AEC TCU Complete Troubleshooting Guide

AEC TCU Complete Troubleshooting Guide
TrueTemp™ TCU Series Water Temperature Control Units
Reference Manual (PN: 682.88106.00) for
Complete Operation and Installation Instructions
(Available online at www.acscustomerservice.com)
Quickstart Installation Checklist
(Refer to main manual for complete installation instructions).
1. Connect 3-phase power based on nameplate data.
2. Install properly sized plumbing between temperature control unit and primary
processing equipment (supply and return).
3. Install properly sized plumbing between temperature control unit and cooling water
supply and return. Cooling water supply must be at least 16 psi (110 kPa/1.1bar) for
a 250˚F (121°C) configuration and 55 psi (379 kPa/3.8bar) for a 300˚F (149°C)
configuration.
4. Ensure proper pump rotation. (The pump should be moving clockwise while looking
at the motor end).
Unit Operation
(Refer to main manual and controller manual for complete operating instructions).
Disconnect Switch
Start Up
1. Turn disconnect switch to ON position.
2. Press START. The unit will automatically vent for approximately one minute.
3. If needed, press and hold the vent button to purge any additional air from the process loop.
4. Set process temperature (PV) by pressing the
Up Arrow or
Down Arrow keys.
5. If the unit does not maintain its process value, allow your process to reach the set point temperature. Then
Autotune the control by pressing the
key.
Standard Controller
Shut Down
1.
2.
3.
Adjust set point below 150˚ F (66˚ C). Allow unit to
stabilize.
Push STOP button.
Turn disconnect switch to OFF position.
AEC, Inc.
1100 Woodfield Road • Suite 588 • Schaumburg, IL 60173 USA
Tel. 847.273.7700 • Fax 847.273.7804
Part No: 682.92594.00
Bulletin No: HC2-300.03
TrueTemp™ TCU Series Water Temperature Control Units
Reference Manual (PN: 682.88106.00) for
Complete Operation and Installation Instructions
(Available online at www.acscustomerservice.com)
Spare Parts Location
(See next page for Spare Parts List)
AEC, Inc.
1100 Woodfield Road • Suite 588 • Schaumburg, IL 60173 USA
Tel. 847.273.7700 • Fax 847.273.7804
Part No: 682.92594.00
Bulletin No: HC2-300.03
TrueTemp™ TCU Series Water Temperature Control Units
Reference Manual (PN: 682.88106.00) for
Complete Operation and Installation Instructions
(Available online at www.acscustomerservice.com)
Spare Parts List
(See previous page for Spare Parts Location)
Cooling Valves
Standard Solenoid
¼-inch (0.64 cm)
1
1¼-inch (3.18 cm)
NA
1½-inch (3.8 cm)
732.00191.00
NA
½-inch (1.27 cm)
732.00188.00
¾-inch (1.91 cm)
732.00189.00
1-inch (2.54 cm)
732.00190.00
9-kW
9-kW contactor (2 req’d)
12-kW
12-kW contactor (2 req’d)
Motor Pumps
¾-HP (0.56 kW)
¾-HP MCP
1-HP (0.75 kW)
1-HP MCP
2-HP (1.50 kW)
3
2-HP MCP
3-HP (2.24 kW)
3-HP MCP
5-HP (3.73 kW)
5-HP MCP
7.5-HP (5.60 kW)
7.5-HP MCP
Pump Seal
Kits
4
NA
044.00512.00 – Cv = 0.4
044.00512.01 – Cv = 1.3
044.00512.02 – Cv = 2.2
044.00512.03 – Cv = 4.4
044.00512.04 – Cv = 5.5
044.00512.05 – Cv = 7.5
044.00512.06 – Cv = 10
044.00512.07 – Cv = 14
044.00512.08 – Cv = 20
Immersion
Heaters
2
Modulating
732.00186.00
230/3/60
460/3/60
575/3/50
722.00137.02
726.00268.02
722.00137.03
726.00270.02
230/3/60
722.00137.01
726.00267.02
722.00137.04
726.00265.02
460/3/60
722.00137.08
726.00267.02
722.00137.22
726.00265.02
575/3/50
075.00708.00 – 250 °F
075.00708.01 – 300 °F
726.00304.02
075.00709.00 – 250 °F
075.00709.01 – 300 °F
726.00305.02
075.00710.00 – 250 °F
075.00710.01 – 300 °F
726.00306.02
075.00711.00 – 250 °F
075.00711.01 – 300 °F
726.00306.02
075.00712.00 – 250 °F
075.00712.01 – 300 °F
726.00316.02
075.00713.00 – 250 °F
075.00713.01 – 300 °F
726.00317.02
(121°C)
(149°C)
(121°C)
(149°C)
(121°C)
(149°C)
(121°C)
(149°C)
(121°C)
(149°C)
(121°C)
(149°C)
075.00708.00 – 250 °F (121°C)
075.00708.01 – 300 °F (149°C)
726.00303.02
075.00709.00 – 250 °F (121°C)
075.00709.01 – 300 °F (149°C)
726.00303.02
075.00710.00 – 250 °F (121°C)
075.00710.01 – 300 °F (149°C)
726.00304.02
075.00711.00 – 250 °F (121°C)
075.00711.01 – 300 °F (149°C)
726.00305.02
075.00712.00 – 250 °F (121°C)
075.00712.01 – 300 °F (149°C)
726.00306.02
075.00713.00 – 250 °F (121°C)
075.00713.01 – 300 °F (149°C)
726.00316.02
075.00744.00 – 250 °F
075.00744.01 – 300 °F
726.00302.02
075.00745.00 – 250 °F
075.00745.01 – 300 °F
726.00303.02
075.00746.00 – 250 °F
075.00746.01 – 300 °F
726.00303.02
075.00747.00 – 250 °F
075.00747.01 – 300 °F
726.00304.02
075.00748.00 – 250 °F
075.00748.01 – 300 °F
726.00305.00
075.00749.00 – 250 °F
075.00749.01 – 300 °F
726.00306.02
(121°C)
(149°C)
(121°C)
(149°C)
(121°C)
(149°C)
(121°C)
(149°C)
(121°C)
(149°C)
250 °F (121°C) (SC/C/EPDM)
300 °F (149°C) (SC/SC/EPDM)
¾-HP (0.56 kW)
1-HP (0.75 kW)
2-HP (1.50 kW)
162.00024.104
162.00024.104
162.00024.104
162.00024.107
162.00024.107
162.00024.107
3-HP (2.24 kW)
5-HP (3.73 kW)
7.5-HP (5.60 kW)
162.00024.104
162.00024.105
162.00024.105
162.00024.107
162.00024.113
162.00024.113
Common Parts
5A
5B
6A
6B
7
8
(121°C)
(149°C)
250 °F (121°C) pressure switch **
692.86688.00K
300 °F (149°C) pressure switch **
692.86688.01K
250 °F (121°C) safety thermostat
724.00665.00
300 °F (149°C) safety thermostat
724.00666.00
Relief valve
044.00138.00
Type “K” thermocouple
701.00124.00
Temperature control module (OMRON E5CK) less outputs
724.00671.00
Relay, relay output
714.00167.00
AEC
2005-spares-tcu
Document #
** Reference complete manual (PN: 682.88106.00) for proper settings and installation.
AEC, Inc.
1100 Woodfield Road • Suite 588 • Schaumburg, IL 60173 USA
Tel. 847.273.7700 • Fax 847.273.7804
Part No: 682.92594.00
Bulletin No: HC2-300.03
TrueTemp™ TCU Series Water Temperature Control Units
Reference Manual (PN: 682.88106.00) for
Complete Operation and Installation Instructions
(Available online at www.acscustomerservice.com)
Troubleshooting - Quick Guide
Problem
Possible cause
No power.
Unit does not turn on
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.
Unit does not run
Low water pressure light on.
Water supply to unit is turned off.
Pump overload light on.
Undersized connectors/ water lines.
Long connecting lines between unit and mold.
Temperature fluctuations/
rapid cycling from hot to
cold.
Serpentine flow through mold.
Blocked water line in mold.
Quick disconnect fitting with check valve.
Lime buildup in unit piping.
Drain is plugged or excessive back pressure is in drain
line.
Faulty solenoid valve.
Controller Cool output relay open.
Unit overheats or does not
cool
Solenoid valve is not operating, but COOL LED is on.
Solenoid coil circuit is open.
Modulating valve is not operating, but OUT2 LED is on.
Insufficient pressure differential between cooling
WATER IN and OUT lines.
Cooling valve is undersize.
Defective heater contactor.
Unit does not heat/cannot
achieve set point
Defective immersion heater.
Heater contactor is not energizing, but HEAT LED is on.
Faulty/dirty solenoid valve.
AEC, Inc.
1100 Woodfield Road • Suite 588 • Schaumburg, IL 60173 USA
Tel. 847.273.7700 • Fax 847.273.7804
Solution
Check main disconnect, fuses, wiring, and
power lead to unit.
Voltage must be within plus or minus 10% 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 or CITY
WATER MAKEUP.
Open water supply.
Reset and test each leg for balanced amp
draws.
Increase size of connectors/ water lines.
Move the unit closer to the mold and shorten
connecting lines.
Connect lines for parallel flow instead of
series flow.
Check mold for metal chips or lime buildup.
Clean mold.
Remove and replace fitting or valve.
Clean or replace.
Clear drain line or eliminate back pressure
condition.
Test solenoid valve by pressing VENT
button and listen for valve operation.
Replace if faulty.
Replace output relay.
Set process temperature to minimum and
check for magnetism on solenoid coil top.
Check coil resistance. If MΩ range, replace
solenoid coil.
Set process temperature to minimum and
check for complete travel of valve.
Find a means to get less back pressure in
the WATER OUT line.
Replace cooling valve with a larger valve.
Visually inspect coil and 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.
Set process temperature to maximum and
check for control voltage at heater contactor.
Press VENT button several times to flush
the valve.
Part No: 682.92594.00
Bulletin No: HC2-300.03
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