ACS TCO-U User manual

Upright Hot Oil
Temperature Control Units
Models Covered:
TCO-U; 2016U
Part Number: 882.12044.00
Bulletin Number: WTR2-640
Effective: August 1, 2012

WTR1-640 ii
Write Down Your Serial Numbers Here For Future Reference:
_________________________ _________________________
_________________________ _________________________
_________________________ _________________________
We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.
DCN No. ____________
© Copyright 2012
All rights reserved.

WTR1-640 iii
Shipping Info
Unpacking and Inspection
You should inspect your granulator 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:
!Portable Hot Oil TCU
!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, contact the shipping department immediately. For
immediate assistance, please contact the correct facility located in the technical assistance
section of this manual. Have the order number and item number available. Hold the items
until you receive shipping instructions.

WTR1-640 iv
Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.
Credit Returns
Prior to the return of any material, authorization must be given by the manufacturer. A
RMA number will be assigned for the equipment to be returned.
Reason for requesting the return must be given.
ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00
minimum) restocking charge.
ALL returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
No credit will be issued for material that is not within the manufacturer’s warranty period
and/or in new and unused condition, suitable for resale.
Warranty Returns
Prior to the return of any material, authorization must be given by the manufacturer. A
RMA number will be assigned for the equipment to be returned.
Reason for requesting the return must be given.
All returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
After inspecting the material, a replacement or credit will be given at the manufacturer’s
discretion. If the item is found to be defective in materials or workmanship, and it was
manufactured by our company, purchased components are covered under their specific
warranty terms.

WTR1-640 v
Table of Contents
CHAPTER 1:!SAFETY................................................................ 5!
1-1!How to Use This Manual .............................................................................................. 5!
Safety Symbols Used in this Manual..................................................................... 5!
1-2!General Safety Regulations.......................................................................................... 7!
1-3!Responsibility ............................................................................................................... 7!
1-4!Warnings and Precautions ........................................................................................... 8!
CHAPTER 2:!FUNCTIONAL DESCRIPTION............................. 9!
2-1!Models Covered in This Manual ................................................................................... 9!
2-2!General Description...................................................................................................... 9
2-3!Typical Features and Components............................................................................... 9
Mechanical Features……………………………………………………………………9
Electrical Features……………………………………………………………………..10
Options……………………..…………………………………………………………...10
2-4 Feature Descriptions………………………………………………………..……………..10
Immersion Heaters…………………………………………………………………….10
Heater Tank…………………………………………………………………………….10
Pump……………………………………………………………………………………11
Ful-Flo Valve…………………………………………………………………………...11
Connection Lines………………………………………………………………………11
Electrical System Control……………………………………………………………..11
Electrical Panel and System Components………………………………………….12
Air Purge………………………………………………………………………………..12
Pressure Switch………………………………………………………………………..12
Safety Thermostat……………………………………………………………………..12
Reservoir Tank…………………………………………………………………………13
Cooling (Optional)……………………………………………………………………..13
2-5!Safety Devices and Interlocks……………………………………………………………..13
Safety Circuit Standards………………………………………………………………13
Fail Safe Operation…………………………………..………………………………...14
Safety Device Lock-Outs……………………………………………………………...14
CHAPTER 3:!INSTALLATION ................................................. 15!
3-1!Uncrating the Equipment…………………………………………………………………...15!
3-2!Rigging and Placing the TCU………………………………………………………………15
Installation Location Considerations…………………………………………………15
3#3! Electrical Connections ................................................................................................ 16!
3-4 Setup Procedures…………………………………………………………………………...16
Connecting Piping……………………………………………………………………..16
Connecting Process Piping…………………………………………………………...17
3-5!Initial Start-up ............................................................................................................. 19
Starting the Hot Oil TCU………………………………………………………………19
CHAPTER 4:!OPERATION ...................................................... 21!
4-1!Start-up....................................................................................................................... 21!

WTR1-640 vi
4-2!Controller Description & Operation............................................................................. 21
Identifying Control Panel Switches…………………………………………………..21
Identifying System Status Board Indicators…………………………………………22
Status Indicator Lights………………………………………………………………...23
Mode Indicator Lights……………………………………........................................24
Fault Indicator Lights…………………………………………………………………..24
4-3!Returning Fluid to the Tank………………………………………………………………...25
4#4! Shutting Down the Hot Oil TCU.................................................................................. 26!
CHAPTER 5:!MAINTENANCE ................................................. 27!
5-1!Maintenance Schedule ............................................................................................... 27!
5-2!Preventative Maintenance .......................................................................................... 28
Routine Servicing………………………………………………………………………28
Draining the Unit for Storage…………………………………………………………28
Preventative Pump Maintenance…………………………………………………….28
5-3!Corrective Maintenance.............................................................................................. 29
Pumps and Seals………………………………………………………………………29
Maintaining the Pump…………………………………………………………………30
Thrust Bearing Adjustment……………………………………………………………32
Installation of Carbon Graphite Bushings…………………………………………...32
CHAPTER 6:!TROUBLESHOOTING ..................................... 333!
6-1!Introduction............................................................................................................... 333!
CHAPTER 7:!APPENDIX ....................................................... 346!
7-1!Returned Material Policy……………………………………………………………………36!
7-2!Technical Specifications ............................................. Error! Bookmark not defined.7!
7-3!Drawings and Diagrams ............................................................................................. 39!
7-4!Spare Parts List .......................................................................................................... 42!
7-5!Technical Assistance.................................................................................................. 45!
Parts Department ................................................................................................ 45!
Service Department ............................................................................................ 45!
Sales Department ............................................................................................... 45!
Contract Department........................................................................................... 45!

WTR2-640 Chapter 1: Safety 7 of 46
Chapter 1: Safety
1-1 How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining your
granulator. 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 upright hot oil unit. 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 granulator.
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 granulator 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 granulator 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 indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury.
WARNING indicates a potentially hazardous situation or practice that, if
not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation or practice that, if
not avoided, may result in minor or moderate injury or in property damage.

WTR2-640 Chapter 1: Safety 8 of 46
Safety Tags and warning features
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.
Pinch Point/Entanglement. The pump and
motor are linked using v-groove belts. Use
caution when using or maintaining this
product.
Every month inspect the belt(s) for any
type of wear. For further information
see the Maintenance Chapter in this
manual.
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.
1-2
.

WTR2-640 Chapter 1: Safety 9 of 46
1-2 Warnings and Precautions
Our units are designed to provide safe and reliable operation when installed and operated
within design specifications, following national and local safety codes.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this unit, use good judgment and follow these safe practices:
!Follow all SAFETY CODES.
!Wear SAFETY GLASSES and WORK GLOVES.
!Disconnect and/or lock out power before servicing or maintaining the hot oil
temperature control unit.
!Use care when LOADING, UNLOADING, RIGGING, or
!MOVING this equipment.
!Operate this equipment within design specifications.
!OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.
You should remove the fuses and carry them with you.
!Make sure the hot oil temperature control unit and components are properly
GROUNDED before you switch on power.
!Do not jump or bypass any electrical safety control.
!Do not restore power until you remove all tools, test equipment, etc., and the hot oil
temperature control unit and related equipment are fully reassembled.
!Only PROPERLY TRAINED personnel familiar with the information in this
manual should work on this equipment.
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.

WTR2-640 Chapter 2: Functional Description 10 of 46
Chapter 2: Functional Description
2-1 Models Covered in This Manual
This manual provides operation, installation, and maintenance instructions for portable hot oil
temperature control units. Model numbers are listed on the serial tag. Make sure you know the
model and serial number of your equipment before contacting the manufacturer for parts or
service.
Your portable hot oil temperature unit circulates thermal transfer-type oil through your process
and precisely, automatically, and reliably maintains it at a temperature you can select. Portable
hot oil temperature control units are sized to meet the specific requirements stated by the
Customer at the time of purchase.
2-2 General Description
The operating range of your temperature control unit is from 100°F to 550°F (38°C to 288°C).
The unit is best suited for use with a specially formulated Heat Transfer Fluid. A recommended
list of commercially available heat transfer fluids can be obtained through Customer Service.
Rapid recirculation of the relatively small amount of fluid provides a close and uniform
temperature relationship between the TO PROCESS and FROM PROCESS lines. This does, of
course, depend on the configuration of your process, and any restrictions within the mold.
This recirculation, combined with the immersion heater and optional cooling capability, gives
fast and accurate response to bring fluid up to temperature or to changes in the settings when
needed.
Performance is assured through matching the unique controllers to the high temperature system.
The two systems are fully integrated to achieve accurate control, along with efficient use of
water and electricity.
2-3 Typical Features and Components
Mechanical Features
•Dual stage immersion heater with IEC contactors
•550°F (288°C) maximum operating temperature {400°F (244°C) maximum operating
temperature for 6kW heaters}
•Manual bypass
•Pressure switch for low pump pressure shut-down
•To Process pressure gauge
•Independent safety thermostat
•Y strainer on From Process line
•Automatic venting sequence
•Positive displacement pumps capable of reversing to evacuate the process
•Easily removable panels for quick access to internal components
•1 year warranty on parts and labor (Labor at factory)

WTR2-640 Chapter 2: Functional Description 11 of 46
Electrical Features
•Non-fused lockable rotary disconnect
•Branch circuit fusing
•NEMA 12 electrical enclosure
•UL listed subpanel
Options
•Drain valve
•Hour meter; measures total pump run time hours
•General fault visual alarm
•Autovent sequence; deducts available
•Low level alarm; deducts available
•High level indicator light
•Manual bypass; deducts available
•M2B+ microprocessor controller options include:
"4-20 mA remote set point and retransmission
"SPI protocol, RS-485
"General protocols, types RS-232, -485
"Remote sensor; 10 Ft. (3m)
"Heat exchanger options of 3.9 sq. ft. (0.3627 sq. m) and 6.7 sq. ft.
(0.6231 sq. m)
"Remote controller
"Lexan cover
"Optional operating voltages of 208/3/60, 575/3/50, and 415/3/50
2-4 Feature Descriptions
Immersion Heaters
The fluid is heated by the specially designed three-phase low watt density electrical immersion
heater, and regulated by the controller. The standard heater has a steel sheath for low watt
density and good heat transfer.
These models 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.
Heater Tank
The Upright features a single pass heater tank. The tank is designed to maintain an optimum
balance of fluid velocity versus watt density, and turbulence for excellent heat transfer, and
minimal pressure drop. The high fluid velocity will greatly prolong the life of the heater and
fluid.

WTR2-640 Chapter 2: Functional Description 12 of 46
Pump
The pump is a mechanical seal, positive displacement pump. It features a nearly maintenance
free design, and was selected after extensive testing to provide superior performance, flexibility,
and low maintenance. It is well suited for use with a variety of commercially available heat
transfer fluids. The pump has only two internal moving parts, and a specially designed seal to
give years of trouble free service, even at high temperatures. The only routine maintenance
required is the monthly greasing and occasional head space adjustment; see Section 5-3 on Page
40 for more information.
The pump is capable of running in either direction. Thus, the pump reverse feature can be used
to draw fluids back from the process. It is not necessary to install a service air line to purge
lines before changing molds. Since the pump is capable of achieving extremely high pressures,
it is necessary to regulate the pressure through use of a regulating bypass line (Ful-Flo valve).
Because the pump is a positive displacement pump, it will supply the process with rated flow at
or below the rated pressure.
The flow is constant until the pressure reaches the rated pressure. The pressure however is a
function of frictional losses through the process that it is attached to. Systems with large
process connections, ports, and piping will operate at low pressures. While systems with small
process connections, ports, and piping will operate at higher pressures. Once pressure
requirements exceed the rated pressure, the Ful-Flow valve will open and bypass the necessary
fluid to prevent high pressures.
Ful-Flo Valve
A regulating bypass line featuring a Ful-Flo valve is standard in all units. This is a safety
device to prevent excessive pressure in the event that the delivery line is obstructed. Each Ful-
Flo valve is factory preset to limit system pressure as specified by the customer. It must not be
tampered with in any way.
In the event of an obstruction in the line, the Ful-Flo valve will open and divert fluid from the
delivery TO PROCESS line to the return FROM PROCESS line. A constant flow of fluid is
maintained through the heater tank to prevent damage to the heating elements and fluid.
Connection Lines
Connections for TO PROCESS and FROM PROCESS lines are 1” NPT (25.4 mm). Water
connections for COOLING WATER SUPPLY and COOLING WATER DRAIN are ¾” NPT
(19.1 mm). The customer is responsible for conversions to metric standards.
The manufacturer stocks many lengths of flexible metal hose; the part number is 572-16969.
State the length of hose you want when ordering.
Component failure may result in high-temperature oil spray, causing serious injury or death.
Make sure hoses, valves, and other components installed in your process can withstand
maximum temperature and pressure of the Upright unit; check unit nameplate for specific
capacities. All components must be carefully inspected for condition before installing. Make
sure factory components if you have any doubt.
Electrical System Controls
The electrical controls of your Upright unit are specially engineered for reliability, safety, and
simplicity of operation. Switch functions are clearly labeled. Your Upright unit has a system
status board so you can evaluate the status and performance of the unit at a glance. Pilot lights
are provided to indicate key unit functions.

WTR2-640 Chapter 2: Functional Description 13 of 46
An audible alarm is standard with your unit. The alarm will sound in the event of the following
conditions:
•Motor overload
•Safety thermostat trip (over temperature)
•Low fluid pressure
•Low fluid level
•High fluid level (optional)
Push the ALARM SILENCE button to silence the alarm. See Section 4-2 on Page ???? for
more information on control functions.
Electrical Panel and System Components
The pump motor and immersion heater operate on three-phase, 50/60 cycle, nominal voltage
with the control circuit at 115 V single phase. The control circuit voltage is provided by a
single phase machine tool transformer with primary fuse protection and a grounded secondary.
A main power disconnect is included for ease of service. The electrical panel is UL listed and
complies with N.F.P.A. 79 provisions.
All components are IEC rated for long life and reduced maintenance. The heater elements are
branch fused, and protected from contactor welding by a separate primary voltage contactor.
The pump motor is controlled by a full voltage magnetic reversing starter, with fused branch
circuit overcurrent and thermal overload protection. Many additional features are available as
options.
A NEMA 12 enclosure is standard, with NEMA 4 available as an option.
Air Purge
Upon initial start-up and mold/process change-out, you’ll need to purge all air and water from
the system. The Upright unit has appropriate valving to ensure complete purging.
Failure to purge the system of air before heating may result in serious injury or critical
system and equipment damage. Make sure you properly purge the system of air before
starting the heater cycle.
Pressure Switch
A pressure switch is built into each unit to guard against heater damage. This feature prevents
the heater elements from being energized unless the pump is running and fluid is in the system.
After a preset time, the pump shuts down if the fluid pressure is not re-established. The
pressure switch is preset at the factory; do not tamper with it.
Safety Thermostat
The safety thermostat is a J-thermocouple sensing, adjustable fail-safe device located in the
heater tank. This is to guard against the unlikely event of “runaway” heating. If over-heating
does occur, the safety thermostat shuts down the heater outputs and sounds an audible alarm. A
red pilot light on the status board also illuminates. The unit continues to pump fluid through the
system to prevent heater damage. Auxiliary factory installed alarms such as beacons and
klaxons are available as options.
All controller functions are locked out until the main supply power is disconnected. Resetting
the alarm condition is initiated by depressing the red pump stop button. The reset button is
located inside the electrical enclosure, mounted on the left wall of the enclosure. It is

WTR2-640 Chapter 2: Functional Description 14 of 46
imperative that a qualified maintenance technician determine and correct the cause of the fault
before resuming operation.
Reservoir Tank
A reservoir tank with sight gauge is standard; usable capacity is seven (7) gallons (26.5 liters).
The tank permits thermal expansion of the heat transfer fluid, and provides makeup fluid.
The reservoir tank may cause serious injury if it ruptures from not being properly vented.
Make sure that the reservoir tank is always properly vented to prevent tank rupture.
The reservoir tank drain is extended beyond the base of the unit for ease of draining. Optional
ball valves are available to further simplify draining.
Cooling (Optional)
The manufacturer-designed shell and tube heat exchanger is provided as optional equipment in
this unit. The design features U-tube construction and copper-nickel tubes for durability and
optimal heat transfer.
The modular construction (unique to our units) allows the tube bundle to be easily removed for
periodic cleaning. Additionally, check valves are installed on the water supply and drain lines
to prevent water from back flowing into the heat exchanger from a closed drain or into the
water supply piping.
The controller automatically regulates cooling by opening and closing the cooling solenoid.
This allows the proper amount of cooling water to pass through the tubes of the heat exchanger
and out the drain. A water supply of 75 psi (517.1 kPA/5.2 bars) maximum is required for
connection to the heat exchanger.
2-5 Safety Devices and Interlocks
This section includes information on safety devices and procedures that are inherent to the
portable hot oil tcu. This manual is not intended to supersede or alter safety standards
established by the user of this equipment. Instead, the material contained in this section is
recommended to supplement these procedures in order to provide a safer working environment.
At the completion of this section, the operator and maintenance personnel will be able to do the
following:
•Identify and locate specific safety devices.
•Understand the proper use of the safety devices provided.
•Describe the function of the safety device.
Safety Circuit Standards
Safety circuits used in industrial systems protect the operator and maintenance personnel from
dangerous energy. They also provide a means of locking out or isolating the energy for
servicing equipment.
Various agencies have contributed to the establishment of safety standards that apply to the
design and manufacture of automated equipment. The Occupational Safety and Health
Administration (OSHA) and Joint Industrial council (JIC) are just a few of the organizations
that have joined with the plastics industry to develop safety standards.
Every effort has been made to incorporate these standards into the design of the portable hot oil
tcu; however, it is the responsibility of the personnel operating and maintaining the equipment
to familiarize themselves with the safety procedures and the proper use of any safety devices.

WTR2-640 Chapter 2: Functional Description 15 of 46
Fail Safe Operation
If a safety device or circuit should fail, the design must be such that the failure causes a “Safe”
condition. As an example, a safety switch must be a normally open switch. The switch must be
held closed with the device it is to protect. If the switch fails, it will go to the open condition,
tripping out the safety circuit.
At no time should the safety device fail and allow the operation to continue. For example, if a
safety switch is guarding a motor, and the safety switch fails, the motor should not be able to
run.
Safety Device Lock-Outs
Some safety devices disconnect electrical energy from a circuit. The safety devices that are
used on these temperature control units are primarily concerned with electrical power
disconnection and disabling of moving parts that may need to be accessed during the normal
operation of the machine.
Some of the safety devices utilize a manual activator. This is the method of initiating the safety
lock out. This may be in the form of a plug, lever, or a handle. Within this lockable handle,
there may be location for a padlock. Personnel servicing the equipment should place a padlock
in the lockout handle.
In addition to the safety devices listed above, these temperature control units are equipped with
a line cord plug. This allows the operator or maintenance personnel to unplug the tcu from its
power source and tag it out. The plug can then be tagged with any number of approved
electrical lockout tags available at most electrical supply stores.
Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)
sources prior to servicing or cleaning the temperature control unit. Failure to do so may
result in serious injury. No one but the person who installed the lockout may remove it.

WTR2-640 Chapter 3: Installation 16 of 46
Chapter 3: Installation
3-1 Uncrating the Equipment
Portable hot oil temperature control units are shipped mounted on a skid, enclosed in a plastic
wrapper, and contained in a cardboard box.
1. Pry the crating away from the skid.
Remove the nails holding the box to the skid and lift the box off carefully;
avoiding staples in the 1’ x 4’ wood supports. Cut the steel banding.
2. Use a pry bar to remove the blocks securing the unit to the skid.
3. Lift unit from sides. Use a pry bar if necessary to carefully remove the skid from the
unit.
4. Lower slowly.
3-2 Rigging and Placing the TCU
Make sure that you meet the following requirements when installing and operating your Upright
hot oil temperature control unit.
Installation Location Considerations
Locate the Upright unit as close as possible to the process for proper circulation and
temperature control. Take care when selecting a location. The area surrounding the unit must
be free of obstructions to ensure proper ventilation of internal components. Allow a minimum
clearance of at least 30 inches (76 cm).
Make sure that the unit location is not in a confined space to ensure proper air circulation.
Special air circulation/ventilation is required for units operating at temperatures exceeding
500°F (260°C). Vapors can escape from areas such as the reservoir tank during high
temperature operation.
Harmful vapors may be generated from thermal fluid during high temperature operation.
Prolonged or repeated exposure of these heat-generated vapors may result in eye and
respiratory tract irritation. Avoid contact or inhaling harmful amounts or material. Consult
the Material Safety Data Sheet (MSDS) for precautions and instructions for the thermal fluid
you are using.
Before storing your Upright temperature control unit, make sure you remove all residual
water with compressed air to avoid a potential freezing hazard. See Section 5-2 on Page 39
for more information.
Note the following table of ambient temperature ranges permitted for storage and operation:
Ambient storage range
Ambient operation range
ºF
ºC
ºF
ºC
-40ºF to 185ºF
-40ºC to 85ºC
-4ºF to 120ºF
-20ºC to 49ºC
You should preheat the process heat transfer fluid first if you want to start the unit below an
ambient temperature of 30°F (-1°C).

WTR2-640 Chapter 3: Installation 17 of 46
3-3 Electrical Connections
These units are designed for three-phase voltage operation. Refer to the unit nameplate for
proper voltage and amperage requirements, and make sure your electrical service conforms.
Check the unit nameplate for correct voltage and amperage before making electrical
connections!
1. Provide a correctly sized and protected power supply to the unit.
2. If an electrical supply disconnect is not installed as a factory option, the customer is
responsible to properly size and install a suitable disconnect.
3. Refer to National Electric Code (NEC) 430-24-26 for proper feed conductor and
supply disconnect sizing.
4. Voltages must be within plus or minus ten percent (+ 10%S) of the nameplate rating.
5. Maintain a safe ground and disconnect the power supply before servicing the unit.
A qualified electrician should make electrical connections and disconnect the electricity
when service calls are needed.
•Locate disconnects in an easily accessible location. Operators should not
have to squeeze around the Upright unit to reach disconnects, especially in
case of emergency.
•When running conduit whips to the Upright unit, make sure that whips are
routed away from hot piping.
Improper electrical connections can cause damage to the unit and cause serious operator
injury or death! Make sure that ALL electrical connections are made by a qualified
electrician, and that ALL connections are tight.
Make all electrical supply connections at the front of the unit. An access panel covers all
electrical connections. Run electrical connections to the supply terminals from either side of
the unit. Make sure that all three phases are wired correctly. The pump runs backwards if not
wired properly.
3-4 Setup Procedures
This section provides the procedures necessary for configuring your portable hot oil
temperature control unit.
Configuration of your TCU includes connecting cooling, process and vent piping. We
recommend that you carry out these procedures in the order given here.
Before carrying out these procedures, install all equipment as described in this section.
Connecting Piping
Make sure that all external piping is properly sized t reduce external pressure drop as much as
possible. Do not install process or water supply/drain piping smaller than the fittings on the
unit. If the water supply piping is larger than unit fittings, reduce the pipe size at the unit.

WTR2-640 Chapter 3: Installation 18 of 46
The following table lists recommended Upright TCU pipe sizes.
Connection
Size diameter
inches NPT
mm (approx.) c
To Process
1”
25.4
From Process
1”
25.4
Cooling Water Supply
¾”
19.1
Cooling Water Drain
¾”
19.1
Oil Drain
½”
12.7
Fill Port
1”
25.4
c Customer is responsible for converting to metric.
Always use a backup wrench to support Upright unit piping when making
connections. Make sure all external piping is supported independently of the
Upright unit.
The manufacturer recommends that you have strainers installed on the
cooling water inlets and customer-supplied shut-off valves on all piping
connections. Use common black welded pipe for permanent installations.
The Upright is designed to operate with an open, unrestricted drain line.
Steam rapidly expands within the heat exchanger, so any overpressure
condition from backpressure or standing columns of water against the drain
must be avoided.
If you must use a pipe joint compound, use a compound that can withstand the high
te mperatures and pressures of your Upright unit. Always insulate all piping to prevent burn
hazards and to retain heat. Make sure insulation is properly rated for maximum operating
temperatures of your Upright unit.
Piping Considerations for Mobile Installations
Because your Upright unit is fitted with casters, its portability is well suited for multiple
applications. You can purchase high-quality flexible metal hose from the manufacturer to
enhance the mobility of your Upright unit; state the length you want when ordering.
Although they cause a drop in pressure, you can also install quick disconnects to your
Upright unit. However, do not install check valves with quick disconnects unless absolutely
necessary!
Connecting Process Piping
When connecting process piping, ensure that the Cautions listed below are observed and
followed:
•Hoses, valves, and other components in your process must be able to
withstand Upright unit maximum temperatures and pressures.
•Maximum temperatures and pressures are listed on the unit nameplate.
•Carefully inspect all components before installation.
•If in doubt about component suitability, obtain factory components.
•Fix all leaks! Fluid can be a potential fire and slip hazard.

WTR2-640 Chapter 3: Installation 19 of 46
Connecting Cooling Water Piping
You must provide cooling water at 25 psi to 75 psi (172.4 kPa to 517.1 kPa/1.7 bars to 5.2 bars)
for proper operation. Untreated water can foul or corrode the heat transfer surfaces, slowing
water flow and causing fluid temperature control problems. The manufacturer sells a complete
line of water treatment equipment that can reduce downtime and maintenance costs.
Run properly-sized cooling water lines—never smaller than the outlets on the Upright unit. If
external piping is larger than Upright unit connections, reduce the size of the piping at the unit.
Connecting Vent Piping
You must leave the vent connection open to the atmosphere at all times. The vent connection is
located on top of the reservoir. On systems with piping above the reservoir level, you must run
vent piping to a minimum height of one foot (1’ / 31 cm) above the highest point in the system.
Run the piping down into an auxiliary vented overflow chamber, such as a vented, covered 55-
gallon (208-liter) drum. This practice ensures that overflow will not create a hazard to
personnel.
All external piping must be supported independently of the Upright unit.
The reservoir tank must be vented to prevent pressurization. A pressurized
reservoir could rupture, allowing hot fluid to escape and become a potential fire
and slip hazard.
Heat transfer fluids expand when heated. Expansion rates vary, depending on
fluid types and temperatures. For more information on expansion rates, refer to
specification information for the heat transfer fluid you select.
Generally, most heat transfer fluids expand at the rate of 2.5% for every
increase of 50°F/°C from temperatures above 60°F (16°C).
Figure 1: Upright Unit Piping Setup

WTR2-640 Chapter 3: Installation 20 of 46
Connect the TO PROCESS hookup to the entrance of the process and the FROM PROCESS
hookup to the exit of the process. Connect the COOLING WATER SUPPLY to your plant
water supply. Connect the COOLING WATER DRAIN line to an open drain, or to the return
line of your central water system. If returning to a central water system, use a
condensate/return tank to avoid a standing water column on the heat exchanger drain line.
If you are routing the drain line to an open drain, make sure that the line is
directed away from personnel to avoid scalding.
Carefully select connecting lines and connectors between the Upright unit
and the process to best meet the needs and requirements of your
application.
Make sure lines and connectors have a service rating of at least 100 psig
(689.5 kPa/6.9 bars), and a temperature rating at least equal to the
maximum operating temperature of your Upright unit.
To prevent debris from fouling reservoir fluid, the Upright unit is
equipped with an internal vent on the reservoir tank. Use the plug
provided to close off the external fill port after filling the unit with heat
transfer fluid.
3-5 Initial Start-up
Starting the Hot Oil TCU
Before you begin your heating process, perform the following startup procedures. Doing so
ensures that all air is vented from the system to prevent fluid degradation and damage to the
heater.
1. Add recommended heat transfer fluid to the reservoir tank until the level is near the
top of the sight glass.
2. If so equipped, open the manual vent valve on the back of the unit.
3. Push the PUMP START button to start the pump, then check motor rotation by
observing the pressure gauge.
If the gauge indicates positive pressure, rotation is correct. If not, disconnect power
and reverse the incoming power leads.
4. As fluid is drawn out of the reservoir tank to fill the process, the fluid level falls in
the tank. Continue to add fluid to maintain the level about four inches (4”/10 cm)
from the bottom of the sight glass.
Air and thermal fluid vent through the vent solenoid or the manual vent valve and
into the reservoir tank.
You must purge the system of air before the heating cycle. Personal injury
and system damage can occur from a pressurized system.
Make sure that the reservoir tank vent port is not plugged. The reservoir
tank must never be pressurized!
5. When the unit has built at least five (5) psi (34.5 kPa) of pressure, wait two (2)
minutes, then select a set point of 100°F (38ºC) and switch the unit into AUTO mode.
As the oil warms up, viscosity decreases and pressure falls.
6. Increase the set point to 150ºF, then 200ºF (65ºC, then 93ºC) at two-minute intervals.