Installation, Operation and
Maintenance Manual
RO Series
Oil Temperature Control Units
1½ amd 2 hp
Table of Contents
Foreword ..................................................................................................................................................... 1
General Data ................................................................................................................................................ 2
Safety Guidelines ......................................................................................................................................... 3
Pre-Installation............................................................................................................................................. 3
Receiving Inspection ...................................................................................................................................... 3
Unit Storage ................................................................................................................................................... 4
Installation ................................................................................................................................................... 4
Unit Location .................................................................................................................................................. 4
Rigging ............................................................................................................................................................ 4
Cooling Water and Oil Line Connection ....................................................................................................... 4
Installation - Electrical .................................................................................................................................. 6
Controller Operation .................................................................................................................................... 7
On Button ....................................................................................................................................................... 8
Off Button ...................................................................................................................................................... 8
Temperature Adjustment Button ................................................................................................................. 8
Increase Button.............................................................................................................................................. 8
Decrease Button ............................................................................................................................................ 8
Timer Adjustment Button ............................................................................................................................. 8
Timer On/Off Button ................................................................................................................................... 10
Deviation Alarm Button ............................................................................................................................... 10
Tank Temperature Button ........................................................................................................................... 10
Password Entry Buttons .............................................................................................................................. 10
Pump Operation LED ................................................................................................................................... 11
Heating LED .................................................................................................................................................. 11
Cooling LED .................................................................................................................................................. 11
Reservoir Low Level Alarm LED ................................................................................................................... 11
Deviation Alarm LED .................................................................................................................................... 11
Timer LED ..................................................................................................................................................... 11
Unit Operation ........................................................................................................................................... 12
Vacuum Mold Drain Option ........................................................................................................................ 12
Start-Up ..................................................................................................................................................... 13
Preventive Maintenance ............................................................................................................................ 15
Once a Week ................................................................................................................................................ 15
Once a Month .............................................................................................................................................. 15
Once a Year .................................................................................................................................................. 15
Troubleshooting......................................................................................................................................... 16
Charts and Drawings .................................................................................................................................. 17
Warranty.................................................................................................................................................... 19
Foreword
The intent of this manual is to serve as a guide for placing our oil mold temperature control unit in
service and operating and maintaining it properly. Improper installation can lead to poor equipment
performance or severe equipment damage. Failure to follow the instructions may reesult in damage not
covered by your warranty. It is extremely important that a qualified technician perform the installation.
Please supply these instructions to your installer. This manual is for our standard product line with
supplements as required to accommodate any special items provided for a specific application. Unit
specific drawings are included with the equipment for troubleshooting and servicing of the unit.
Additional copies of drawings are available upon request. We strive to maintain an accurate record of all
equipment during the course of its useful life.
Due to the ever-changing nature of applicable codes, ordinances, and other local laws pertaining to the
use and operation of this equipment we do not reference them in this manual. There is no substitute for
common sense and good operating practices when placing any mechanical equipment into operation.
We encourage all personnel to familiarize themselves with this manual's contents. Failure to do so may
unnecessarily prolong equipment down time.
Follow good piping practices and the information in this manual to ensure successful installation and
operation of this equipment. We are not responsible for liabilities created by substandard piping
methods and installation practices external to the chiller.
We trust your equipment will have a long and useful life. If you should have any questions, please
contact our Customer Service Department specifying the serial number and model number of the unit
as indicated on the nameplate.
1
General Data
Table 1 – RO Series Genral Data (60 Hz)
Model
RO0615
RO0615V
RO1220
RO1220V
RO1820
RO1820V
RO2420
RO2420V
RO3620
RO3620V
Pump
Pump Heater
(HP)
(KW) gpm psi
1½
1½
2
2
2
2
2
2
2
2
6
6
12
12
18
18
24
24
36
36
Figure 1 – Unit Drawing
2
14
14
14
14
14
14
14
14
14
14
32
32
44
44
44
44
44
44
44
44
Max
Vacuum
(PSI)
Na
-13
Na
-13
Na
-13
Na
-13
Na
-13
Oil Reservoir Size
Holding Expansion
(Gal)
(Gal)
3.5
4
3.5
4
7
4
7
4
13
6
13
6
13
6
13
6
13
6
13
6
FLA Amps
460V/3/60
10
10
19
19
26
26
34
34
49
49
Dimensions
Ship
L x W x H Weight
(Inches)
(Lbs.)
34 x 13 x 31
275
34 x 13 x 31
275
34 x 13 x 35
290
34 x 13 x 35
290
34 x 20 x 36
300
34 x 20 x 36
300
34 x 20 x 36
305
34 x 20 x 36
305
34 x 20 x 39
325
34 x 20 x 39
325
Safety Guidelines
Observe all safety precautions during installation, start-up, and service of this equipment due to the
presence of high voltage and refrigerant charge. Only qualified personnel should install, start-up, and
service this equipment.
When working on this equipment, observe precautions in literature, and on tags, stickers, and labels
located on the equipment. Wear work gloves and safety glasses.
WARNING: This equipment contains hazardous voltages that can cause severe injury or death.
Disconnect and lock out incoming power before installing or servicing the equipment.
Pre-Installation
Receiving Inspection
When the unit arrives, verify it is the correct unit by comparing the information that appears on the unit
nameplate with that which appears on the order acknowledgement and shipping papers. Inspect the
equipment condition for any visible damage and verify all items shown on the bill of lading are present.
If damage is evident, properly document it on the delivery receipt and clearly mark any item with
damage as “unit damage” and notify the carrier. In addition, make note of the specific damage and
notify our Customer Service Department and they will provide assistance in preparation and filing of
your claims, including arranging for an estimate and quotation on repairs; however, filing the claim is
the responsibility of the receiving party. Do not install damaged equipment without getting the
equipment repaired.
Shipping damage is the responsibility of the carrier. To protect against possible loss due to damage
incurred during shipping and to expedite payment for damages, it is important to follow proper
procedures and keep records. Photographs of damaged equipment are excellent documentation for
your records.
Start unpacking the unit, inspect for concealed damages, and take photos of any damages found. Once
received, equipment owners have the responsibility to provide reasonable evidence that the damage
did not occur after delivery. Photographs of the equipment damage while the equipment is still partially
packed will help in this regard. Check for broken lines, damaged controls, or any other major component
torn loose from its mounting point.
Record any signs of concealed damage and file a shipping damage claim immediately with the shipping
company. Most carriers require concealed damages be reported within 15 days of receipt of the
equipment. In addition to notifying the carrier, notify our Customer Service Department and they will
provide assistance in preparation and filing of your claims, including arranging for an estimate and
quotation on repairs; however, filing the claim is the responsibility of the receiving party.
3
Unit Storage
If the unit is stored prior to installation, it is important to protect it from damage. Blow out any water
from the heat exchanger to protect the unit from damage from freezing. Cover the equipment to keep
dirt and debris from accumulating on it. Units should not be stored in areas warmer than 145°F.
Installation
Unit Location
Locate the unit in an area where the temperature is between 40°F and 120°F. In all cases install the
equipment on a rigid surface suitable to support the full operating weight of the unit. Level all
equipment to ensure proper operation.
Serviceability was an important factor in the design of our equipment. Do not compromise this feature
by locating the unit in an inaccessible area. When locating the unit it is important to consider
accessibility to the components to allow for proper maintenance and servicing of the unit. In general,
whenever possible allow a minimum of 36 inches of clearance around all sides and above the unit. Avoid
locating piping or conduit over the unit. This ensures easy access with an overhead crane or lift to lift
out heavier components when they are replaced or serviced.
Proper ventilation is another important consideration when locating the unit. Locate the unit in an area
that will not rise above 120°F.
Rigging
The unit has a base frame on casters that has been designed to allow the unit to facilitate easy
movement and positioning. Follow proper rigging methods to prevent damage to components. Avoid
impact loading caused by sudden jerking when lifting or lowering the unit. Use pads where abrasive
surface contact is anticipated.
Cooling Water and Oil Line Connection
Most cooling water sources will operate with a supply temperature above the dew point of the air in
which the unit will operation. If cooler water is used, such as 50°F chilled water, proper insulation of
chilled water piping is crucial to prevent condensation. The formation of condensation on chiller water
piping, the state change of the water from gas to liquid, adds a substantial heat load to the system and
becomes an additional burden for the chiller.
The oil circuit has the potential to operate up to 575°F with oil pressures of 80 psi. May sure all oil lines
are designed to safely operate at these temperatures.
Note: Do not use brass, bronze, or copper (yellow) metals for oil line plumbing as they tend to promote
oxidation of the oil which will cause a signification reduction of the oil
The importance of properly sized piping to and from the unit cannot be overemphasized. See the
ASHRAE Handbook or other suitable design guide for proper pipe sizing. In general, run full size piping to
and from the unit then reduce the pipe size to match the connections on the process equipment and
cooling source as needed. One of the most common causes of unsatisfactory performance is poor piping
4
system design. Avoid long lengths of hoses, quick disconnect fittings, and manifolds wherever possible
as they offer high resistance to fluid flow. When manifolds are required, install them as close to the use
point as possible. If the unit is cooling multiple molds, provide flow-balancing valves at each machine to
assure adequate oil distribution in the entire system.
Figure 2 – RO Series Pump Curves
RO Series
60 Hz Pump Curves
90
80
70
Pressure (psi)
60
50
40
30
20
10
1½ hp Vacuum
0
2 hp Vacuum
-10
-20
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Flow (gpm)
Figure 3 – RO Series Cooling Capacity
RO Series Cooling Capacity
130,000
120,000
Cooling Capacity (Btu/Hr)
110,000
100,000
90,000
80,000
70,000
60,000
50,000
40,000
30,000
20,000
10,000
0
0
50
100
150
200
250
300
350
400
450
500
∆T Between Set Point and Cooling Water In ( F)
5
Installation - Electrical
All wiring must comply with local codes and the National Electric Code. Minimum Circuit Ampacity
(MCA) and other unit electrical data are on the unit nameplate. A unit specific electrical schematic ships
with the unit. Measure each leg of the main power supply voltage at the main power source. Voltage
must be within the voltage utilization range given on the drawings included with the unit. If the
measured voltage on any leg is not within the specified range, notify the supplier and correct before
operating the unit. Voltage imbalance must not exceed two percent. Excessive voltage imbalance
between the phases of a three-phase system can cause motors to overheat and eventually fail. Voltage
imbalance is determined using the following calculations:
%Imbalance = (Vavg – Vx) x 100 / Vavg
Vavg = (V1 + V2 + V3) / 3
Vx = phase with greatest difference from Vavg
For example, if the three measured voltages were 442, 460, and 454 volts, the average would be:
(442 + 460 + 454) / 3 = 452
The percentage of imbalance is then:
(452 – 442) x 100 / 452 = 2.2 %
This exceeds the maximum allowable of 2%.
There is a disconnect for main power connection to the main power source. There is a separate lug in
the main control panel for grounding the unit. Check the electrical phase sequence at installation and
prior to start-up. Check the phasing with a phase sequence meter prior to applying power. The proper
sequence should read “ABC” on the meter. If the meter reads “CBA”, open the main power disconnect
and switch two line leads on the line power terminal blocks (or the unit mounted disconnect). Do not
interchange any load leads that are from the unit contactors or the motor terminals.
Table 2 - Voltage Utilization Range
Rated Voltage
Utilization Range
230
208 to 254
460
414 to 506
575
516 to 633
WARNING: To prevent equipment damage due to reverse rotation, connect L1-L2-L3 in the A-B-C phase sequence.
WARNING: Connecting an appropriate power source to the main terminal block energizes the entire electric
circuitry of the chiller. Electric power at the main disconnect should be shut off before opening access panels for
repair or maintenance. Ground the unit properly in compliance with local and national codes.
6
Controller Operation
Display
Timer Adjust
Temperature Adjust
Increase
Decrease
Timer On/Off
Off
Cooling Light
Heating 1 Light
Pump Light
On
Pump Overload Light
Heating 2 Light
Low Level Light
Tank
Temperature
Deviation Alarm Light
Timer Activation Light
Deviation Alarm Adjust
ON
Password Entry
OFF
Main Power Disconnect
Table 3 – Controller Fault Indication
Fault
Alarm Indicating LED
Tank Low Level
Yes
Internal Temperature Sensor Disconnected
No
Sensor Short Circuited (internal or external)
No
Actual Temperature Deviation Beyond
Deviation Alarm Set Point
Yes
Pump Motor Overload
Yes
Digital Display Indicator
F
I
A
2
A
1
A
L
L
▪
▪
X
X
7
On Button
Depressing the On button will enable the control circuit. If the oil level in the reservoir is below the level
required to satisfy the Low Level sensor, the controller will display FILL and the Low Level light will turn
on. The Low Level light will remain on until the oil level is above the level required to satisfy the Low
Level sensor at which point the Low Level light will turn off.
If the oil temperature in the tank is below 70°F, the controller will turn the heaters on and the pump will
not run. When the oil temperature is between 70°F and 85°F, the controller will continue to heat using
the heaters and will turn the pump on but the display will only show "A", indicating that it is in an alarm
mode and not in a running mode. Above 85°F, the unit enters a normal operation mode. The display will
show a "1" as the first digit followed by the tank temperature. The heaters and pump remain on until
the pump bearing reaches 250°F, at which time the controller will turn off the heaters and continue to
run the pump.
Off Button
Depressing the Off button will stop the pump and disable the control circuit.
CAUTION: Stopping the unit without cooling the oil in the reservoir can lead to potential user injury during
servicing of the unit. In order to allow the oil in the reservoir to be cooled automatically during shut down, depress
the Temperature Adjust button and the Password ‘C’ button to initiate an automatic cool down cycle. The
controller will open the cooling valve and keep it open until the temperature of the oil in the reservoir is below
120°F (49°C). The automatic cool down cycle can be stopped at any time by depressing the Off button.
Temperature Adjustment Button
Depressing the Temperature Adjust button will show the current set point temperature in the display.
After depressing the Temperature Adjust button, it is possible to change the set point temperature by
using the Increase or Decrease buttons. Once the desired set point temperature displays, release all
buttons. After five seconds, the display will return to the actual temperature and the new set point is
active.
Increase Button
Depressing the Increase button will adjust the set point, deviation alarm, and timer settings when those
adjustment features are active.
Decrease Button
Depressing the Decrease button decreases the value of the set point, deviation alarm, and timer settings
when those adjustment features are active.
Timer Adjustment Button
Depressing the Timer Adjust button will activate the various timer adjustments.
8
Setting Clock
Depressing the Timer Adjust button once will show the current time value in the display. If the power to
the unit is disconnected, the clock resets to 0000 hours (based on a 24-hour clock) and will begin
keeping time from that point forward until reset. To adjust the time, use the Increase and Decrease
buttons to set the current time. Releasing all buttons sets the time to the time shown in the display.
After five seconds, the display will return to the actual temperature and the new time is set.
Setting Day
Depressing the Timer Adjust button twice will show the current time value in the display. If the power to
the unit is disconnected, the day resets to Monday (based on a 24-hour clock) and will begin keeping
dates from that point forward until reset. To adjust the day, use the Increase and Decrease buttons to
set the current day as follows.
Table 3 – Calendar Day Values
Day
Display Value
Monday
1000
Tuesday
2000
Wednesday
3000
Thursday
4000
Friday
5000
Saturday
6000
Sunday
7000
Releasing all buttons sets the day to the one shown in the display.
After five seconds, the display will return to the actual temperature
and the new day is set.
Setting Start Time
Depressing the Timer Adjust button and then immediately depressing
the Timer On/Off button once will reset the display to 0000. To adjust
the start time, use the Increase and Decrease buttons to set the
desired start time (based on a 24-hour clock). Releasing all buttons sets the start time to the time shown
in the display. After five seconds, the display will return to the actual temperature and the new start
time is set.
Setting Stop Time
Depressing the Timer Adjust button and then immediately depressing the Timer On/Off button twice
will reset the display to 0000. To adjust the stop time, use the Increase and Decrease buttons to set the
desired stop time (based on a 24-hour clock). Releasing all buttons sets the stop time to the time shown
in the display. After five seconds, the display will return to the actual temperature and the new stop
time is set.
Setting Days for Automatic Start/Stop
Depressing the Timer Adjust button twice and then immediately depressing the Timer On/Off button
once will reset the display to show the settings for Monday. When reviewing the settings for each day of
the week, the first digit on the left of the display indicates the day of the week as follows.
Table 4 – Timer Day Values
Day
Display Value
Monday
1
Tuesday
2
Wednesday
3
Thursday
4
Friday
5
Saturday
6
Sunday
7
The remaining three digits of the display indicate the activation status
of that day. If there is a decimal in the first and third digits for the day,
automatic start/stop is scheduled. If there is there is a decimal in the
second and third digits for the day, automatic start/stop is not
scheduled.
Example
Displays
If the automatic start/stop is active for Monday
1
If the automatic start/stop is not active for Monday
1
▪
▪
▪
▪
9
To toggle the schedule status, press the On button once. The display will indicate the change. When all
changes for that day are complete, depress the Increase button to display the next day. Set all days to
the settings selected, release all buttons. After five seconds, the display will return to the actual
temperature and the days for automatic start/stop are set.
Timer On/Off Button
Depressing the Timer On/Off button will activate or deactivate the automatic start/stop timer. If the far
right hand display shows a decimal after the number displayed, then the automatic start/stop timer is
active. If no decimal is displayed the automatic start/stop timer is deactivated.
Deviation Alarm Button
Depressing the Deviation Alarm Adjust button will show the current deviation alarm set point in the
display. The deviation alarm set point is the number of degrees the actual tank temperature must rise
above the set point temperature before the alarm horn will activate. After depressing the Deviation
Alarm, adjust the deviation alarm set point temperature by using the Increase or Decrease buttons.
Releasing all buttons sets the deviation alarm to the temperature shown in the display. After five
seconds, the display will return to the actual temperature and the new deviation alarm is set.
To activate the deviation alarm, press the deviation alarm button and release and immediately press the
on button. To deactivate the deviation alarm, press the deviation alarm button and release and
immediately press the off button. When the deviation alarm is active, the deviation alarm LED will be on
and green.
Note: There is a time delay after initial start-up before the temperature deviation alarm is active. The unit must be on with the
pump running for 45 minutes before the alarm function is active. This time delay feature minimizes the potential for unwanted
alarms during initial start-up as the unit brings the system up to operating temperature.
Tank Temperature Button
Depressing the Tank Temperature button will show the current tank temperature in the display.
Password Entry Buttons
Depressing any of the Password Entry buttons will allow for secured access to the control program and
will prevent unauthorized personnel from making changes. The correct four-letter password will be
required to adjustment temperatures or timer functions. The password remains in memory even if the
power is disconnected.
Entering or Changing Password
Depress the Off button and then immediately depress and hold the ‘C’ Password Entry button for three
seconds. The display will now show a ‘C’ in the second display. Immediately enter a password consisting
of any combination of four letters. The controller counts the number of letters entered and the display
will show a ‘4’ in the last display when all four of the password letters are entered. Once the ‘4’ appears,
release all buttons and press the ‘Off’ button to store the password. Press the ‘On’ button to restart the
unit. The display will return to the actual temperature and the controls will be password protected.
10
Deleting Password
Depress the ‘C’ and hold until the second display show ‘C’ then press the ‘Off’ button to delete the
password. When there is no password the first and last displays will show “• •”. To resume operation
press the ‘On’ button and the unit will resume normal operation without password protection.
Pump Operation LED
There are two indicating lights in the Pump icon. When the pump is on the upper LED will be green.
When the pump overloads the lower LED will be yellow.
Heating LED
There are two indicating lights in the Heating icon. When Heat 1 is on the upper LED will be green.
When Heater 2 is on the lower LED will be green.
Cooling LED
When the cooling valve is open, the LED in the Cooling icon will be green.
Reservoir Low Level Alarm LED
The LED in the Low Level icon will be yellow when the oil level in the reservoir is too low.
Deviation Alarm LED
The LED in the Deviation Alarm icon will be green when the Deviation Alarm is active. The LED will not be
on if the Deviation Alarm has been turned off.
Timer LED
The LED in the Timer icon will be green when the Automatic Start/Stop Timer is active. The LED will not
be on if the Automatic Start/Stop Timer is not active.
11
Unit Operation
The temperature control unit circulates oil through a process while precisely, automatically, and reliably
maintaining the oil temperature at the selected set point temperature. The operating range of the unit
is from 85°F to 575°F. The unit is well suited or use with city water, water from chillers, cooling towers,
or wells to provide the cooling water supply.
The unit is a compact corrosion-proof unit with an integral stainless steel tank, stainless steel heating
elements, cooling heat exchanger and an immersed stainless steel centrifugal pump without rotating
seals. The pump sends oil to the process through the discharge line and returns to the tank through the
return line. The unit is an open system. The microprocessor controls the temperature in the tank. The
tank (process) temperature is displayed on the control panel LED's.
During the heating cycle, the heating elements turn on as required. During the cooling cycle, the
solenoid valve opens and the cooling water goes through the heat exchanger as needed to maintain the
proper temperature.
When the unit is on, an LED connected to a level probe inside the tank indicates if the oil level is to the
correct level. When the unit is operating and there is too little oil in the tank, the Low Level light turns
on, the pump stops and heating ceases. As soon as the oil level is high enough to satisfy the Low Oil
Level switch the unit will start automatically.
The microprocessor controls the temperature and monitors the oil level in the unit. The microprocessor
includes alarms for low tank level and temperature deviation as well as a timer making automatic
start/stop of the temperature controller possible.
Vacuum Mold Drain Option
We offer an option for a vacuum mold drain. If the unit is equipped with this option, it has a special
venture valve in the oil circuit that used the positive pressure of the pump to create a vacuum on the
return line. The unit will also include a program sequence to automatically cool to 120°F before draining
the mold.
To initiate a mold drain sequence depress the Temperature Adjust button and then immediately depress
the ‘On’ button. The display will show ‘E’ followed by the actual temperature in the tank. The cooling
solenoid valve opens and will remain energized until the tank temperature drops to 120°F. When the
tank temperature reaches 120°F, the alarm horn will sound to signal the mold is ready for draining.
Once the unit has cooled to 120°F, close the vacuum adjusting valve and remove the hose on the valve.
The vacuum created will automatically pull the oil through the hoses and the mold back to the unit.
When the unit is finished draining, turn the unit off by depressing the Off button and remove the hoses.
12
Start-Up
Every unit is factory set to perform in accordance with the standard operating specifications for that
particular temperature control unit. Due to variables involved with different applications and different
installations, minor adjustments may be required during the initial start-up to ensure proper operation.
The following start-up procedure should be followed in sequence. If trouble is encountered during startup, the fault can usually be traced to one of the control or safety devices. This outline can be used as a
checklist for the initial start-up and for subsequent start-ups if the unit is taken out of service for a
prolonged period of time.
1. Assure the main power source is connected properly, that it matches the voltage shown on the
nameplate of the unit, and that it is within the voltage utilization range given in Table 1. Electrical
phase sequence must be checked at installation and prior to start-up. Operation of the temperature
control unit with incorrect electrical phase sequencing will result in improper performance and could
lead to mechanical damage. The phasing must be checked with a phase sequence meter prior to
applying power. The proper sequence should read “ABC” on the meter. If the meter reads “CBA”,
open the main power disconnect and switch two line leads on the line power terminal blocks (or the
unit mounted disconnect). All components requiring electric power are wired in-phase at the
factory. Do not interchange any load leads that are from the unit contactors or the motor terminals.
Once proper power connection and grounding have been confirmed, turn the main power on.
WARNING: It is imperative that L1-L2-L3 are connected in the A-B-C phase sequence to prevent equipment
damage due to reverse rotation.
2. The temperature control unit is provided with an inlet cooling water filter (shipped separately in
crate). Install this in the inlet chilled water line before the line is connected to the unit.
3. Check to make sure that all process water and oil piping connections are secure.
WARNING: Only use hoses and connectors that are properly rated for operation with this unit. The unit can
develop up to 100 PSI of pump pressure at 600°F. Do not use hose couplings or old or damaged hose when
connection the unit to the process equipment. Always ensure the unit is fully cooled and the power is off before
connecting or disconneting hoses or fittings.
4. Check to make sure all cooling water piping connections are secure. Make sure sufficient cooling
water flow and pressure are available and that all shut-off valves are open.
5. Turn on the control power by pressing the On button. The panel displays should now be illuminated.
6. If the display shows a decimal point in the first and last LED displays the unit is full of oil and ready to
operate. If the temperature control unit has never been filled or if the oil level in the reservoir is
insufficient, the digital displays with read FILL and the Low Level light will turn on. If this occurs,
remove the plug fron the fill connection located on the top of the unit and fill the unit with oil until
the display shows the tank temperature and the Low Level light turns off. The 6 kW and 12 kW
models hold about 8 gallons of oil and the 18 kW and 24 kW units hold about 15 gallons of oil.
13
WARNING: The use of improper oils can lead to built-up of sludge and scorching of oil in the unit. Use high-quality
synthetic oil such as Paratherm NF® Heat Transfer Fluid. Do not use mineral oils and do not mix oils.
7. After the reservoir is sufficiently full of oil and the pump is operating, press the Temperature
Adjustment button to display the current set point temperature. If the oil temperature in the tank is
below 70°F, the unit will heat in pulses and the pump will not run. Between 70°F and 85°F, the unit
will heat and the pump runs, but the display will only show "A", indicating that it is in an alarm mode
and not in a running mode. Above 85°F, the unit works according to design. Once the pump bearing
reaches 250°F, the heaters will turn off, but the pump will continue to run. Check to make sure the
fan in the electrical cabinet is operating.
8. Set the desired temperature using the Increase and Decrease buttons. When finished release all
buttons. After five seconds the tank temperature is displayed and the new set point is stored. The
unit will now activate the heaters and/or cooling solenoid valve to maintain set point temperature.
9. (Vacuum Units Only) Adjust the positive/negative flow through the mold by using the vacuum
adjusting valve on top of the back panel. Start by fully closing this valve so that the injector makes a
vacuum in the return line from process. The vacuum creative will allow air to enter the circuit
through any leaks that are present. Opening the adjusting valve slowly allows oil to flow to the mold
and pressurize the supply line. The leak will reappear as the pressure increases. Slowly closing the
adjusting valve now eliminates the leak.
10. Operate the unit for approximately 30 minutes. Check the unit for signs of leaks. Once proper flow
and temperature are achieved, press the Off button.
The unit is now ready to be placed into service.
14
Preventive Maintenance
Once your oil temperature control unit is in service, please adhere to the following maintenance
procedures. The importance of a properly established preventive maintenance program cannot be
overemphasized. Taking the time to follow these simple procedures will result in substantially reduced
downtime, reduced repair costs, and an extended useful lifetime for the unit.
Once a Week
1. Check all water and oil line connections for signs of leaks. Replace or repair water and/or oil lines
and/or fittings as necessary.
2. Check to make sure the To Process temperature is maintained reasonably close to the Set Point
temperature. If the temperature varies more than 5°F from the set point temperature, there may be
a problem with the unit. If this occurs, refer to the Troubleshooting Chart or contact our Customer
Service Department.
3. Check the pump discharge pressure of the unit. If the discharge pressure starts to stray from the
normal operating pressure this could be an indication that the leak in the mold has worsened or that
there may be a problem with the unit. If this occurs, refer to the Troubleshooting Chart or contact
our Customer Service Department.
Once a Month
Repeat items 1 through 3 as listed above and continue with the following.
4. With the main disconnect shut off and locked out, check the condition of electrical connections at all
contactors, starters and controls. Check for loose or frayed wires.
5. Check the incoming voltage to make sure it is within 10% of the design voltage for the unit.
6. Check the amp draws to each leg of the pump and heaters to confirm that they are drawing the
proper current.
7. Check the heat exchanger inlet strainer and clean debris out as necessary.
8. Check the condition of the oil and replace as necessary as instructed by the oil manufacturer.
Once a Year
Repeat items 1 through 8 as listed above and continue with the following.
9. Carefully inspect the heat exchanger for signs of scale build-up and carefully clean and remove scale
as necessary.
CAUTION: The amount of scale build-up is dependent upon the amount of cooling required for each process along
with the quality of the cooling water supply. We have supplied the unit with a stainless steel heat exchanger to
allow the use of strong lime-scale removal chemicals (acids). We recommend you clean the heat exchanger
thoroughly on a periodic basis, or after each job, to allow for the longest life and highest heat removal potential of
the unit. If the heat exchanger becomes completely blocked, lime scale removal will be impossible.
15
Troubleshooting
Table 5 – Troubleshooting Chart
Problem
Possible Cause
Remedy
Main fuses blown
Replace blown fuses
Motor defective
Contact factory
Reset tripped
Reset
Control circuit breaker tripped
Reset
Motor buzzes after pressing the On
button and overload trips
Voltage on two of the phases only
Check incoming power supply, check
and replace blown fuse
Motor defective
Contact factory
No oil circulation, even though the
pump is rotating
Pump is rotating in the wrong direction
Change two of the incoming power
leads
Process oil lines clogged
Clean lines
Contactor defective
Replace contactor
Thermostat defective
Replace thermostat
Heating element defective
Replace heating element
Safety fuse defective
Replace safety fuse
Solenoid valve at “Cooling Water In”
defective
Replace solenoid valve
Cooling heat exchanger clogged
Clean coil
Thermostat defective
Replace thermostat
Dirt in the cooling solenoid valve
Take apart the valve, clean out, replace
if required
Thermostat defective
Replace thermostat
Tank overfilled
Drain some oil
Water in the system
Drain tank and refill with new oil
The unit does not start after
connection, tank filling, and pressing
the On button
The unit does not heat
The unit does not cool
The unit cooling all the time
Oil comes out the overflow pipe
16
Charts and Drawings
Figure 4 – Principle of Operation
1. From process
2. To process
3. Cooling water in
4. Cooling water out
5. Pump
6. Tank
7. Level switch
8. Temperature sensor
9. Microprocessor control
10. Heat exchanger
11. Heating element
12. Overflow
13. Expansion tank
14. Solenoid valve for cooling
15. Connection, remote sensor (optional)
16. Fill
17. Check valve
18. Negative pressure adjustment valve (negative pressure units only)
19. Negative pressure venture (negative pressure units only)
20. Drain (negative pressure units only)
17
Figure 5 – Microprocessor Control Board Drawing (Drawing 592)
18
Warranty
Thermal Care warrants its equipment to be free from defects in material and workmanship when used under recommended
operating conditions.
Thermal Care’s obligation is limited to repair (i.e. rewind a motor) or replacement (not adjustment or maintenance), F.O.B.
the factory of any parts supplied by Thermal Care within a period as shown below from the date of shipment to the original
purchaser.
Model
SQ, LQ
EQ
EQR, LQR, SQR(remote condensers)
TCW, TSW, TXW
TCR, TSR, TXR (remote condensers)
Optional Compressor Warranty
Chilled Water Systems
FT or FC Tower Systems
FT Cooling Tower
FC Cooling Tower
RA, RB
All other products
Parts
18 months
12 months
12 months
12 months
12 months
5 years
3
See note
3
See note
12 months (10 years - shell)
5 years (10 years - shell)
(See Warranty Sheet – Form 1-415)
12 months
1
Labor
12 months
12 months
2
12 months
12 months
2
12 months
4
12 months
4
12 months
1
Continental U.S.A., Canada, and Puerto Rico only.
Refrigerant and any labor associated with its evacuation or replacement are not covered for remote condenser systems.
3
See individual product listing for parts warranty coverage.
4
The labor warranty covers all equipment purchased at the same time consisting of a minimum of at least one pumping
system and one cooling tower and/or chiller.
2
This warranty does not cover the cost of labor during overtime hours (after normal working hours or during weekends and
holidays). Any cost differential for overtime labor will be the responsibility of the customer. Thermal Care is not responsible
for any sales, use, excise or other applicable taxes associated with the replacement of parts under this warranty. This
warranty will be voided when, in Thermal Care’s opinion, the equipment and/or system has been subject to misuse,
negligence or operation in excess of recommended limits, including freezing, or has been altered, and/or repaired without
express factory authorization. If equipment is installed in hostile environments, unless such conditions were specified at the
time of purchase; or the serial number has been removed or defaced, this warranty shall not apply. This warranty is not
transferable.
Under no circumstances shall Thermal Care be liable for loss of prospective or speculative profits, or special, indirect,
incidental or consequential damages.
Thermal Care must authorize all warranty service prior to work being performed and have a Thermal Care purchase order
issued. All defective parts become the property of Thermal Care and must be returned as advised by Thermal Care.
Thermal Care neither assumes, nor authorizes any person to assume for it, any liability not expressed in this warranty. There
is an implied warranty of merchantability and of fitness for that particular purpose; all other implied warranties, and any
liability not based upon contract are hereby disclaimed and excluded by this warranty. This warranty is part of the standard
conditions and terms of sale of Thermal Care.
7720 N. Lehigh Avenue
Niles, Illinois 60714-3491
Phone: (847) 966-2260
(888) 828-7387
Fax:
(847) 966-9358
Email: info@thermalcare.com
www.thermalcare.com
Customer Service
Phone: (847) 966-2636
Fax: (847) 966-2906
Form 1-410.11
Effective 4/9/07
19
Thermal Care, Inc.
7720 N. Lehigh Ave.
Niles, IL 60714-3491
www.thermalcare.com
RO Series IOM 7-315.20
Ferbruary 2014
New Equipment Sales
Tel
(847) 966-2260
Fax
(847) 966-9358
info@thermalcare.com
Customer Service
Tel
(847) 966-2636
Fax
(847) 966-2906
service@thermalcare.com
Parts
Tel
(847) 966-8560
Fax
(847) 966-6065
tcparts@thermalcare.com
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