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Thermolator®vacuTracPositive/Negative PressureWater Temperature Controllerwith TW-1 or TW2 MicroprocessorInstant Access Parts and Service(800) 458-196

Actual temperature of water supplied to the mold ishigher than the setpoint deviation limit allows.1. High deviation temperature is set too low. Incre

IMS0002/0296 SERVICE INFORMATIONAPPENDIX A-1Conair has made the largest investment in customer support inthe plastics industry. Our service experts ar

WARRANTY INFORMATION IMS0003/0796APPENDIX A-2EQUIPMENTGUARANTEEPERFORMANCEWARRANTYWARRANTYLIMITATIONSConair guarantees the machinery and equipment on

UGH015/0100 PLUMBING DIAGRAMSAPPENDIX B-1ThermocoupleHeaterThermocouplePurge Valve(optional)To ProcessFrom ProcessCooling Water InCooling Water OutCoo

PLUMBINGDIAGRAMSPLUMBING DIAGRAMS UGH009/0499APPENDIX B-2Return ThermocoupleHeaterSupply ThermocoupleTo ProcessFrom ProcessCooling Water InCooling Wat

PUMPCURVESUGH015/0100 TECHNICAL INFORMATIONAPPENDIX C-1MTRSPSI FEETGallons/MinuteLiters/Minute55 7818049 6916043 6114037 5212030 4310024 358018 264012

IMH001/0300 THERMOLATOR SPI COMMANDSAPPENDIX D-1The SPI commands supported by Conair Thermolator®moldtemperature controllers are listed in the followi

Status, ProcessPoll: 0x20 0x40SPI STATUS WORDWord BIT position 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0EEprom error SET SET*A/D converter error SET SET*

IMH001/0499 THERMOLATOR SPI COMMANDSAPPENDIX D-3Status, Machine 1Poll: 0x20 0x42SPI STATUS WORDWord BIT position 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

THERMOLATOR SPI COMMANDS IMH001/0499APPENDIX D-4Status, Machine 2Poll: 0x20 0x44SPI STATUS WORDWord BIT position 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Material Safety Data SheetAn explanation of the terms used in this document may be found in OSHA 29 CFR 1910.1200,which is available from OSHA regiona

5. Fire and Explosion DataFire and explosionhazards:Mercury presents a slight fire and explosion hazard whenexposed to heat or flame. Mercury vapors a

PD-1UGH015/0100 Thermolator TW-1 and TW-2●●Spare Parts Lists . . . . . . . . . .PD-1●●TW-1 Wiring . . . . . . . . . . . . . . .PD-5●●TW-1 Circuit Bo

PUMP ASSEMBLIESNickle resistant seal, open drip proof type motorPart No. Description09000952 ¾ HP pump model 11C (with cast iron impeller)09000953 1 H

RECOMMENDEDSPARE PARTSUGH015/0100 RECOMMENDED SPARE PARTSPD-3PUMPMOTORSPart No. Description09001403 ¾ HP 208/230/460V/3/60 ODP (Open Drip Proof)09000

RECOMMENDEDSPARE PARTSRECOMMENDED SPARE PARTS UGH015/0100PD-4HEATER CONTACTORSPart No. Description20004401 Heater contactor for 9kW 208/230/460V200044

UGH015/0100 TW-1 230/460V WIRING DIAGRAMPD-5

1 2345678CONFIGURATIONDIP SWITCHOFFON43214321UNLDR 1/ VENT 2 SOL +UNLDR 1/ VENT 2 SOL UNLDR 2/ COOL 1 SOL +UNLDR 2/ COOL 1 SOL F

UGH015/0100 TW-2 230/460V WIRING DIAGRAMPD-72

TW-2 CIRCUIT BOARD UGH015/0100PD-81 2345678CONFIGURATIONDIP SWITCHOFFON43214321UNLDR 1/ VENT 2 SOL +UNLDR 1/ VENT 2 SOL UNLDR 2/ COOL 1 SO

OPERATIONTHE TW-2 CONTROLActual values displayThe green window displays the temperatureat the middle of the mold. This temperatureis calculated as an

Actual temperature of water supplied to the mold ishigher than the setpoint deviation limit allows.1. High deviation temperature is set too low. Incre

Thermolator®TW-1 and TW-2Instant Access Parts and Service(800) 458-1960(814) 437-6861www.conairnet.comThe Conair Group, Inc.One Conair DrivePittsburgh

It’s a good idea to record the model and serial number(s) ofyour equipment and the date you received it in the UserGuide. Our service department uses

UGH015/0100 Thermolator TW-1 and TW-2TABLE OFCONTENTSINTRODUCTION . . . . . . . . . . . . . . . . . . .1-1Purpose of the User Guide . . . . . . . .

Thermolator TW-1 and TW-2 UGH015/0100TABLE OFCONTENTSMAINTENANCE . . . . . . . . . . . . . . .(continued)Performing System Tests . . . . . . . . . .

TEMPERATURE CONTROL UNITSThermolator®vacuTrac (VTR1-DI and VTR2-DI)Positive/Negative Pressure One Conair Drive ● Pittsburgh, PA 15202 ● 412-312-6000 ●

1-1UGH015/0100 Thermolator TW-1 and TW-2●●Purpose of the User Guide . . . .1-2●●How the guide is organized . . . .1-2●●Your responsibilities as a use

Thermolator TW-1 and TW-2 UGH015/01001-2 INTRODUCTIONThis User Guide describes the Conair Thermolator®TW-1 andTW-2 water temperature control units and

UGH015/0100 Thermolator TW-1 and TW-2INTRODUCTION 1-3We design equipment with the user’s safety in mind. You canavoid the potential hazards identified

WARNING: Hazardous substanceThe electrical contactors in theThermolator have mercury contactors.Mercury is considered a hazardous sub-stance and must

2-1UGH015/0100 Thermolator TW-1 and TW-2●●What is the Thermolator TW Series? . . . . . . . . . . . . . . .2-2●●Typical applications . . . . . . . .

The Thermolator TW models circulate water at a temperaturehigher than the available water supply, to add or remove heatas needed to maintain a uniform

Direct injection models maintain the process temperatureby electrically heating and injecting cool water supplied tothe Thermolator by a chiller, towe

HOW IT WORKS:CLOSED CIRCUITThermolator TW-1 and TW-2 UGH015/01002-4 DESCRIPTIONReturn ThermocoupleHeaterSupply ThermocoupleTo ProcessFrom ProcessCooli

Return ThermocoupleHeaterSupply ThermocoupleTo ProcessFrom ProcessCooling Water InCooling Water OutVent LineCoolingValveReliefValveCooling HeatExchang

SPECIFICATIONSThermolator TW-1 and TW-2 UGH015/01002-6 DESCRIPTIONCABINET STYLE REFERENCEHeater Voltage Selection Single Zone 2 Zone 3 ZoneDirect Inje

TPHF017/1101FEATURESOne Conair Drive ● Pittsburgh, PA 15202 ● 412-312-6000 ● FAX 412-312-6227 ● www.conairnet.comTEMPERATURE CONTROL UNITSThermolator®

SPECIFICATIONSUGH015/0100 Thermolator TW-1 and TW-2DESCRIPTION 2-7TW1TW2Zones(1, 2 or 3)Direct Injection (DI)Closed Circuit (CC)Isolated Circuit (IC)P

High efficiency pumpsfrom 3/4 to 7.5 Hp. Siliconcarbide seals are standard.Pump seal flush linecontinuously cleans thepump seal for extended life.Inco

3-1UGH015/0100 Thermolator TW-1 and TW-2●●Unpacking the boxes . . . . . . . . .3-2●●Preparing for installation . . . . . .3-3●●Connecting the water s

UNPACKING THEBOXESThermolator TW-1 and TW-2 UGH015/01003-2 INSTALLATIONCarefully remove the Thermolator and compo-nents from their shipping containers

UGH015/0100 Thermolator TW-1 and TW-2INSTALLATION 3-3The Thermolator is easy to install, if you plan the location andprepare the area properly.Positio

Motorized Cooling ValveIf you have the optional motorizedcooling valve, connect the coolingwater supply to the female 3/4inchNPT fitting on the valve.

A purge valve is available as an option on Direct Injection andClosed Circuit units only. This valve quickly evacuates fluidfrom the process circuit,

Thermolator TW-1 and TW-2 UGH015/0100Before beginning, note the electrical specifications on thenameplate mounted to the side of the unit. The electri

UGH015/0100 Thermolator TW-1 and TW-2INSTALLATION 3-7Turn on the cooling water supply and check forleaks.If any leaks appear, stop the test and fix th

Thermolator TW-1 and TW-2 UGH015/01003-8 INSTALLATIONINITIALSETUPThe factory-set parameters and operating modes will satisfymost applications. But you

TPHO017/1101FEATURESOne Conair Drive ● Pittsburgh, PA 15202 ● 412-312-6000 ● FAX 412-312-6227 ● www.conairnet.comTEMPERATURE CONTROL UNITSThermolator®

UGH015/0100 Thermolator TW-1 and TW-2CHANGINGTEMPERATUREUNITSThe temperature units are factory-set as degrees Celsius ordegrees Fahrenheit, as specifi

Thermolator TW-1 and TW-2 UGH015/0100The TW-1 and TW-2 Thermolators provide the ability to pro-tect system parameters from unauthorized changes during

UGH015/0100 Thermolator TW-1 and TW-2Press the RUN button to save the passcode.◆◆ The control will display “Pr OFF” to prompt you toremove power to t

Thermolator TW-1 and TW-2 UGH015/0100TW-1 models control the process temperature based upon theaverage of the temperatures recorded at the supply (to

UGH015/0100 Thermolator TW-1 and TW-2SELECTING THETEMPERATURECONTROL POINT(TW-2 ONLY)INSTALLATION 3-13Press the RUN button to save the control point.◆

Thermolator TW-1 and TW-2 UGH015/01003-14 INSTALLATIONYou can establish a normal operating range around the processtemperature setpoint using the high

UGH015/0100 Thermolator TW-1 and TW-2INSTALLATION 3-15TW-1 and TW-2 Thermolators provide SPI compatible supportfor RS-485 serial communications with

If you have a TW-2 model, you can automatically start andstop the Thermolator from a remote switching or timingdevice that has power contacts rated 11

Set dip switch 4 to theON position.Close the electricalenclosure and restorepower to the unit.When Auto Start is enabled:◆ The Auto Start indicator li

One Conair Drive ● Pittsburgh, PA 15202 ● 412-312-6000 ● FAX 412-312-6227 ● www.conairnet.comTPHS017/1101 SPECIFICATIONSTEMPERATURE CONTROL UNITSTherm

4-1UGH015/0100 Thermolator TW-1 and TW-2●●TW-1 control . . . . . . . . . . . . . . . .4-2●●TW-2 control . . . . . . . . . . . . . . . .4-3●●Mounting

All normal operating functions can be controlled from theTW-1 control panel. If you have the optional manual moldpurge, the control button is located

TW-2 CONTROLUGH015/0100 Thermolator TW-1 and TW-2OPERATION 4-3Purge ValveThe light indicates the operating status of the purge valve. Except inTest Mo

Thermolator TW-1 and TW-2 UGH015/01004-4 OPERATIONMOUNTING THETW-2 CONTROLIN AREMOTELOCATIONCAUTION: Improper use of the swivelingcontrol panel can da

UGH015/0100 Thermolator TW-1 and TW-2OPERATION 4-5TW-1 and TW-2 Thermolators have a security feature that pre-vents accidental or unauthorized changes

Thermolator TW-1 and TW-2 UGH015/01004-6 OPERATIONBefore starting the Thermolator, verify that the system hasbeen installed correctly for your applica

UGH015/0100 Thermolator TW-1 and TW-2OPERATION 4-7STOPPING THETHERMOLATORYou must shut down the Thermolator whenever you:● Change the water hookups.●

Thermolator TW-1 and TW-2 UGH015/01004-8 OPERATIONTW-1 and TW-2 direct injection and closed circuit models canbe ordered with an optional purge valve,

UGH015/0100 Thermolator TW-1 and TW-2OPERATION 4-9The TW-2 direct injection models can be ordered with anoptional purge valve, which clears the proces

You should perform an Auto Tune after the first two hours ofoperation and whenever process variables change (changes incooling water pressure, piping

CONAIR THERMOLATOR VTR POSITIVE/NEGATIVE OPERATION1.0 PROCESS WATER CONNECTIONSPROCESS CONNECTIONSConnect the FROM PROCESS and TO PROCESS connection

Press and (the Setpoint Select button)simultaneously to begin the Auto Tune. The Actual display will flash “At” and the current processtem

5-1UGH015/0100 Thermolator TW-1 and TW-2●●Maintenance schedule . . . . . . . .5-2●●Accessing the Thermolatorenclosure . . . . . . . . . . . . . . . .

Thermolator TW-1 and TW-2 UGH015/01005-2 MAINTENANCEPREVENTATIVEMAINTENANCESCHEDULEThermolator TW-1 and TW-2 water temperature controllersare essentia

PREVENTATIVEMAINTENANCESCHEDULEUGH015/0100 Thermolator TW-1 and TW-2MAINTENANCE 5-3●●Annually (every 12 months)❒❒ Test and calibrate the unit’s contr

The isolated, or totally closed, circuit models separate thecooling water from the process fluid, which is held in a reser-voir inside the unit. This

TW-1 and TW-2 Thermolators provide a Test Mode that testsdisplays and keys on the control panel, as well as inputs andoutputs. The Test Mode also allo

The Key/Display Test verifies the function of displays, LEDsand buttons on the control panel.Enable Test Mode.Press any key.If necessary, index to the

The Input Test verifies the function of inputs available on thevarious TW-1 and TW-2 models. Not all inputs are used on allmodels. The performance ev

OUTPUT TESTThermolator TW-1 and TW-2 UGH015/01005-8 MAINTENANCEThe Output Test verifies the function of outputs available onthe various TW-1 and TW-2

water level float switch will make, opening the COOLING/MAKE-UP (3/8”) solenoid valve, replacing thehot discharged water with cooler water.This unit’s

All output monitors on the Thermolator can be enabled or dis-abled permanently through the OM Enable/Disable Menu inTest Mode.You need to use this fea

TW-1 and TW-2 Thermolators use type “K” thermocouples tosense the temperature in the return and supply process lines.These thermocouples should be cal

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

You can see the total numbers of operation by accessing theTotal Operating Hours Log in Test Mode.Enable Test Mode.Press any key to display the first

6-1UGH015/0100 Thermolator TW-1 and TW-2●●Before beginning . . . . . . . . . . . .6-2●●A few words of caution . . . . . . .6-2●●How to identify the

You can avoid most problems by following the recommendedinstallation, operation and maintenance procedures outlined inthis User Guide. If you do have

UGH015/0100 Thermolator TW-1 and TW-2TROUBLESHOOTING 6-3A status light that turns fromgreen to red indicates analarm condition.Most Thermolator malfun

Thermolator TW-1 and TW-2 UGH015/01006-4 TROUBLESHOOTINGSHUT DOWNALARMSAlarmThe cooling waterpressure is less than25 psi.Note: The unit will re-start

UGH015/0100 Thermolator TW-1 and TW-2TROUBLESHOOTING 6-5AlarmThe actual tempera-ture of water supplied to theprocess exceeds the260° F safety switchli

Thermolator TW-1 and TW-2 UGH015/01006-6 TROUBLESHOOTINGAlarmActual temperatureof water supplied tothe process is belowthe programmed 20° F safety lim

Figure 1.

UGH015/0100 Thermolator TW-1 and TW-2TROUBLESHOOTING 6-7SHUT DOWNALARMSThe Thermolator has detected a problem that could lead to equip-ment damage or

Thermolator TW-1 and TW-2 UGH015/01006-8 TROUBLESHOOTINGWARNINGALARMSAlarmThe Thermolatorwill not heat to thesetpoint temperature,or takes too long to

UGH015/0100 Thermolator TW-1 and TW-2TROUBLESHOOTING 6-9WARNINGALARMSAlarmThe Thermolatorwill not cool down,or takes too long tocool down. The actu-al

WARNINGALARMSThermolator TW-1 and TW-2 UGH015/01006-10 TROUBLESHOOTINGThe Thermolator has detected a problem that could lead to a shutdown condition i

SYSTEMALARMSUGH015/0100 Thermolator TW-1 and TW-2TROUBLESHOOTING 6-11AlarmRAM hardwarefailure.ROM, checksumfailure.COP failures.Illegal Opcode.through

Thermolator TW-1 and TW-2 UGH015/01006-12 TROUBLESHOOTINGTHERMOLATORWILL NOTPOWER UPIf you apply power to the Thermolator and the control panel doesno

UGH015/0100 Thermolator TW-1 and TW-2TROUBLESHOOTING 6-13CHECKING ANDREPLACINGFUSESIMPORTANT: Alwaysrefer to the wiring dia-grams that came withyour T

Disconnect and lockout the main power.Open the electrical enclosure door. Turn the screwon the front panel counterclockwise to open.Locate the pump ov

UGH015/0100 Thermolator TW-1 and TW-2TROUBLESHOOTING 6-15REPLACING THEMOTHERBOARDIMPORTANT: Alwaysrefer to the wiring dia-grams that came withyour The

Thermolators use mercury displacement heater contactors.The heater contactors should be replaced if:● You have checked the amp draw on each of the thr

OPERATIONTHE TW-1 CONTROLActual values displayThe green window displays the temperatureat the middle of the mold. This temperatureis calculated as an

UGH015/0100 Thermolator TW-1 and TW-2TROUBLESHOOTING 6-17The Thermolator uses two type ‘K’ thermocouples to monitor supply and return process temperat

Thermolator TW-1 and TW-2 UGH015/01006-18 TROUBLESHOOTINGEvery Thermolator has a solenoid valve assembly that controlsthe cooling water out flow. Clos

UGH015/0100 Thermolator TW-1 and TW-2TROUBLESHOOTING 6-19Reassemble the valve and other components.Reassemble in reverse order. Seal all pipe fittings

Thermolator TW-1 and TW-2 UGH015/01006-20 TROUBLESHOOTINGDisconnect and lockout the main power.Remove the top panel of the Thermolator.Remove the heat

UGH015/0100 Thermolator TW-1 and TW-2TROUBLESHOOTING 6-21Lift the heating element out of the heater tube.Lift the element straight up.Replace the heat

Disconnect and lockout the main power.Shut off the cool-ing water in feed.Drain the unit ofall fluid. Removethe drain plugs at therear of the unit.Rem

To replace a failed seal, you must disassemble the pump.Remove the impeller nut. Insert a screwdriver in oneof the impeller waterway passages and back

To replace a failed seal, you must disassemble the pump.Remove the impeller retaining assembly. Insert ascrewdriver in one of the impeller waterway pa

UGH015/0100 Thermolator TW-1 and TW-2TROUBLESHOOTING 6-25Reattach the pump tothe volute case. Makesure you replace any dam-aged gasket or O-ringbetwee