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

TC 120 682.98767.00 • 10/04/2018 ii
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.

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Reporting a Safety Defect
If you believe that your equipment has a defect that could cause injury, you should
immediately discontinue its use and inform the manufacturer.
The principle factors that can result in injury are failure to follow proper operating
procedures (i.e. lockout/tagout), or failure to maintain a clean and safe working
environment.
Figure 1: Safety Tags and Warning Labels
Hazard Alert Symbol Description/Explanation Preventative Maintenance
High Voltage Hazard. The electrical
enclosure is supplied with 3-phase
electrical power. Use caution when
using or maintaining this product.
Every six months inspect all
electrical connections for secure
attachment. For further information
see the Maintenance Chapter in this
manual
Hot Surface Hazard. When the unit
operates above 212F (100C) the
surface of the unit may reach excessive
temperatures. Use caution when using
or maintaining this product.
Every six months inspect all surfaces
for signs of heat degradation. If any
appear remove panel and verify
cause of degradation and repair.
Mandatory Symbol Description/Explanation
Read Operators Manual. This equipment must be operated and maintained by
properly trained personnel. The information contained within this manual
must be read and understood prior to operating this equipment.
Lock Out. This equipment is operated with 3-phase electrical power.
Therefore, when performing any maintenance operations we recommend
following the local standards for performing a lock-out/tag-out procedure.
Wear Safety Gloves. This equipment operates above 212F (100C) and its
surfaces may reach excessive temperatures. We recommend that technicians
use safety gloves while performing maintenance to protect hands from being
exposed to these hot surfaces.
Disconnect before opening. Before servicing or maintaining the machine be
sure to disconnect the power and/or compressed air source to avoid electrical
shock and/or serious injury.
1-4 Warnings and Precautions
Our machines are designed to provide safe and reliable operation when installed and operated
within design specifications, and follow national and local safety codes.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this machine, use good judgment and follow these safe practices:
 Read and follow these operation and installation instructions when installing,
operating, and maintaining this equipment. If these instructions become
damaged or unreadable, additional copies are available from the manufacturer.

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 LEARN AND OBEY your company’s safety policy regarding mechanical and
electrical equipment.
 MOVING OR LIFTING THE MACHINE: Although our equipment is built and
engineered for great ruggedness in operation, care must be taken when moving the
machine along the floor or lifting it. Damage may occur to sheet metal covers,
electrical cabinets, or small brackets if pressure is applied to them when moving the
machine. When lifting the machine, be certain of total machine weight does not
exceed the capability of the lifting equipment.
 EQUIPMENT LOCATION: Adequate area for routine maintenance should be
provided in order to open the machine for service. Proper service area clearances also
should allow people who are working on the machine to be clearly visible to others,
thereby reducing the potential safety hazards.
 SAFE HOUSEKEEPING: The work area must be kept clean and uncluttered during
periods of operation or maintenance. No hand tools or other metal objects should be
left on or around the machine.
 SAFETY GLASSES OR A FACE SHIELD MUST ALWAYS BE WORN
when servicing or operating the machine.
 NEVER attempt to operate the machine unless it is fully assembled with all guards
and interlocks in place and functional.
 OBSERVE all danger, warning, caution and safety labels on the equipment.
 Upon completion of any machine maintenance, be certain ALL SAFETY GUARDS
AND COVERS are securely and properly fastened prior to resuming machine
operation. All fasteners must be in place and properly tightened. ANY
SHORTCUTS MAY RESULT IN INJURY TO PERSONNEL OR DAMAGE
TO EQUIPMENT.
 NEVER wear any loose fitting clothes, neckties, or dangling items such as earrings,
belts, or shoestrings. Jewelry, such as wristwatches, bracelets, or rings should
NEVER be worn. Long hair must be tied back or placed in a tight fitting hairnet.
NEVER lean against or rest hands or feet on the equipment when it is in operation or
open for maintenance. NEVER stand on the machine when it is in operation.
 ROTATION OF MOTORS: The correct rotating direction for the machine motor is
clearly marked on the machine. Always check for proper rotation of motors. Incorrect
rotation direction can cause severe damage.
 ELECTRICAL GROUNDING: All electrical equipment on the machine must be
grounded in accordance to all local codes and Article 250 of the National Electric
Code.
 ALWAYS DISCONNECT AND LOCKOUT the main electrical power to the
machine before performing any service.
 SAFETY INTERLOCKS MUST NOT BE BYPASSED. The mechanical and
electrical safety interlocks ensure the safety of personnel. They should never be
tampered with or removed for ANY reason. They should be checked frequently by a
qualified mechanic for proper operation.
 NEVER modify the machine configuration or any individual component without
written notice from the factory.

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We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide
by the foregoing recommendations in order to make operator safety a reality.

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Chapter 2: Functional Description
2-1 Introduction
The TC 120 water temperature control units are reliable, accurate, and easy-to-use process
temperature control units. They are self-contained, portable, and shipped ready to use.
The TC 120 water temperature control units are designed to circulate water through your
process and to precisely, automatically, and reliably maintain it at a specified temperature.
Standard unit operating range is from 0ºF (-17ºC) to 250°F (121°C), or up to 300°F (149°C)
as an option. The unit is suited for use with city water, water from portable or central chillers
or towers, or well water.
These units are designed for rapid recirculation of a relatively small amount of water to
provide close and uniform temperature relation between delivery and return lines. This
performance, of course, depends on the configuration of your process and any restrictions
within the mold. The recirculation, combined with the large immersion heater and cooling
capability, gives fast and accurate response to bring the water up to temperature or to changes
in the settings when needed.
The water temperature control unit is a self-contained system consisting of a centrifugal
pump, electric immersion heater, cool/vent solenoid valve, and electrical control, including a
PID microprocessor controller and thermocouple. It is designed for use in process
temperature control applications using water or a water/glycol mix. Any other use or fluid is
prohibited.
Some standard safety devices include a mechanical over-temperature safety thermostat, a
pressure relief valve, motor overload protection, a low pressure cutout switch, branch fusing,
and non-fused lockable rotary disconnect.
A properly installed, operated, and maintained water temperature control system provides
years of reliable operation. Please read and follow the instructions in this manual to get the
most satisfaction from your temperature control system.
2-2 Necessary Documents
The following documents are necessary for the operation, installation, and maintenance of a
TC 120 water temperature control unit. Additional copies are available from ACS Group.
Familiarize the appropriate personnel with these documents:
 This manual.
 The controller operation manual.
 The electrical schematic and connection diagram placed inside the
control enclosure.
 The operation and installation manuals for accessories and options
selected by the customer.
 The Customer Parts List included in the information packet.

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2-3 Models Covered
This manual provides operation, installation, and maintenance instructions for the
TrueTemp™ TC 120 and Sterlco® TC 120 series water temperature control units.
Model numbers are listed on the serial tag. A model number followed by Q indicates a
specially constructed unit, and not all information in this manual may apply. Make sure that
you know the model number, serial number, and operating voltage of your temperature
control unit if you contact the ACS Group.
2-4 Standard TCU Series Features
 Compact, rugged cabinet with easy-access side panels
 Cast-and-flange design to reduce connection points
 Half- and full-heat capability (M2C only)
 Over Current Protection for motor and transformer
 Dual circuit Incoloy™ immersion heater with IEC contactors
 NEMA 12 electrical enclosure
 Forward-facing liquid-filled To and From Process pressure
gauges
 Independent high temperature safety thermostat
 Off-the-shelf microprocessor-based PID temperature
controller with Process and Set Point LED readouts
 ¼” cooling solenoid valve on ¾ to 3 hp (0.56 to 2.24 kW)
models; ½” cooling solenoid valve on 5 & 7½ hp (3.73 &
5.60 kW) models
 Graphic control panel with indicator and warning status
lights
 Adjustable low supply water pressure switch; factory-set at
16 psig (110 kPa/1.1 bar)
 150 psig (1,034 kPa/10.3 bar) pressure relief valve
 Choice of 208 V-575 V operating voltages
 ¾” NPT water supply connection; 1½” NPT process
connections
 Automatic vent sequence
 3” (51 mm) casters
 Operating range of 0ºF to 250ºF (-17ºC to 121ºC)
 PID Auto-tuning temperature controller
 Quick Cool function

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2-5 Available Options
Temperature control unit systems are available with options to tailor the unit to your
requirements. Some are factory installed; some can be retro-fitted in the field. Consult
ACS Group sales for more information. Available TCU options include:
Digital flow meter with:
 Up to 30 gpm (114 lpm) flow indicator
- or -
 30 to 60 gpm (114 to 227 lpm) flow indicator
- or -
 Greater than 60 gpm (> 227 lpm) flow indicator
1/16 DIN PID Temperature controller with:
 4-20 mA current control output
 Retransmission and remote set point; 4-20 mA, 2-10 V
 RS-232 or RS-485 communications (Modbus, SPI,
Ethernet)
 Remote sensor; 10 ft. (3 m)
 Remote controller enclosure
 Heaters available in 12 kW, 18 kW, and 24 kW; 18 kW and
24 kW heaters available on 5 hp and 7½ hp (3.73 kW, 5.60
kW) direct-injection models only
 3.7 sq. ft. closed-loop heat exchanger
 Auto system water purge (mold purge)
 Y-strainer
 Hammer arrestor (water hammer shock stop)
 Remote start/stop control
 Rubber feet; available in lieu of casters
 Non-ferrous brass construction
 Slow-close cooling solenoid valves available in 1/2” x 9/16” (CV
= 3.5) and 3/4” x 3/4” (CV = 5.5)
 Modulating valves available in 1/2” (CV = 0.4, 1.3, 2.2, or
4.4), 3/4” (CV = 5.5 or 7.5), 1” (CV = 11), and 11/4” (CV = 16)
 Two-zone stack rack with casters; common wiring and piping
available
 300ºF (149ºC) operation; includes silicon carbide seal

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 Audible and visual general fault alarm
 Electrical operation available in 208, 460, and 575 volts, 60
Hz; 380, and 415 volts, 50 Hz
 UL/CUL-listed electrical subpanel, CE Compliance per EMC
Low Voltage Directive

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Chapter 3: Installation
3-1 Installation Location Considerations
The TC 120 Temperature control systems are portable and can be installed almost anywhere.
As with all equipment installations, follow all applicable codes and regulations.
 The recommended ambient temperature range from +14ºF (-10ºC) to
a maximum operating ambient temperature of 131F (55ºC).
Recommended ambient storage temperature range is from -13ºF to
149ºF (-25ºC to 65ºC). If storing the unit below freezing
temperatures, make sure the unit has an antifreeze mixture circulated
inside.
 Provide a minimum of twelve inches (12” or about 30 cm) clearance
on all side of the cabinet to allow circulation of cooling air.
 Locate the unit as close to the process as is practical.
3-2 Process Approach Temperature Considerations
If the differential (Δ) between COOLING WATER IN and TO PROCESS temperatures is
less than 10°F (7ºC), consult our Sales Department for advice on how to control low
approach applications.
3-3 External Piping Sizing Considerations
 All external hose and piping should be adequately sized to assure minimum external
pressure drop.
 Low external piping pressure drop is needed for best operation.
Use a backup wrench to support the TC 120 temperature control system piping
when making process piping connections.

All external valves, fittings, and hoses must be rated at a minimum of
150 psig and 250ºF (1,030 kPa/10.3 bar and 121ºC).
The exception is when the temperature control unit
is optionally rated for 300ºF (149ºC) operation;
external valves fittings and hoses must then be rated at a minimum of
150 psig and 300ºF (1,030 kPa/10.3 bar and 121ºC).
3-4 Piping Considerations for Permanent Installations
ACS recommends an optional (or customer-installed) strainer on the COOLING WATER IN
inlet.

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The unit must have at least 16 psig (110 kPa/1.1 bar) water supply pressure to prevent pump
cavitation that can be caused by the water “flashing” to steam. To avoid damage to the pump
or other components, make sure that maximum supply pressure does not exceed 55 psig (379
kPa/3.8 bar).
Keep restrictions to a minimum by using proper inlet pipe sizing. If the water supply piping is
larger than ¾”, reduce the size at the unit. The table below contains the pipe sizes that are
used in the unit.
Pipe sizes for ¾ hp to 10 hp (0.56 kW to 7.46 kW) units
Location Size in inches NPT
Process delivery 1½”
Process return 1½”
Water supply ¾”
Drain - depends on solenoid used -
Common black pipe is recommended for permanent installations. The temperature control
unit water circuit piping is primarily ferrous (iron) and reacts electro-chemically with non-
ferrous metallic materials such as copper. Some water contains dissolved minerals that
greatly accelerates the reaction between dissimilar metals. Ferrous piping is recommended to
minimize galvanic action. If piping must be copper, use dielectric unions at the unit.
3-5 Piping Considerations for High Mobility Installations
Mobile temperature control systems must use high quality hose rated for at least 150 psig and
250F (1,030 kPa/10.3 bar and 121ºC). Special 300F (149ºC) high temperature control
systems must use hosing rated at 150 psig and 300F (1,030 kPa/10.3 bar and 149ºC) or
greater.
Quick disconnects may be used for mobility, although they cause a drop in pressure. If
used, they must be sized carefully to minimize pressure drop. Don’t use quick disconnects
with check valves unless absolutely necessary.
Non-relieving quick connect fittings or check valves on the water supply
must have a pressure relief piped to the drain.
Failure to do so could result in a dangerous over-pressure condition!
3-6 Process Water Considerations
Raw Water
Water treatment is vital in any piping system. In some cases, raw water may be used in the
system without problems; in other cases, it can result in large deposits of scale and corrosion.

TC 120 682.98767.00 • 10/04/2018 20
ACS offers a complete line of water treatment equipment. Contact your ACS sales
representative for water testing and treatment options.
Distilled Water
Non-ferrous (brass, copper or high-temperature plastic) piping is recommended for distilled
water processes.
Deionized Water
Stainless steel (316 SS minimum) or PVC plastic components must be used with deionized
water. Stainless steel is recommended because of the temperature constraints with plastic.
3-7 Making Process Water Connections
Closed Circuit/Direct Injection
For both types of systems, the connections are basically the same. On the back of each unit,
the connections are labeled appropriately. Connect the DELIVERY hookup to the entrance of
the process and the RETURN hookup to the exit of the process. Connect the WATER
SUPPLY to your plant water supply. Connect the DRAIN line to an open drain, or to the
return line of your central water system.
Make sure you carefully select the connecting lines and connectors between the
temperature control unit and the process to suit the needs and requirements of your
application.
If your unit has a maximum operating temperature of 250ºF (121ºC), the connecting
lines and connectors should have a service rating of at least 250ºF (121ºC) and 150 psig
(1,030 kPa/10.3 bar). If it has a maximum temperature of 300ºF (149ºC), the lines and
connectors should have a service rating of at least 300ºF (149ºC) and 150 psig (1,030
kPa/10.3 bar).
TO PROCESS — 1½” NPT
This is the outlet for the tempered water leading to the process being controlled.
FROM PROCESS — 1½” NPT
Water from the process re-enters the water temperature control system to be tempered and re-
circulated back into the process.
3-8 Making Cooling Water Connections
Water In — ¾”
The cooling water supply inlet from a cooling tower, a chiller, or a city water supply.