Nordson Single Reference guide

Temperature Control
Systems
Customer Product Manual
Document Number1615094-03
Issued 09/21
For parts and technical support, call the Industrial Coating
Systems Customer Support Center at [phone] or
contact your local Nordson representative.
This document is subject to change without notice.
Check http://emanuals.nordson.com for the latest version.
NORDSON CORPORATION • AMHERST, OHIO • USA

© 2021 Nordson Corporation
1615094-03
Contact Us
Nordson Corporation welcomes requests for information, comments, and
inquiries about its products. General information about Nordson can be found on
the Internet using the following address:
http://www.nordson.com.
Address all correspondence to:
Nordson Corporation
Attn: Customer Service
555 Jackson Street
Amherst, OH 44001
Notice
This is a Nordson Corporation publication which is protected by copyright.
Original copyright date 2019. No part of this document may be photocopied,
reproduced, or translated to another language without the prior written consent of
Nordson Corporation. The information contained in this publication is subject to
change without notice.
Trademarks
Nordson and the Nordson logo are registered trademarks of Nordson
Corporation. All other trademarks are the property of their respective owners.
Table of Contents
Safety............................................................................................ 1
Introduction................................................................................... 1
...................................................................... 1
Intended Use................................................................................ 1
Regulations and Approvals........................................................... 1
Personal Safety............................................................................ 2
High-Pressure Fluids................................................................... 3
Fire Safety.................................................................................... 4
Halogenated Hydrocarbon Solvent Hazards............................... 4
Action in the Event of a Malfunction............................................. 5
Disposal........................................................................................ 5
System Overview......................................................................... 5
Chilled Water Loop Operation ...................................................... 8
Refrigerant Cycle ........................................................................ 8
Fault Indicators............................................................................ 8
Flowsetter Valves ......................................................................... 9
Control Panel Front .................................................................... 10
Control Panel Interior ................................................................. 12
Chiller Junction Box.................................................................... 14
 ............................................................................. 15
Dimensions ............................................................................... 16
Single-Air Cooling System ....................................................... 16
Dual-Air Cooling System.......................................................... 17
Triple-Air Cooling System ........................................................ 18
Quad Air Cooling System......................................................... 19
Water Cooling Systems ........................................................... 19
Installation.................................................................................. 20
Location and Clearances............................................................ 20
Mounting..................................................................................... 20
Ambient Temperature ................................................................. 20
Electrical Connections................................................................ 20
Heat Exchanger Installation ....................................................... 21
Cabinet Mounting...................................................................... 21
Remote Mounting...................................................................... 21
Process Material Connections.................................................... 22
Additional Temperature Control Loop......................................... 23
Water Treatment......................................................................... 23
Operation.................................................................................... 24
Preparation for First-Time Startup.............................................. 24
Filling System............................................................................. 25
Temperature Controller Settings................................................. 26
Chiller Controller ....................................................................... 26
Process Controller..................................................................... 26
Changing Material Temperature Setpoint.................................. 28
Controller Security..................................................................... 28
Auto-Tuning............................................................................... 28
System Shutdown ...................................................................... 28
Flowsetter Optimization.............................................................. 29
Remove Air from Water Side of Heat Exchanger...................... 29
Adjust Flowsetters..................................................................... 30
Maintenance............................................................................... 31
System Pressure........................................................................ 31
Process Water Temperature....................................................... 31
System Condenser..................................................................... 31
Heat Exchanger.......................................................................... 31
Water Level and Quality ............................................................. 32
Water Test Kit Instructions.......................................................... 33
Molybdate Test .......................................................................... 33
pH Test ...................................................................................... 33
Troubleshooting ........................................................................ 34
Repair ......................................................................................... 38
RT Replacement ........................................................................ 38
Heat Exchanger Disassembly and Cleaning.............................. 38
Disassembly.............................................................................. 39
Cleaning.................................................................................... 39
Assembly................................................................................... 41
Parts............................................................................................ 42
System Components.................................................................. 42
Heat Exchanger ........................................................................ 46
Flushing Manifold...................................................................... 47
RTD Assemblies........................................................................ 48
Air Filters................................................................................... 48
Test Kit........................................................................................ 48
Water Treatment......................................................................... 48
Appendix .................................................................................... 49
E5EC Temperature Controller Settings ...................................... 49
Love Chiller Controller Settings.................................................. 52
............. 53
Optional Water Cooled Condensor ............................................ 56
 .............................................................. 56

i
Change Record
© 2021 Nordson Corporation 1615094-03
Change Record
Revision Date Change
01 01/19 Combined single and dual systems into one manual. Updates to all sections.
02 07/19 Updated Process Material Connections to show straps.
03 09/21 Various manual updates.

© 2021 Nordson Corporation
1615094-03
ii Change Record

1
Temperature Control Systems
© 2021 Nordson Corporation 1615094-03
Safety
Introduction

cautions, and instructions are included in equipment documentation where appropriate.
Make sure all equipment documentation, including these instructions, is accessible to
persons operating or servicing equipment.
Qualied Personnel
Equipment owners are responsible for making sure that Nordson equipment is installed,

or contractors who are trained to safely perform their assigned tasks. They are familiar
with all relevant safety rules and regulations and are physically capable of performing
their assigned tasks.
Intended Use
Use of Nordson equipment in ways other than those described in the documentation
supplied with the equipment may result in injury to persons or damage to property.
Some examples of unintended use of equipment include:
• using incompatible materials
• 
• removing or bypassing safety guards or interlocks
• using incompatible or damaged parts
• using unapproved auxiliary equipment
• operating equipment in excess of maximum ratings
Regulations and Approvals
Make sure all equipment is rated and approved for the environment in which it is
used. Any approvals obtained for Nordson equipment will be voided if instructions for
installation, operation, and service are not followed.

2Temperature Control Systems
© 2021 Nordson Corporation
1615094-03
Personal Safety
To prevent injury follow these instructions.
• 
• Do not operate equipment unless safety guards, doors, or covers are intact and
automatic interlocks are operating properly. Do not bypass or disarm any safety
devices.
• Keep clear of moving equipment. Before adjusting or servicing moving equipment,
󰀨
Lock out power and secure the equipment to prevent unexpected movement.
• 󰀨
pressurized systems or components. Disconnect, lock out, and tag switches before
servicing electrical equipment.
• While operating manual spray guns, make sure you are grounded. Wear electrically
conductive gloves or a grounding strap connected to the gun handle or other true earth
ground. Do not wear or carry metallic objects such as jewelry or tools.
• If you receive even a slight electrical shock, shut down all electrical or electrostatic
equipment immediately. Do not restart the equipment until the problem has been

• 
manufacturer’s instructions for safe handling and use of materials, and use
recommended personal protection devices.
• Make sure the spray area is adequately ventilated. To prevent injury, be aware of less-
obvious dangers in the workplace that often cannot be completely eliminated, such as
hot surfaces, sharp edges, energized electrical circuits, and moving parts that cannot
be enclosed or otherwise guarded for practical reasons.

3
Temperature Control Systems
© 2021 Nordson Corporation 1615094-03
High-Pressure Fluids



death. Fluids penetrating the skin can also cause toxic poisoning.
󰀨

The National Spray Equipment Manufacturers Association has created a wallet card that
you should carry when you are operating high-pressure spray equipment. These cards
are supplied with your equipment. The following is the text of this card:
WARNING:Any injury caused by high pressure liquid can be serious. If you are injured
or even suspect an injury:
• Go to an emergency room immediately.
• Tell the doctor that you suspect an injection injury.
• Show them this card
• Tell them what kind of material you were spraying
MEDICAL ALERT — AIRLESS SPRAY WOUNDS: NOTE TO PHYSICIAN
Injection in the skin is a serious traumatic injury. It is important to treat the injury
surgically as soon as possible. Do not delay treatment to research toxicity. Toxicity is a
concern with some exotic coatings injected directly into the bloodstream.
Consultation with a plastic surgeon or a reconstructive hand surgeon may be advisable.
The seriousness of the wound depends on where the injury is on the body, whether the


the wound. If the injected paint contains acrylic latex and titanium dioxide that damage

doctors recommend for an injection injury to the hand includes immediate decompression
of the closed vascular compartments of the hand to release the underlying tissue
distended by the injected paint, judicious wound debridement, and immediate antibiotic
treatment.

4Temperature Control Systems
© 2021 Nordson Corporation
1615094-03
Fire Safety

• 
equipment and workpiece grounding devices regularly. Resistance to ground must not
exceed one megohm.
• Shut down all equipment immediately if you notice static sparking or arcing. Do not

• 
used or stored. Do not heat materials to temperatures above those recommended
by the manufacturer. Make sure heat monitoring and limiting devices are working
properly.
• Provide adequate ventilation to prevent dangerous concentrations of volatile particles
or vapors. Refer to local codes or your material SDS for guidance.
• 
󰀨
• 󰀨
󰀨
exhaust fans.
• 󰀨
cleaning, or repairing electrostatic equipment.
• Clean, maintain, test, and repair equipment according to the instructions in your
equipment documentation.
• Use only replacement parts that are designed for use with original equipment. Contact
your Nordson representative for parts information and advice.
Halogenated Hydrocarbon Solvent Hazards
Do not use halogenated hydrocarbon solvents in a pressurized system that contains
aluminum components. Under pressure, these solvents can react with aluminum and
explode, causing injury, death, or property damage. Halogenated hydrocarbon solvents
contain one or more of the following elements:
Element Symbol 
Fluorine F “Fluoro-”
Chlorine Cl “Chloro-”
Bromine Br “Bromo-”
Iodine I “Iodo-”
Check your material SDS or contact your material supplier for more information. If you
must use halogenated hydrocarbon solvents, contact your Nordson representative for
information about compatible Nordson components.

5
Temperature Control Systems
© 2021 Nordson Corporation 1615094-03
Action in the Event of a Malfunction
󰀨
and perform the following steps:
• Disconnect and lock out system electrical power. Close hydraulic and pneumatic
󰀨
• Identify the reason for the malfunction and correct it before restarting the system.
Disposal
Dispose of equipment and materials used in operation and servicing according to local
codes.
System Overview

application temperature.
The temperature control unit heats or cools process water, which then circulates through

through the heat exchanger and is heated or cooled to the desired temperature.
The temperature controller contains a process water loop and a chilled water loop.
See Figure 1.



NOTE:Some systems may have two pumps connected in series in the process water
loop.



through the evaporator.

• 

and heat exchanger, warming the coating material.
• 


cooling the coating material. Water from the process loop returns to the chilled water

If the coating material temperature deviates from the process temperature setpoint by

An adjustable thermostat in the heater assembly acts as a high water temperature safety

to the heater is disabled. In addition, the heater high temp fault indicator on the electrical
panel will light.

6Temperature Control Systems
© 2021 Nordson Corporation
1615094-03
Figure 1 Temperature Control Unit Diagram – Air-Cooled Condensor
Material In
Material Out Material In Material Out
From Process

6Y1

CH 2
6Y1
CH 2
3M3
CH 2
9KW
To Process From Process To Process










 
5Y1
CH 1
9KW
CH 1
5Y1
CH 1
3M2
3M1
9TC1
2S8
11
23
4 4
5
10a
10b
6
11
79
TP
23
4 4
5
10a
10b
6
11
79
TP
17
16
15
14
13
12
48
34
23 24
L
H
25
26
4343
29
30 31 32
7S1
7S2
8M3 8M3
8S1
8S5
8M2 8M1
21
19
7S3
5
20
7Y1
33
47
38
Return From
Process
Condensing
Unit
8
46

7
Temperature Control Systems
© 2021 Nordson Corporation 1615094-03
Item Description
1 Heat exchanger
2RTD
3 Temperature controller
4 Service valves - 3.4 in.
5 Y strainer
6 Cooling solenoid valve
7 Immersion heater
8 Thermometer
9 Pressure gauge 5-20 psi
10a 
10b 
11 Process pump 7.2-10 gpm 24 psi
12 Chilled water pump 7.2 gpm 9.7 psi
13 Chilled water RTD
14 Chilled water reservoir
15 Drain valve
16 Float switch
17 Check valve
19 Freeze stat
20 Evaporator
21 Metering valve
23 Compressor heater
24 Compressor
25 Fan 2 pressure switch
26 Fan 1 variable speed control
27 Fan blade
28 Fan guard
29 Air condenser
30 Refrigerant receiver
31 
32 Refrigerant sight glass
33 Liquid line solenoid valve
34 High pressure switch
38 Accumulator
43 Fan motor
44 Water pressure regulator
46 Back mount termometer
47 Liquid line solenoid valve head
48 Low pressure switch

8Temperature Control Systems
© 2021 Nordson Corporation
1615094-03
Chilled Water Loop Operation
See Figure 1.





compressor contactor. Power is provided to the compressor and condenser fan motors.
If the ambient temperature is low, a fan control switch de-energizes one condenser fan
󰀨
the compressor is running.

fan motors, and liquid line solenoid are de-energized while the crankcase heater is still
energized, completing the cycle.
Refrigerant Cycle



󰀨

contaminants.



evaporator and is transformed into a low-pressure gas. The low-pressure gas is then
drawn into the compressor to complete the cycle.
Fault Indicators


or low refrigerant pressure, or low water temperature condition occurs. These conditions
󰀨
indicator.

the low water level fault indicator on the electrical panel if the water in the reservoir falls
below the switch level.

9
Temperature Control Systems
© 2021 Nordson Corporation 1615094-03
Flowsetter Valves
See Figure 2.

of water through the system. The valves have a slotted screw head. When the screw




Some installations may need additional optimization upon setup to provide maximum
cooling. See page 29 for Flowsetter Optimization.
Figure 2 Temperature Control Unit Diagram – Air Cooled Condensor
Chilled Water Supply Flowsetter Process Return Water Flowsetter
Flowsetter Slot Screw

10 Temperature Control Systems
© 2021 Nordson Corporation
1615094-03
Control Panel Front
See Figure 3 and refer to Table 1.
Figure 3 Control Panel
HEATER
HIGH TEMP.
FAULT NO. 2
LAMP
TEST
FLOAT SWITCH
LOW LEVEL
POWER
ON
SYSTEM NO. 1
OFF ON
SYSTEM NO. 2
OFF ON
COOLING
OFF ON
HEATER
HIGH TEMP.
FAULT
TEMPERATURE
RANGE
FAULT NO. 2
TEMPERATURE
RANGE
FAULT
MASTER
START
MASTER
STOP
COOLING
ON
CHILLER
FAULT
1A
1B
2
3
4
5
6A
7A
8A
6B
7B
8B
9
10
11
12
13

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Temperature Control Systems
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Table 1 Control Panel Front
Item Control Description
1A Temperature Controller 1 Controls coating material temperature.
1B Temperature Controller 2
2Lamp Test Press to turn on all indicator lights to ensure they are working.
3 Power On Lights when system power is on.
4 Master Start Starts chiller pump and provides power to rest of system.
5 Master Stop Stops all system functions except compressor crankcase heater.
6A System No.1 OFF/ON Starts/stops process water pump.
6B System No.2 OFF/ON
7A Heater High Temp. Fault 
7B Heater High Temp. Fault No.2
8A Temperature Range Fault Lights if the coating material temperature deviates from the process

8B Temperature Range Fault No.2
9 Float Switch Low Level 
10 Cooling OFF/ON Enables/disables the refrigeration system.
11 Cooling ON Lights when the refrigeration system is enabled.
12 Chiller Fault

loop, if the high- or low-pressure refrigerant switch is tripped, or if the
low-temperature thermostat senses that the water temperature in the

13 Main Disconnect 󰀨
repairs or for long shutdowns. Refer to Warning placard on panel.

12 Temperature Control Systems
© 2021 Nordson Corporation
1615094-03
Control Panel Interior
See Figure 4 and refer to Table 2.
Figure 4 Control Panel Interior Fuses, Disconnects, and Controls
1F1
1F2
1F3
1F4
2K3
2K5
6K2
2K3
2K1
2K6
5F1
6F1

13
Temperature Control Systems
© 2021 Nordson Corporation 1615094-03
Table 2 Control Panel Interior
Label Component Function
1F1 Heater 1 fuse Heater number 1
1F2 Heater 2 fuse Heater number 2
1F3 Condensor unit fuse Condensing unit
1F4 Transfomer Transformer
1Q1 Main disconnect Supplies power to the unit
2K3 Heater number 1 high temp Heater number 1 high temperature
2K5 Heater number 2 high temp Heater number 2 high temperature
5K2 Heater 1 solid state relay Heater number 1 solid state contactor
6K2 Heater 2 solid state relay Heater number 2 solid state contactor
2K1 Master start/stop Master start/stop
2K6 Low water level fault Low water level
5F1 Cooling solenoid valve 1 For process circuit 1
6F1 Cooling solenoid valve 2 For process circuit 2

14 Temperature Control Systems
© 2021 Nordson Corporation
1615094-03
Chiller Junction Box
See Figure 5 and refer to Table 3.
Figure 5 Chiller Junction Box
Table 3 Chiller Junction Descriptions
Label Component Function
6TC1 Chiller controller
Uses RTD to sense chilled water temperature. Factory settings trigger
󰀨


6S3 Low temperature thermostat 󰀨

6K1 Chiller fault relay Chiller fault
6K3 Chiller start relay Chiller start
7T1 Transformer 480V-24V transformer
7T2 Transformer 480V-220V transformer
7K3 󰀨 󰀨
7S5 Variable speed controller Controls fan speed on the condenser
7K3
Chiller ON/OFF
7S5
6TC1 6S3
6K1
6K3
7T1
7T2

15
Temperature Control Systems
© 2021 Nordson Corporation 1615094-03
Specications
Specication Single Dual Triple Quad
Water Reservoir 3 ton/26 gal

5 ton/26 gal

7.5 ton/70 gal

10 ton/70 gal

Capacity
36,000 BTU/
hour

60,000 BTU/
hour

90,000 BTU/
hour

120,000 BTU/
hour

Operating Sound Level (Full Load Operation) 78.5 dBA 78.5 dBA Contact
Nordson
Contact
Nordson
US
60 Amps
minimum, 480
Vac 3 Phase
60 Hz
60 Amps
minimum, 480
Vac 3 Phase
60 Hz
 
CE
60 Amps
minimum, 400
Vac 3 Phase
50 Hz
60 Amps
minimum, 400
Vac 3 Phase
50 Hz
 
Weight  1200 lb

1400 lb

1600 lb

Contact
Nordson
Dimensions See Dimensions section beginning on page 16.
Standard 6 ft Heat Exchanger Weight with
Stand  
Electrical Panel Rating NEMA 12, IP rating 66
Ambient Temperature Range 
Maximum Material Flow 
Conditioning Capacity 

Heater Exchanger Ratings 

Refrigerant 
Saturated Discharge Temp 
Saturated Suction Temp 
High Pressure Control 

Low Pressure Control 

Low Temp Thermostat 
Cut in: Manual reset
Fan Control #1 (variable speed control)

Cut out: 50%
Hard start: 75%
Fan Control #2 

NOTE: A. Use distilled water for water reservoir.
B. Reference system drawing set for power requirements.
C. Does not include weight of heat exchangers or water.
D. This is a dry weight with no water

16 Temperature Control Systems
© 2021 Nordson Corporation
1615094-03
Dimensions
Single-Air Cooling System
See Figure 6.
Figure 6 Single-Air Cooling System Dimensions
67.0 in.
(1702 mm)
34.5 in.
(876 mm)
32.0 in.
(813 mm)
80.25 in.
(2038 mm)
36.0 in.
(914 mm)
32.0 in.
(813 mm)
8.13 in.
(207 mm)
72.0 in.
(1829 mm)