ACS TC 120 Guide

TC 120 682.98767.00 • 8/22/2018 1
TC 120 Water Temperature Control Units
Part Number:
682.98767.00
Revision: 10/04/18
OPERATION AND INSTRUCTION MANUAL
TC 120

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Write Down Your Serial Numbers Here For Future Reference:
_________________________ _________________________
_________________________ _________________________
_________________________ _________________________
We are committed to product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without
notice.
DCN No. ____________
© Copyright 2018 All rights reserved.

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Shipping Info
Unpacking and Inspection
You should inspect your equipment for possible shipping damage.
Thoroughly check the equipment for any damage that might have occurred in transit, such as
broken or loose wiring and components, loose hardware and mounting screws, etc.
In the Event of Shipping Damage
According to the contract terms and conditions of the Carrier, the responsibility of the
Shipper ends at the time and place of shipment.
Notify the transportation company’s local agent if you discover damage.
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization.
File a claim with the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.
Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.
If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. You should have:
 Machine
 Bill of lading
 Packing list
 Operating and Installation packet
 Electrical schematic and panel layout drawings
 Component instruction manuals
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.
If the Shipment is Not Correct
If the shipment is not what you ordered, please contact customer service at 262.641.8600.
Have the order number and item number ready. Hold the items until you receive shipping
instructions.
Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.

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Table of Contents
CHAPTER 1: SAFETY ................................................................ 7
1-1 How to Use This Manual ............................................................................................ 7
Safety Symbols Used in this Manual ................................................................... 7
1-2 General Safety Regulations ....................................................................................... 8
1-3 Responsibility ............................................................................................................ 8
1-4 Warnings and Precautions ....................................................................................... 11
CHAPTER 2: FUNCTIONAL DESCRIPTION ........................... 14
2-1 Introduction .............................................................................................................. 14
2-2 Necessary Documents ............................................................................................. 14
2-3 Models Covered ...................................................................................................... 15
2-4 Standard TCU Series Features ................................................................................ 15
2-5 Available Options ..................................................................................................... 16
CHAPTER 3: INSTALLATION .................................................. 18
3-1 Installation Location Considerations ........................................................................ 18
3-2 Process Approach Temperature Considerations ...................................................... 18
3-3 External Piping Sizing Considerations ..................................................................... 18
3-4 Piping Considerations for Permanent Installations ................................................... 18
3-5 Piping Considerations for High Mobility Installations ................................................ 19
3-6 Process Water Considerations................................................................................. 19
Raw Water .........................................................................................................19
Distilled Water ....................................................................................................20
Deionized Water ................................................................................................20
3-7 Making Process Water Connections ........................................................................ 20
Closed Circuit/Direct Injection ............................................................................20
TO PROCESS — 1½” NPT ................................................................................20
FROM PROCESS — 1½” NPT ..........................................................................20
3-8 Making Cooling Water Connections ......................................................................... 20
Water In — ¾” ...................................................................................................20
Water Out ..........................................................................................................21
Pressure Relief — ¾” .........................................................................................21
3-9 Making System Purge Connections ......................................................................... 21
3-10 Making Electrical Connections ................................................................................. 22
CHAPTER 4: IDENTIFYING CONTROLS AND FEATURES ... 24
4-1 Identifying Mechanical Controls and Features ......................................................... 24
To Process Probe ..............................................................................................24
Safety Thermostat ..............................................................................................24
Pressure Relief Valve ........................................................................................24
Pumps ...............................................................................................................24
Heaters ..............................................................................................................25
Solenoid Valves .................................................................................................25
Motorized Modulating Valves .............................................................................25
Water Hammer Arrestor (Shock Stop) ................................................................25

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Pump Starter ......................................................................................................25
Transformer .......................................................................................................25
Heater Contactor................................................................................................25
Cooling ..............................................................................................................25
Electricals ..........................................................................................................26
Automatic Vent ..................................................................................................26
Pressure Switch .................................................................................................26
4-2 The Microprocessor Controller ................................................................................. 26
Controller Display ...............................................................................................27
Digital Flow Meter ..............................................................................................28
4-3 Identifying Graphic Panel Indicators (Eurotherm only) ............................................. 28
POWER ON Indicator ........................................................................................28
PUMP OVERLOAD Indicator .............................................................................28
HEATER ON Indicator .......................................................................................29
OVER TEMPERATURE Indicator ......................................................................29
COOLING VALVE ON Indicator .........................................................................29
LOW WATER PRESSURE Indicator ..................................................................29
VENT CYCLE Indicator ......................................................................................29
PURGE VALVE ON Indicator .............................................................................29
Units with Optional System Purge ......................................................................29
4-4 Using Graphic Panel Buttons ................................................................................... 30
START Button ....................................................................................................30
STOP Button ......................................................................................................30
VENT Button ......................................................................................................30
QUICK COOL Switch .........................................................................................30
ALARM SILENCE Button ...................................................................................30
AIR PURGE Switch ............................................................................................30
LOCAL/REMOTE Switch ...................................................................................30
4-5 Alarms ..................................................................................................................... 30
Audible/Visual General Fault Alarm ...................................................................30
4-6 Controller Internal Switches ..................................................................................... 31
CHAPTER 5: STARTUP AND OPERATION ............................ 32
5-1 Introduction .............................................................................................................. 32
5-2 Startup Checklist ..................................................................................................... 32
5-3 Starting the Temperature Control Unit ..................................................................... 33
5-4 Sequence of Operation ............................................................................................ 34
5-5 Checking Motor Rotation Direction .......................................................................... 34
5-6 Shutting Down the Temperature Control Unit ........................................................... 35
CHAPTER 6: UNIT MAINTENANCE ........................................ 36
6-1 Preventative Maintenance ....................................................................................... 36
Draining .............................................................................................................36
Every Six Months ...............................................................................................36
6-2 Corrective Maintenance ........................................................................................... 37
Pumps and Seals ...............................................................................................37
Heaters ..............................................................................................................38
Solenoid Valves .................................................................................................38
6-3 Electrical Connections ............................................................................................. 38
6-4 Safety Devices ......................................................................................................... 39

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Motor Overload ..................................................................................................39
Pressure Switch .................................................................................................39
Safety Thermostat ..............................................................................................39
6-5 Cleaning and Storage .............................................................................................. 39
CHAPTER 7: TROUBLESHOOTING ........................................ 40
7-1 Introduction .............................................................................................................. 40
CHAPTER 8: APPENDIX .......................................................... 43
8-1 Customer Satisfaction Warranty Program ................................................................ 43
8-2 Technical Specifications .......................................................................................... 44
8-3 Drawings and Diagrams........................................................................................... 44
8-4 Spare Parts List ....................................................................................................... 47
8-5 Technical Assistance ............................................................................................... 48

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Chapter 1: Safety
1-1 How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining your
machine. The purpose is to assist you in applying efficient, proven techniques that enhance
equipment productivity.
This manual covers only light corrective maintenance. No other maintenance should be
undertaken without first contacting a service engineer.
The Functional Description section outlines models covered, standard features, and safety
features. Additional sections within the manual provide instructions for installation, pre-
operational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the machine. We can also provide the assistance of a factory-trained technician to help
train your operator(s) for a nominal charge. This section includes instructions, checks, and
adjustments that should be followed before commencing with operation of the machine.
These instructions are intended to supplement standard shop procedures performed at shift,
daily, and weekly intervals.
The Operation chapter includes a description of electrical and mechanical controls, in
addition to information for operating the machine safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and
disassembly instructions for those areas of the equipment requiring service. Preventive
maintenance sections are included to ensure that your machine provides excellent, long
service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, parts lists, and
available options. A spare parts list with part numbers specific to your machine is provided
with your shipping paperwork package. Refer to this section for a listing of spare parts for
purchase. Have your serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER! DANGER indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury.
WARNING! WARNING indicates a potentially hazardous situation or practice that, if
not avoided, could result in death or serious injury.
Caution! CAUTION indicates a potentially hazardous situation or practice that, if
not avoided, may result in minor or moderate injury or in property damage.

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1-2 General Safety Regulations
These regulations should be read, understood and periodically reviewed by all personnel
involved in any way with this machine.
Never operate or remove any machine components that are secured by mechanical fasteners
unless the motor is electrically locked out and all moving parts are motionless.
Do not circumvent the safety interlocks.
Extreme care should be taken to see that all bolts are properly tightened at all times during the
operation of the machine.
Proper PPE (personal protective equipment) should always be used with the equipment in
compliance with Osha 1910 and NEC70, arc flash hazard.
1-3 Responsibility
These machines are constructed for maximum operator safety when used under standard
operating conditions and when recommended instructions are followed in the maintenance
and operation of the machine.
All personnel engaged in the use of the machine should become familiar with its operation as
described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.
Become familiar with materials, inspection, speed limitations, guard maintenance, and total
user responsibility while using or servicing the equipment.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All caution, warning and danger signs must be observed and obeyed. Any actual or potential
dangerous conditions must be reported to your immediate supervisor.
General Responsibility
No matter who you are, safety is important. Owners, operators and maintenance
personnel must realize that every day, safety is a vital part of their jobs.
If your main concern is loss of productivity, remember that production is always
affected in a negative way following an accident. The following are some of the ways
that accidents can affect your production:
 Loss of a skilled operator (temporarily or permanently)
 Breakdown of shop morale
 Costly damage to equipment
 Downtime
An effective safety program is responsible and economically sound.
Organize a safety committee or group, and hold regular meetings. Promote this group
from the management level. Through this group, the safety program can be
continually reviewed, maintained, and improved. Keep minutes or a record of the
meetings.

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Hold daily equipment inspections in addition to regular maintenance checks. You will
keep your equipment safe for production and exhibit your commitment to safety.
Please read and use this manual as a guide to equipment safety. This manual contains
safety warnings throughout, specific to each function and point of operation.
Operator Responsibility
The operator’s responsibility does not end with efficient production. The operator
usually has the most daily contact with the equipment and intimately knows its
capabilities and limitations.
Plant and personnel safety is sometimes forgotten in the desire to meet incentive
rates, or through a casual attitude toward machinery formed over a period of months
or years. Your employer probably has established a set of safety rules in your
workplace. Those rules, this manual, or any other safety information will not keep
you from being injured while operating your equipment.
Learn and always use safe operation. Cooperate with co-workers to promote safe
practices. Immediately report any potentially dangerous situation to your supervisor.
 NEVER place your hands or any part of your body in any dangerous location.
 NEVER operate, service, or adjust the temperature control unit without appropriate
training and first reading and understanding this manual.
 NEVER try to pull material out of the temperature control unit with your hands while
it is running!
 Before you start the temperature control unit, check the following:
 Remove all tools from the temperature control unit;
 Be sure no objects (tools, nuts, bolts, clamps, bar) are laying
in the area;
 If your temperature control unit has been inoperative or unattended, check all settings
before starting.
 At the beginning of your shift and after breaks, verify that the controls and other
auxiliary equipment are functioning properly.
 Keep all safety guards in place and in good repair. NEVER attempt to bypass, modify,
or remove safety guards. Such alteration is not only unsafe, but will void the warranty
on your equipment.
 When changing control settings to perform a different mode of operation, be sure
selector switches are correctly positioned. Locking selector switches should only be
adjusted by authorized personnel and the keys removed after setting.
 Report the following occurrences IMMEDIATELY:
 unsafe operation or condition
 unusual temperature control unit action
 leakage
 improper maintenance
 NEVER stand or sit where you could slip or stumble into the
temperature control unit while working on it.
 DO NOT wear loose clothing or jewelry, which can be caught while working on the
temperature control unit. In addition, cover or tie back long hair.
 Clean the temperature control unit and surrounding area DAILY, and inspect the
machine for loose, missing or broken parts.

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 Shut off power to the temperature control unit when it is not in use. Turn the switch to
the OFF position, or unplug it from the power source.
Maintenance Responsibility
Proper maintenance is essential to safety. If you are a maintenance worker, you must
make safety a priority to effectively repair and maintain equipment.
Before removing, adjusting, or replacing parts on a machine, remember to turn off all
electric supplies and all accessory equipment at the machine, and disconnect and
lockout electrical and pneumatic power. Attach warning tags to the disconnect switch
and air shutoff valve.
When you need to perform maintenance or repair work on a temperature control unit
above floor level, use a solid platform or a hydraulic elevator. If there is a
permanently installed catwalk on your temperature control unit, use it. The work
platform should have secure footing and a place for tools and parts. DO NOT climb
on the temperature control unit, machines, or work from ladders.
If you need to repair a large component, use appropriate handling equipment. Before
you use handling equipment (portable “A” frames, electric boom trucks, fork trucks,
overhead cranes) be sure the load does not exceed the capacity of the handling
equipment or cause it to become unstable.
Carefully test the condition of lifting cables, chains, ropes, slings, and hooks before
using them to lift a load.
Be sure that all non-current carrying parts are correctly connected to earth ground
with an electrical conductor that complies with current codes. Install in accordance
with national and local codes.
When you have completed the repair or maintenance procedure, check your work and
remove your tools, rigging, and handling equipment.
Do not restore power to the temperature control unit until all persons are clear of the
area. DO NOT start and run the temperature control unit until you are sure all parts
are functioning correctly.
BEFORE you turn the temperature control unit over to the operator for production,
verify all enclosure panels, guards and safety devices are in place and functioning
properly.