDENTIFYING CONTROLS AND FEATURES 26 5 1 Mechanical Controls and Features ccccccccecccececeeeseeeseeeceeeceeseeeceeeeeeseeeseeeseeees 26 5 2 The Microprocessor 711 1 20 5 3 Identifying Controller Panel Components cccccccececeeeceeeeeeeee cece eeseeeseeese
37. on heater voltage on heater contact controller Set process temperature to Solenoid valve is not operating minimum and check for but COOL LED is on magnetism on top of solenoid coil Press VENT button several times to flush the valve Defective immersion heater Unit does not heat cannot achieve set point Faulty dirty solenoid valve 42 of 42 WTR1 605 Chapter 8 Troubleshooting Chapter 9 Appendix Technical Assistance Parts Department The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service For immediate assistance please contact North Central and South America 8am 5pm CST 1 800 483 3919 for drying conveying heating and cooling and automation For size reduction 1 800 229 2919 North America emergencies after 5pm CST 847 439 5855 North America email acsuscanadacustserv corpemail com Mexico Central amp South America Email acslatinamericacustserv corpemail com Europe Middle East amp Africa 48 22 390 9720 Email acseuropecustserv co
38. ping if the compressed air 15 turned off and the check valve fails Don t depend on the solenoid valve to hold water pressure in the temperature control unit Figure 2 Typical Piping Schematic WTRI 605 Chapter 4 Installation 20 of 44 4 11 Making Electrical Connections TrueTemp Mini Series systems are designed for three phase voltage operation Refer to the unit nameplate for proper voltage and amperage requirements NOTICE Make sure you provide a correctly sized and protected supply of electrical power to the unit Refer to National Electric Code NEC Article 430 24 through 430 26 for proper feeder conductor and supply disconnect sizing Maintain a safe ground and disconnect the power supply before servicing the unit A qualified electrician should make electrical connections and disconnect and lock out electricity using OSHA 29CFR 1910 147 standards when you need a service call Check serial tag voltage and amperage requirements and make sure your electrical service conforms before making any electrical connections Total running amps for Mini Micro Series systems are listed on the nameplate Customer connections can be run to the supply terminals from either side of the unit Make sure that all three phases are wired correctly If not wired properly the unit will run backwards Again check the unit nameplate for correct voltage and amperage DANGER Improper electrical connections can damage the unit and cause serious op
39. r damage M Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods to ACS Group before the transportation company inspection and authorization M File a claim against the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice 15 available upon request The original Bill of Lading 15 attached to our original invoice M Advise ACS Group regarding your request for assistance and to obtain an RMA return materials authorization number 3 3 Ifthe Shipment is Not Complete Check the packing list The apparent shortage may be intentional Back ordered items are noted on the packing list You should have Mini Micro Series water temperature control unit Bill of lading Packing list Operating and Installation packet Electrical schematic and panel layout drawings E RS NN SW Component instruction manuals WTRI 605 Chapter 3 Shipping Information 13 of 44 Re inspect the container and packing material to see if you missed any smaller items during unpacking Determine that the item was not inadvertently taken from the area before you checked in the shipment Notify ACS Group immediately of the shortage 3 4 If the Shipment is Not Correct If the shipment is not what you ordered contact the shipping department immediately For immediate assistance please contact the correct facility located in the technical assistance sectio
40. rpemail com India 91 21 35329112 Email acsindiacustserv corpemail com Asia Australia 86 512 8717 1919 Email acsasiacustserv corpemail com Sales and Contracting Department Our products are sold by a worldwide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations For assistance with your sales or system contracting needs please Call North Central and South America 1 262 641 8600 or 1 847 273 7700 Monday Friday 8am 5pm CST Europe Middle East Africa 48 22 390 9720 India 91 21 35329112 Asia Australia 86 512 8717 1919 Facilities ACS offers facilities around the world to service you no matter where you are located For more information please visit us at www acscorporate com United States Asia Australia India Middle East ACS Schaumburg Corporate Offices ACS Suzhou ACS India 109 Xingpu Road SIP Gat No 191 1 Sandbhor Complex Suite 588 Suzhou China 215126 Mhalunge Chakan Tal Khed Schaumburg IL 60173 Phone 86 8717 1919 Dist Pune 410501 India Phone 1 847 273 7700 Fax 86 512 8717 1916 Phone 91 21 35329112 Fax 1847 273 7804 Fax 91 20 40147576 Europe ACS New Berlin Manufact
41. s it may indicate a worn pump seal 7 2 Corrective Maintenance Pumps and Seals Before leaving our factory we test each unit extensively then we calibrate each unit Afterwards the unit is drained and blown out with air to remove water from piping systems If the unit is allowed to stand idle for a long time before being installed in your factory the housing gasket at the pump can dry out and can possibly leak when the unit 15 started In most cases these gaskets will soon swell and form a tight seal In other cases it may be necessary for you to tighten the pump bolts to stop a leaking condition Pump seal surfaces can separate slightly because of rough handling or from vibration during transit This could cause a leak at the pump seal when the pump is started but in most cases the surfaces will mate again after the pump is allowed to run for a short period of time If they do not reseal you may need to open the pump and free the seal by hand It is seldom necessary to install a replacement seal in a new unit unless the seal has been damaged because the unit was started without water Our pump seals have a long period of service life Some conditions of course can shorten seal life including the presence of grit operation of the unit without water sustained high water temperature or presence of certain chemicals in the water Our pump seal assembly has been developed to resist abrasive particles that are present in many water systems T
42. s piping is recommended to minimize galvanic action If piping must be copper use dielectric unions at the unit WTRI 605 Chapter 4 Installation 17 of 44 4 6 Piping Considerations for High Mobility Installations Mobile water temperature controls systems must use high quality hose rated for at least 150 psig and 250 F 1 034 25 kPa 10 34 bars and 121 C Quick disconnects may be used for mobility although they cause a drop in pressure If used they must be sized carefully to minimize pressure drop Don t use quick disconnects with check valves unless absolutely necessary Non relieving quick connect fittings or check valves on the water supply must have a pressure relief piped to the drain Failure to do so could result in a dangerous over pressure condition 4 7 Process Water Considerations Raw Water Water treatment 15 vital in any piping system In some cases raw water may be used in the system without problems in other cases it can result in large deposits of scale and corrosion ACS Group offers a complete line of water treatment equipment Contact your sales representative for water testing and treatment options Distilled Water Non ferrous brass copper or high temperature plastic piping 15 recommended for distilled water processes Deionized Water Stainless steel 316 SS minimum or PVC plastic components must be used with deionized water It is recommended that stainless steel because of the temperature constra
43. ty terms WTRI 605 Chapter 3 Shipping Information 14 of 44 3 5 Uncrating your Mini Micro Series System M Mini Micro Series water temperature control units are shipped in a four fold cardboard box surrounded by expandable foam ACAUTION M Carefully lift the unit out of the carton Caution the unit weighs 110 Ibs Be careful when cutting straps Straps may spring back and cause injury M Carefully remove the staples on the top of the box and open the top two 2 flaps M Remove the foam packing from the top of the box M Carefully cut the bands on the cardboard box This removes the box from the base WTRI 605 Chapter 3 Shipping Information 15 of 44 Chapter 4 Installation 4 1 Work Rules The installation operation and maintenance of this equipment must be conducted in accordance with all applicable work and safety codes for the installation location This may include but is not limited to OSHA NEC CSA and any other local national and international regulations e Read and follow these instructions when installing operating and maintaining this equipment If the instructions become damaged or unreadable obtain additional copies from ACS Group Only qualified personnel familiar with this equipment should work on or with this hot oil temperature control unit e Work with approved tools and devices e Disconnect the electricity before maintenance or service If the unit is installed with a
44. uded with your Mini Micro temperature control unit It 1s located in the heater tank to sense TO PROCESS temperature Safety Thermostat The safety thermostat mounted on the side of the heater tank protects against thermal runaway The thermostat guards against the unlikely event of runaway heating If overheating occurs the safety thermostat shuts down heater outputs The unit continues to pump water through the system to prevent heater damage It is recommended that you install an audible or visual alarm to the terminals provided Factory installed alarms are available see the electrical schematics in Figure 3 in Chapter 4 for more information Pressure Relief Valve If the combined pressure of the cooling supply water and pump discharge exceeds 150 psig 1 034 25 kPa 10 34 bars the pressure relief valve opens and relieves the pressure This is a non adjustable ASME construction valve with a stainless steel spring Route a pipe from the pressure relief valve to a suitable drain to reduce potential scalding hazard The drain line must not have any restrictions or back pressure Low Pressure Cutout Switch This switch set at 16 psig with a 2 psig differential 110 3 kPa 1 10 bars with a 13 79 kPa 0 14 bars differential shuts down the unit if the COOLING WATER IN water pressure drops below 16 psig 110 3 kPa 1 10 bars Pumps Pumps range in power from hp to hp 0 37 kW to 0 56 kW and are equipped with 3 phase ODP motors
45. uring Facility 2900 S 160 Street ACS Warsaw New Berlin Wl 53151 Ul Dzialkowa 115 Phone 1 262 641 8600 02 234 Warszawa Fax 1 262 641 8653 Phone 48 22 390 9720 Fax 48 22 390 9724 44 of 44 WTRI 605 Chapter 9 Appendix
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