ACS TCO-U - User Manual

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

This document describes the Upright Hot Oil Temperature Control Units, models TCO-U and 2016U. These units are designed for precise temperature control in various industrial applications, particularly those requiring hot oil circulation.

Function Description

The Upright Hot Oil Temperature Control Unit is a single-pass heater tank system designed to maintain optimal balance of fluid velocity versus watt density, and turbulence for excellent heat transfer, with minimal pressure drop. The high fluid velocity significantly prolongs the life of the heater and fluid. It operates as an easy-to-operate microprocessor-based PID control device, where the process reaches the set point, and PID control cycles the cooling valve and/or immersion heater to maintain the proper leaving water temperature. The controller is factory tested and set to the desired process temperature set point, controlling the rest of the unit's operations.

The unit features a pump and immersion heaters to circulate and heat the thermal fluid. A cooling valve is included for temperature regulation. The system incorporates various safety features, including a pressure switch, safety thermostat, and reservoir tank. The electrical control system is designed for reliability, safety, and simplicity of operation, with clear labeling of switches and status indicators.

Important Technical Specifications

The units are designed for three-phase voltage operation. The nominal supply voltage is 460/3/60 (Verify on serial number tag). The allowable voltage fluctuation is +/- 10%, and allowable frequency fluctuation is continuous +/- 1%. The maximum operating temperature is 550°F (288°C), with a minimum operating temperature of 0°F (-18°C). The reservoir capacity is 7 gallons (26.5 liters).

Key electrical features include non-fused lockable rotary disconnect, branch circuit fusing, and NEMA 12 electrical enclosure. The unit can be supplied with 6, 12, 18, or 24 kW low density immersion heaters, depending upon the heating needs of the process. The 18 and 24 kW models are built to provide full or partial heat as required by the process and determined by the controller, to provide more precise control.

The pump is a mechanical, positive displacement pump, featuring a nearly maintenance-free design and excellent heat transfer capabilities. It is well suited for use with a variety of commercially available heat transfer fluids. The pump is capable of running in either direction. The pump reverse feature can be used to draw fluids back from the process.

The unit's ambient operating conditions are 40 degrees Celsius – Maximum (104 degrees Fahrenheit), with 50% relative humidity. It is designed for sea level altitude and clean, dust-free, non-explosive environments. The unit is equipped with minimal, i.e., machine mounting vibration.

Usage Features

The unit is designed for ease of use with a microprocessor-based PID control device. The control panel includes a START button to initiate the pump, a STOP button to halt the pump, and a REVERSE button for pump reversal. A VENT button is used to purge air and water from the unit and process. The MODE SELECT switch allows selection between AUTO or Maintained (manual cooling) positions. An ALARM SILENCE button is present to mute audible alarms.

The system includes various indicators for operational status:

Pump Overload Indicator Light: Illuminates when the pump is overloaded.
Pump Reverse Indicator Light: Illuminates when the pump runs in reverse.
Pump Forward Indicator Light: Illuminates when the pump runs in the normal forward direction.
Power On Mode Indicator Light: Illuminates to indicate that the control circuit is energized.
Auto Mode Indicator Light: Illuminates when the unit is active and the controller is monitoring the system and controlling the process.
Cool Solenoid Indicator Light: Illuminates when the controller is disabled and the cooling solenoid is open.
Fault Indicator Lights: Indicate pump overload, low pressure, and high level conditions.
Safety Thermo Indicator Light: Illuminates when the unit is overheating.
High Level Indicator Light (Optional): Illuminates when the heat transfer fluid level in the reservoir tank is too high.
Low Level Indicator Light: Illuminates when the heat transfer fluid level in the system is too low.

The unit is designed for easy installation, with clear instructions for uncrating, rigging, and electrical and piping connections. It is crucial to follow safety warnings regarding high voltage, hot surfaces, pinch points, and lock-out/tag-out procedures during installation and operation.

Maintenance Features

Routine maintenance is crucial for optimal performance and longevity. A maintenance schedule is provided, detailing weekly, monthly, quarterly, and every six months checks.

Weekly:

Check fluid level, add fluid as needed.
Check connecting lines, hoses, and connectors for wear or damage.

Monthly:

Check electrical connections at pump seal, heater, etc.
Check pump drive V-belt for wear.
Check reservoir tank vent for obstructions.

Quarterly:

Check pump heat transfer fluid for degradation.
Perform routine check of the PID control loop and operation.

Every Six Months:

Inspect electrical connections for secure, tight connections and proper connections.
Inspect the power supply entrance point to the electrical enclosure.
Check the pump mounting bolts on the pump, the motor, and the heater flange for tightness.
Inspect the heat exchanger tube bundle and check it for lime and mineral deposits. Clean the bundle as needed.

Preventative Maintenance:

Routine Servicing: Keep surfaces clean and free of any excessive accumulations of dirt, oil, or debris. Check the air intake screen for any accumulation of dirt; clean as needed.
Servicing the Unit Monthly or Every 500 Hours: Lubricate the pump at the grease fittings with a high-quality lithium grease rated at 400°F (204°C) or higher. Adjust the pump drive belt tension. Inspect the screen in the Y strainer for accumulations of debris.
Servicing the Unit Every Three Months: Remove and clean the screen in the Y-strainer. Replace the screen if it is damaged.
Draining the Unit for Storage: Thoroughly flush and drain the Upright unit if you need to take it out of service for a long time, or if you expect it to become exposed to freezing temperatures.
Preventative Pump Maintenance: Extend the life of your pump and reduce the cost per gallon pumped by performing a few preventative maintenance procedures. Lubricate the pump using #2 ball bearing grease and a hand-operated grease gun.

Corrective Maintenance:

Pumps and Seals: The Upright unit is completely tested and calibrated before leaving the factory. If the unit stands idle for a long time before being installed in your factory, gaskets can dry out and possibly leak when you start the unit.
Pump Assembly: Detailed instructions are provided for disassembling and reassembling the pump, including steps for removing the idler pin, thrust bearing assembly, and seals.
Thrust Bearing Adjustment: Instructions are provided for adjusting the thrust bearing assembly to ensure proper operation and prevent damage.
Installation of Carbon Graphite Bushings: Detailed steps for installing carbon graphite bushings, which are critical for pump operation.

Troubleshooting tables are provided to diagnose common problems such as temperature fluctuations, units not heating or achieving set point, and rapid pressure drops. These tables list possible causes and corrective actions.