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UGH015/0100 Thermolator TW-1 and TW-2
TROUBLESHOOTING 6-13
CHECKING AND
REPLACING
FUSES
IMPORTANT: Always
refer to the wiring dia-
grams that came with
your Thermolator to
locate specific electrical
components. Illustrations
in the User Guide are
intended to be represen-
tative only.
This procedure covers the factory-installed fuses on the unit’s
motherboard. If you have installed an electrical disconnect or
emergency stop switch, additional fuses and/or breakers may
have been used elsewhere in the in the main power circuit.
To replace a blown fuse:
Disconnect and lockout the main power.
Open the electrical enclosure door.
Turn the screw
on the front panel counterclockwise to open.
Replace the fuse. The fuses are located on the mother-
board and are labeled and identified on the orange shield.
Close the electrical enclosure and restart the unit.
If fuses continue to fail:
❒ Verify that the unit is receiving the correct voltage.
Check the voltage, phasing and amperage ratings on
the unit’s nameplate.
❒ Verify that the unit’s transformer is operating correctly.
Check for proper voltage (120V 10%) to the voltage
sensing device for the fuse location.
❒ Check all wiring referencing the fusing location for
loose connections, damage or improper grounding.
Verify that the correct device is being used for this fuse
location. See Disabling or Enabling Output
Monitors in the
MAINTENANCE
section.
1
2
3
4
1 23
45
6
78
CONFIGURATION
DIP SWITCH
OFF
ON
4
3
2
1
4
3
2
1
UNLDR 1/ VENT 2 SOL +
UNLDR 1/ VENT 2 SOL
UNLDR 2/ COOL 1 SOL +
UNLDR 2/ COOL 1 SOL
F5
F4
F2
PUMP
PUMP
PUMP OL
PUMP OL
6
5
4
3
2
1
4
3
2
1
6
5
4
3
2
1
F3
4
3
2
1
F6
PMP AUX
PMP AUX
1FS/ COMP AUX
1FS/ COMP AUX
PUMPDOWN
PUMPDOWN
HEAT/COMP
HEAT/COMP
HTS/COMP OL
HTS/COMP OL
N
C
NC
NO
C
110V
ALARM
LLS/PURGE 3SOL
LLS/PURGE 3SOL +
PURGE 4SOL
PURGE 4 SOL +
3 PHASE INPUT
TCPL'S
SUP RET
AC IN 4
AC IN + 3
AC OUT 2
AC OUT + 1
F1
LLS/WPS
LLS/WPS
AUTOSTART
AUTOSTART
HPS/LPS
HPS/LPS
OPS
OPS
FSTAT
FSTAT
L1
L2
L3
6
5
4
3
2
1
4
3
2
1
Y
R
R
Y
1 2 3 4 5 6 7 8 1 2 3 4
(-2) CONTROL
OPER PNL CABLE
+ 120 Ohm
+ TR
TR
GND
GND
+ TR
TR
120 Ohm
Fuse 1
Control
power
Fuse 5
Vent valve
Fuse 4
Cooling valve
Fuse 2
Pump
Fuse 3
Heater
Fuse 6
Purge valve
WARNING:
Shock Hazard
Only qualified service
personnel familiar with
electrical testing and
industrial equipment
should examine and
correct problems that
require opening the
unit with power on to
diagnose the cause of
a problem.
- Thermolator 1
- TEMPERATURE 2
- AND STOP 2
- MOLD LEAKS 2
- TPHF017/1101 3
- CONTROLS 4
- SPECIFICATIONS NOTES: 5
- SEQUENCE OF OPERATION 6
- TROUBLESHOOTING A VTR UNIT 7
- Figure 1 8
- Starting the Thermolator 12
- Stopping the Thermolator 12
- TW-1 and TW-2 16
- Please record your 17
- TABLE OF 18
- CONTENTS 18
- INTRODUCTION 20
- READ THIS SO NO 22
- EAD THIS SO NO 23
- ONE GETS HURT 23
- 1-4 INTRODUCTION 23
- DESCRIPTION 24
- WHAT IS THE 25
- THERMOLATOR ? 25
- HOW IT WORKS: 26
- INJECTION 26
- SPECIFICATIONS 29
- FEATURES AND 31
- INSTALLATION 32
- UNPACKING THE 33
- PREPARING FOR 34
- CONNECTING 35
- PROCESS AND 35
- WATER SUPPLY 35
- PURGE VALVE 36
- TESTING THE 38
- 3-8 INSTALLATION 39
- CHANGING 40
- ENABLING AND 41
- DISABLING 41
- PASSCODE 41
- PROTECTION 41
- SELECTING THE 43
- CONTROL POINT 43
- DEVIATION 45
- ACTIVATING SPI 46
- INSTALLING THE 47
- AUTO START 47
- OPERATION 50
- 4-2 OPERATION 51
- TW-2 CONTROL 52
- MOUNTING THE 53
- LOCATION 53
- ENTERING A 54
- STARTING THE 55
- STOPPING THE 56
- USING THE 57
- MANUAL PURGE 57
- PERATION 4-9 58
- PERFORMING AN 59
- AUTO TUNE 59
- MAINTENANCE 62
- PREVENTATIVE 63
- SCHEDULE 63
- PERFORMING SYSTEM 64
- CHECKING THE 65
- FLUID LEVEL IN 65
- RESERVOIR 65
- AINTENANCE 5-5 66
- KEY/DISPLAY 67
- INPUT TEST 68
- OUTPUT TEST 69
- DISABLING OR 70
- ENABLING 70
- MONITORS 70
- CALIBRATING 71
- OPERATING 73
- TROUBLESHOOTING 74
- A FEW WORDS 75
- HOW TO IDENTIFY 76
- CAUSE OF A 76
- SHUT DOWN 77
- Possible cause 78
- Solution 78
- HUT DOWN 78
- 6-8 TROUBLESHOOTING 81
- 6-10 TROUBLESHOOTING 83
- WILL NOT 85
- POWER UP 85
- CHECKING AND 86
- REPLACING 86
- RESETTING 87
- OVERLOADS 87
- REPLACING THE 87
- PUMP OVERLOAD 87
- MOTHERBOARD 88
- CONTACTOR 89
- CHECKING 90
- THERMOCOUPLES 90
- REPAIRING 91
- SOLENOID 91
- EPAIRING 92
- ELEMENTS 93
- REMOVING 95
- DISASSEMBLING 96
- ASSEMBLING 96
- - 2 HP PUMPS 96
- 3 - 7.5 HP PUMPS 97
- WE’RE HERE 100
- PPENDIX A-2 101
- DIAGRAMS 102
- ECHNICAL INFORMATION 104
- SPI COMMANDS 106
- SUPPORTED BY 106
- THERMOLATOR 106
- SPI STATUS WORDS 107
- Status, Machine 2 109
- 7439-97-6 110
- /DIAGRAMS 112
- SPARE PARTS 113
- IRING DIAGRAM 116
- IRCUIT BOARD UGH015/0100 117
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