Thermal Care Aquatherm RQE Instruction Manual

Table of Contents
Foreword .................................................................................................................................................................................................................. 1
Safety Guidelines .................................................................................................................................................................................................. 1
Pre-Installation....................................................................................................................................................................................................... 2
Receiving Inspection ....................................................................................................................................................................................... 2
Unit Storage........................................................................................................................................................................................................ 2
Installation - Mechanical.................................................................................................................................................................................... 2
Foundation.......................................................................................................................................................................................................... 2
Unit Location...................................................................................................................................................................................................... 2
Rigging ................................................................................................................................................................................................................. 2
Fluid Distribution Piping................................................................................................................................................................................ 2
Installation - Electrical......................................................................................................................................................................................... 3
Controller Operation ........................................................................................................................................................................................... 4
Figure 1 –Basic Controller Home Screen ........................................................................................................................................... 4
Soft Buttons........................................................................................................................................................................................................ 4
Increase Button ................................................................................................................................................................................................. 4
Enter Button........................................................................................................................................................................................................ 4
Decrease Button................................................................................................................................................................................................ 4
Changing Setpoint Temperature................................................................................................................................................................ 4
Changing Temperature Units ...................................................................................................................................................................... 4
Changing Temperature Displayed............................................................................................................................................................. 4
Using Mold Purge Option............................................................................................................................................................................. 4
Changing User Parameters........................................................................................................................................................................... 5
USB Port ............................................................................................................................................................................................................... 5
Table 1 - User Parameters......................................................................................................................................................................... 5
Table 2 - Factory Parameters................................................................................................................................................................... 7
Table 3 - Diagnostic Screens.................................................................................................................................................................... 8
Start-up...................................................................................................................................................................................................................11
Step 1 –Connecting Main Power ............................................................................................................................................................12
Step 2 –Fill Coolant Circuit ........................................................................................................................................................................12
System Fill Water Chemistry Requirements.....................................................................................................................................12
Fill Water Chemistry Requirements.....................................................................................................................................................13
Step 3 –Initial Unit Operation...................................................................................................................................................................13
Preventive Maintenance...................................................................................................................................................................................14
Once a Week ....................................................................................................................................................................................................14
Once a Month..................................................................................................................................................................................................14
Troubleshooting..................................................................................................................................................................................................15
Drawings.................................................................................................................................................................................................................15

Page Intentionally Blank

1
Foreword
The temperature control unit is a packaged unit that
typically includes a fluid pump, electric immersion
heater, and temperature control valve in a cabinet.
The purpose is to provide circulation and
temperature control of a cooling fluid.
This manual is to serve as a guide for installing,
operating, and maintaining the equipment. Improper
installation, operation, and maintenance can lead to
poor performance and/or equipment damage. Use
qualified installers and service technicians for all
installation and maintenance of this equipment.
This manual is for our standard product. The
information in this manual is general in nature. Unit-
specific drawings and supplemental documents are
included with the equipment as needed. Additional
copies of documents are available upon request.
Due to the ever-changing nature of applicable
codes, ordinances, and other local laws pertaining to
the use and operation of this equipment, we do not
reference them in this manual.
Safety Guidelines
Observe all safety precautions during installation,
start-up, and service of this equipment. The
following is a list of symbols used in this manual and
their meaning.
General Warning
Electricity Warning
Sharp Element Warning
Hot Surface Warning
Flammable Material Warning
Explosive Material Warning
General Mandatory Action
Wear Eye Protection
Wear Protective Gloves
Wear Ear Protection
Disconnect Before Carrying Out Maintenance or
Repair
Connect an Earth Terminal to Ground
Only qualified personnel should install, start-up, and
service this equipment. When working on this
equipment, observe precautions in this manual as
well as tags, stickers, and labels on the equipment.
WARNING: Any use or misuse of this equipment
outside of the design intent may cause injury or harm.
WARNING: This equipment contains hazardous
voltages that can cause severe injury or death.
WARNING: This equipment contains hot water or
coolant under pressure. Accidental release of hot water
or coolant under pressure can cause personal injury
and or property damage.
WARNING: This equipment may contain fan blades or
other sharp edges. Make sure all fan guards and other
protective shields are securely in place.
WARNING: The exposed surfaces of motors, piping,
and other fluid circuit components can be very hot
and can cause burns if touched with unprotected
hands.
CAUTION: Disconnect and lock out incoming power
before installing, servicing, or maintaining the
equipment. Connecting power to the main terminal
block energizes the entire electric circuitry of the unit.
Shut off the electric power at the main disconnect
before opening access panels for repair or
maintenance.
CAUTION: Wear eye protection when installing,
maintaining, or repairing the equipment to protect
against any sparks, debris, or fluid leaks.

2
CAUTION: The equipment will exceed 70 dBA sound
pressure at 1 meter distance and 1 meter elevation
when operating. Wear ear protection as required for
personal comfort when operating or working in close
proximity to the chiller.
CAUTION: Wear protective gloves when installing,
maintaining, or repairing the equipment to protect
against any sparks, debris, or fluid leaks.
Pre-Installation
Receiving Inspection
When the unit arrives, verify the information on the
unit nameplate agrees with the order
acknowledgement and shipping papers. Inspect the
equipment for any visible damage and verify all
items shown on the bill of lading are present. If
damage is evident, document it on the delivery
receipt by clearly marking any item with damage as
“unit damage” and notify the carrier. In addition,
notify our Customer Service Department and they
will provide assistance with preparing and filing
freight damage claims, including arranging for an
estimate on repair costs; however, filing the shipping
damage claim is the responsibility of the receiving
party. Do not install damaged equipment without
getting the equipment repaired.
Shipping damage is the responsibility of the carrier.
To protect against possible loss due to damage
incurred during shipping and to expedite payment
for damages, it is important to follow proper
procedures and keep records. Photographs of
damaged equipment are excellent documentation
for your records.
Start unpacking the unit, inspect for concealed
damage, and take photos of any damage found.
Once received, equipment owners have the
responsibility to provide reasonable evidence that
the damage did not occur after delivery. Photos of
the equipment damage while the equipment is still
partially packed will help in this regard. Refrigerant
lines can be susceptible to damage in transit. Check
for broken lines, oil leaks, damaged controls, or any
other major component torn loose from its
mounting point.
Record any signs of concealed damage and file a
shipping damage claim immediately with the
shipping company. Most carriers require concealed
damages be reported within 15 days of receipt of
the equipment. In addition, notify our Customer
Service Department and they will provide assistance
with preparing and filing freight damage claims,
including arranging for an estimate on repair costs;
however, filing the shipping damage claim is the
responsibility of the receiving party.
Unit Storage
When storing the unit it is important to protect it
from damage. Blow out any water from the unit;
cover it to keep dirt and debris from accumulating
on or getting in and store in an indoor sheltered
area that does not exceed 145°F.
Installation - Mechanical
Foundation
Install the unit on a rigid, non-warping mounting
pad, concrete foundation, or level floor suitable to
support the full operating weight of the equipment.
When installed the equipment must be level within
¼ inch over its length and width.
Unit Location
The unit is available in many different configurations
for various environments. Refer to the proposal and
order acknowledgement document for the
equipment to verify the specific design conditions in
which it can operate.
To ensure proper airflow and clearance space for
proper operation and maintenance allow a minimum
of 12 inches of clearance between the sides of the
equipment and any walls or obstructions. Avoid
locating piping or conduit over the unit to ensure
easy access with an overhead crane or lift to lift out
heavier components during replacement or service.
Rigging
The unit has a base with casters to facilitate easy
movement and positioning. Follow proper rigging
methods to prevent damage to components. Avoid
impact loading caused by sudden jerking when
lifting or lowering the unit. Use pads where abrasive
surface contact may occur.
Fluid Distribution Piping
Proper insulation of chilled process fluid piping is
crucial to prevent condensation. The formation of

3
condensation adds a substantial heat load to the
cooling system.
The importance of properly sized piping cannot be
overemphasized. See the ASHRAE Handbook or
other suitable design guide for proper pipe sizing. In
general, run full size piping out to the process and
then reduce the pipe size to match the connections
on the process equipment. One of the most
common causes of unsatisfactory unit performance
is poor piping system design. Avoid long lengths of
hoses, quick disconnect fittings, and manifolds
wherever possible as they offer high resistance to
water flow. When manifolds are required, install
them as close to the use point as possible. Provide
flow-balancing valves at each machine to assure
adequate water distribution in the entire system.
Install shut-off valves at each machine to allow for
isolation of the unit.
Installation - Electrical
All wiring must comply with local codes and the
National Electric Code. Minimum Circuit Amps (MCA)
and other unit electrical data are on the unit
nameplate. A unit specific electrical schematic ships
with the unit. Measure each leg of the main power
supply voltage at the main power source. Voltage
must be within the voltage utilization range given on
the drawings included with the unit. If the measured
voltage on any leg is not within the specified range,
notify the supplier and correct before operating the
unit. Voltage imbalance must not exceed two
percent. Excessive voltage imbalance between the
phases of a three-phase system can cause motors to
overheat and eventually fail. Voltage imbalance is
determined using the following calculations:
% Imbalance = (Vavg –Vx) x 100 / Vavg
Vavg = (V1 + V2 + V3) / 3
Vx = phase with greatest difference from Vavg
For example, if the three measured voltages were
442, 460, and 454 volts, the average would be:
(442 + 460 + 454) / 3 = 452
The percentage of imbalance is then:
(452 –442) x 100 / 452 = 2.2 %
This exceeds the maximum allowable of 2%.
There is a terminal block for main power connection
to the main power source. The main power source
should be connected to the terminal block through
an appropriate disconnect switch. There is a separate
lug in the main control panel for grounding the unit.
Check the electrical phase sequence at installation
and prior to start-up. Operation of the unit with
incorrect electrical phase sequencing will result in
improper pump performance. Check the phasing
with a phase sequence meter prior to applying
power. The proper sequence should read “ABC” on
the meter. If the meter reads “CBA”, open the main
power disconnect and switch two line leads on the
line power terminal blocks (or the unit mounted
disconnect). Do not interchange any load leads that
are from the unit contactors or the motor terminals.
WARNING: This equipment contains hazardous
voltages that can cause severe injury or death.
WARNING: This equipment contains hot water or
coolant under pressure. Accidental release of hot water
or coolant under pressure can cause personal injury
and or property damage.
WARNING: This equipment may contain fan blades or
other sharp edges. Make sure all fan guards and other
protective shields are securely in place.
WARNING: The exposed surfaces of motors, piping,
and other fluid circuit components can be very hot
and can cause burns if touched with unprotected
hands.
CAUTION: Disconnect and lock out incoming power
before installing, servicing, or maintaining the
equipment. Connecting power to the main terminal
block energizes the entire electric circuitry of the unit.
Electric power at the main disconnect should be shut
off before opening access panels for repair or
maintenance.
CAUTION: Wear eye protection when installing,
maintaining, or repairing the equipment to protect
against any sparks, debris, or fluid leaks.
CAUTION: Wear protective gloves when installing,
maintaining, or repairing the equipment to protect
against any sparks, debris, or fluid leaks.
CAUTION: Wire the unit ground in compliance with
local and national codes.

4
Controller Operation
Figure 1 –Basic Controller Home Screen
This is the default operating screen display after
power is applied and the controller has gone
through its initial start-up. It is also the screen that
displays after exiting one of the submenus.
The temperature control unit includes a controller to
perform all control functions directly from the front
panel. When power is applied to the unit, the
controller lights up and “Loading . . .” appears on the
display for a few seconds while the controller boots
up. The controller then displays the software version
followed by a display of temperatures.
Soft Buttons
There are three buttons under the display. The
function of these button changes depending on
which menu is in use. The active function of the soft
button shows in the box on the display immediately
above the soft button.
Increase Button
The increase button is used to raise the temperature
and for selecting items in various menus.
Enter Button
The enter button is used to confirm a temperature or
parameter adjustment in various menus.
Decrease Button
The decrease button is used to lower the
temperature and for selecting items in various
menus.
Changing Setpoint Temperature
Changing the set point temperature requires the unit
display shown on the Home Screen. Use the increase
or decrease buttons to change the temperature
shown until the desired new set point temperature
shows on the screen. Once the desired temperature
shows, press the enter button to enter the new set
point temperature.
Changing Temperature Units
The temperature unit in use shows in the display as
°F or °C following the set point temperature. The
default temperature unit is °F.
To change the temperature units of measure, stop
the unit. Start from the Home Screen and press the
menu soft key (the button under the symbol
in the box on the screen). Use the next soft key (the
button under the “Next” box on the screen) to
navigate to page 3/6. Then press the enter button
until the bottom row shows “Units” and use the
increase or decrease buttons to change the
units. When changed, the controller will reboot to
implement the change.
Changing Temperature Displayed
The controller always displays the set point
temperature. The second temperature display is user
selectable to be supply temperature, return
temperature, or average temperature. The default
display is supply temperature.
To change the temperature displays, start from the
home screen and press the menu soft key (the
button under the symbol in the box on the
screen). Use the next soft key (the button under
the “Next” box on the screen) to navigate to page
3/6. Then press the enter button until the bottom
row shows “PV Source” and use the increase or
decrease buttons to change the units. When the
desired temperature display shows, press the soft
key button to save the new selection. Press the
exit soft key (the button under the “Exit” box on
the screen) to return to the Home Screen. The new
temperature display now shows.
Using Mold Purge Option
If the unit has the mold purge option, this feature is
active and “MP” appears above the soft key on
the Home Screen. The mold purge option allows the

5
unit to clear the process lines of fluid using a
compressed air source connected to the unit.
To initiate a mold purge, stop the unit and make
sure the cooling source water feed is closed to keep
compressed air from enter into the cooling source.
Then press and hold the mold purge soft key (the
button under the “MP” box on the screen) for 3
seconds to initiate a mold purge cycle.
Once initiated, the screen shows “PURGING” and
both the cooling and purge valves open. The valves
remain open until the stop soft key (the button
under the “Stop” box on the screen) is pressed or the
mold purge time out timer has elapsed. The default
time out for the mold purge cycle is 60 seconds.
Start from the home screen and press the menu soft
key (the button under the symbol in the box
on the screen). Use the next soft key (the button
under the “Next” box on the screen) to navigate to
page 5/6. Use the increase or decrease buttons
to change the units. When changed, the controller
will reboot to implement the change.
Changing User Parameters
In most cases, the home screen is sufficient for daily
operation and monitoring of the unit; however, there
are a number of user menus and parameters
accessible for monitoring and adjustment.
To access the user parameters, start from the Home
Screen and press the menu soft key (the button
under the symbol in the box on the screen).
Use the prior soft key (the under the “Prior” box
on the screen) or the next soft key (the button
under the “Next” box on the screen) to navigate to
the desired parameter screen. Then press enter
until the bottom row shows the menu item desired.
Use the increase or decrease buttons to change
the parameter. When the desire setting shows, press
the soft key button to save the new selection.
Press the exit soft key (the button under the
“Exit” box on the screen) to return to the home
screen.
USB Port
The USB port located on the front of the controller is
used for factory programming only. Please do not
connect it to any devices such as a laptop,
thumbdrive, camera, etc.
Table 1 - User Parameters
Category
Screen
Number
Parameter
Default
Value
Range
Description
Deviation
Alarm
Setup
1/6
Warm Up
Delay
30 min
0 to 999
The time the unit waits after start-up that the unit ignores a temperature deviation
condition. If you have a large tool that takes longer than this delay to reach
steady-state conditions, increase this value to eliminate false tripping of the
deviation alarm.
High
Deviation
10 Δ°F
1 to 216
How far the supply temperature must deviate above the setpoint before a high
deviation condition occurs. This deviation condition is also subject to parameter
"High Devtn Dly".
Low
Deviation
10 Δ°F
1 to 216
How far the supply temperature must deviate below setpoint before a low
deviation condition occurs. This deviation condition is also subject to parameter
"Low Devtn Dly".
High Devtn
Dly
30 min
0 to 720
How long the unit waits before alerting the user via an alarm or warning once a
high deviation condition exists. If the deviation condition stops, the timer resets.
See parameter “Deviation Actn” for selecting whether a deviation condition
produces an alarm or a warning.
Limit
Alarm
Setup
2/6
High Temp
Alm
260°F
32 to 260
User configurable maximum temperature alarm.
Low Temp
Alm
32°F
32 to 260
User configurable maximum temperature alarm.
Lo Pres
Recov
1500 ms
0 to
60000
If the unit has paused operation due to low process temperature, this is how long
it will wait before automatically restarting after the return of pressure. If the facility
suffers from water hammer, increase this value to avoid false restarts.

6
Table 1 - User Parameters (continued)
Category
Screen
Number
Parameter
Default
Value
Range
Description
TCU
Setup
3/6
PV Source
To Proc
To Proc
From
Proc
To/From
Average
Allows the user to select which RTD temperature sensor is used for temperature
regulation. The selected signal is used by the control loop where it will attempt to
reach setpoint.
PV
Smoothing
5 sec
0 to 720
Used to smooth the RTD temperature probe signal. Normally, this should remain
in the 0-10 sec range, but can be increased if process fluid is not an equal
temperature throughout.
Low Pres
Count
3
1 to 25
Both of these parameters work hand-in-hand to define the TCU’s reaction to
multiple process fluid low-pressure events while the TCU is in operation. By
default, the TCU will tolerate up to 3 process fluid low-pressure events every 15
minutes; the TCU temporarily shuts down during the low-pressure event, and
automatically restart when the pressure returns. Because excessive, frequent
starting/stopping of the TCU can cause motor/pump damage, the purpose of
these parameters is to protect the TCU if operating in an environment with
unstable fluid pressure.
Low Pres
Time
15 min
1 to 999
Units
°F
°F or °C
Used to select the desired temperature unit of measure. After changing, the
controller will automatically reboot. Note that this parameter is NOT automatically
set to default if the user executes a “Load Defaults” to reset to default parameters.
Venting
4/6
Valve Vent
30 sec
5 to 180
Upon cold startup, the TCU will flush the process loop with fresh fluid to remove
air. The pump will not run during this time. Once finished, it will start the pump
and continue to flush with the pump’s assistance. No loop-temperature regulation
occurs in this state. Increase this value if you have an excessively long fluid loop.
Valve/Pmp
Vent
30 sec
5 to 180
Upon cold startup, and after the “Valve Vent” parameter’s time has expired, the
TCU will start the pump to assist in deaeration. No loop-temperature regulation
occurs in this state. Increase this value if you have an excessively long fluid loop.
Vent Bypass
120°F
32 to 260
If the process loop is above this temperature, the “Valve Vent” and “Valve/Pmp
Vent” will not occur. This makes the TCU restarts quickly, while still deaerating if
the machine starts from a cold state.
Control
Loop
5/6
System Size
---
Small
Medium
Large
This setting quickly selects factory-suggested parameters below for P-Band, I-
Gain, D-Gain, and Deadband. Select the setting that best describes your system.
“Large” is for a slow setting for systems with more than 80 gallons of fluid volume
and more than 5,600 lbs of steel mold mass. This setting has a proportional band
of 3ºF to allow a slower response. “Normal” is the factory default tuning setting
and covers the majority of applications with 10 to 80 gallons of fluid volume and
700 to 5,600 lbs of steel mold mass. This setting has a proportional band of 7ºF.
“Small” is for fast setting for systems with less than 10 gallons of fluid volume and
less than 700 lbs of steel mold mass. This setting has a proportional band of 15ºF
to allow a fast response. Alternatively, you can also directly edit the PID settings as
described below.
P-Band
10 Δ°F
0.2 to
999.7
Proportional Band for PID temperature control. A smaller number will promote a
more aggressive proportional response. At the default 10 Δ⁰F, this means that the
proportional response will be at 100% when the temperature is 10 Δ⁰F from
setpoint.
I-Gain
50
0 to 999
Integral Gain for PID temperature control. A smaller number will promote a more
aggressive integral response. Zero will disable all integral responses.
D-Gain
10
0 to 999
Derivative Gain for PID temperature control. A larger number will promote a more
aggressive derivative response. Zero will disable all derivative responses.
Deadband
0.5 Δ°F
0 to 99.9
Defines a region of process temperature deviation that will have no effect in PID
control loop. By having a deadband, wear-and-tear on the TCU is minimized
because it does not have to try as hard to maintain the process temperature
perfectly to setpoint.

7
Table 1 - User Parameters (continued)
Category
Screen
Number
Parameter
Default
Value
Range
Description
Additiona
l Settings
6/6
Deviation
Actn
Warn
None
Warn
Alarm
Allows the user to select how the TCU responds to a deviation condition (as
defined in screen 1/6 above). Warnings are visible on the screen, but have no
effect on machine operation. Alarms shutdown the machine and require user
intervention to reset.
Mold Purge
T/O
60 sec
1 to 999
After mold purge is started, this is the max time that it can run before being
automatically cancelled. Note that the user can stop mold purge at any time.*
*Only visible on menu if mold purge option is installed.
Diagnostics
No
No or Yes
Select "Yes" if you would like to enter the diagnostics menu.
Load
Defaults
No
No or Yes
Select “Yes” if you would like to load defaults for all user parameters. If you select
“Yes”, all your customized settings will be permanently lost and default
parameters will be used instead. The controller will reboot after implementing
default settings.
Factory
Menu
---
---
Used to enter a password for a factory configuration menu.
Table 2 - Factory Parameters
Category
Screen
Number
Parameter
Default
Value
Range
Description
Included
Options
1/2
MP Installed
No
No or Yes
Allows the factory to set whether or not mold purge is installed as an
option.
Setpoint Max
250°F
40 to 250
Maximum permitted machine setpoint.
Setpoint Min
40°F
40 to 250
Minimum permitted machine setpoint.
Cool-Heat Rto
1.25
0.1 to 10.0
Describes the effectiveness of cooling vs effectiveness of heating. Having
the correct value here enhances the performance for the PID algorithm.
For example, if the TCU’s cooling BTU removal happens at twice the rate of
the TCU’s heating BTU addition, this number should be set to 2.0. Systems
with small heaters and plentiful, cold cooling water may want a value of
1.5. Alternatively, warm cooling water or a very powerful heater would
work best with a value of 0.75. A value of 1.0 means there is no distinction
between heating/ cooling and the PID works in a very traditional manner.
Conduct any experimentation to set this value at lower process
temperatures.
Dynamic Mult:
1.75
0.0 to 10.0
This parameter helps the TCU achieve setpoint quickly and without
overshoot across the entire temperature range of operation. This factor
multiples the “Cool-Heat Rto” set in the parameter above at high
temperatures. For example, if “Dynamic Mult” is set to 1.75, a Cool-Heat
Rto of 1.25 will actually become 2.19 (1.25 x 1.75 = 2.19) when the TCU is
running at a process temperature of 250°F. Set to zero to disable all
dynamic effects, in which case parameter “Cool-Heat Rto” will be solely
responsible and at a fixed value across the entire temperature range.

8
Factory Parameters (continued)
Category
Screen
Number
Parameter
Default
Value
Range
Description
Additiona
l
Settings
2/2
Cooling Cycle
5.0 sec
0.5 to 60.0
Time base for solenoid cooling valve. If Cooling Cycle is set to 5.0s, and
the unit is cooling at 50% capacity, the solenoid cooling valve will
alternate between 2.5s on and 2.5s off.
Heating Cycle
10.0 sec
0.5 to 60.0
Time base for heater contactor. If Heating Cycle is set to 10.0s, and the
unit is heating at 50% capacity, the heater contactor will alternate between
5.0s on and 5.0s off.
Track Health
Yes
No
Yes
Provides machine run statistics and alarm counting for the diagnostics
menu. This can be disabled to decrease processor load or not track these
items.
Diagnostics
No
No
Yes
Select “Yes” to enter the Diagnostics menu. Note: Since you have already
authenticated as a factory user, you will have WRITE access to directly
control outputs for troubleshooting (except for heater output).
Load Defaults
No
No
Yes
Select “Yes” if you would like to load defaults for all user AND factory
parameters. If you select “Yes” all your customized settings will be
permanently lost and default user and factory parameters will be used
instead. The controller will reboot after implementing default settings. As a
factory user, you will need to then go back and properly configure the
factory menu according to the installed TCU options.
Note: The unit will not operate properly if the Factory Parameters are incorrectly changed or modified. For that reason these parameters can only
be changed once the Factory Menu is activated in the User Parameter menu (see screen 6/6 under User Parameters). Only qualified technical
personnel familiar with the operation of the unit should change these parameters and then only at the direction of someone from the factory
Customer Service Department.
Table 3 - Diagnostic Screens
Category
Screen
Number
Parameter
Device
Description
Digital
Inputs
1/18
Pres Swtch
Pressure Switch (input U1)
Pressure switch input shows "ON" when sufficient pressure.
Pump OL
Pump Overload (input U2)
Pump overload input shows "ON" when not tripped.
Pump Aux
Pump Contactor Axillary
Contact (input U3)
Pump contactor auxiliary contact shows "ON" when the pump contactor
is energized and seated.
2/18
Hi Temp
High Temperature Input
Jumper (input U4)
High temperature input shows "ON" when no high temperature
condition exists.
Heater Aux
Heater Contactors Auxiliary
Contact (input U5)
Heater contactor auxiliary contactor shows "ON" when heater contactor
is energized and seated.
Spare
Spare (input U5)
Input not used.
Analog
Inputs
3/18
Supply RTD
Supply RTD (input U7)
Supply "To Proc" RTD Temperature Probe, units always in °C.
Return RTD
Return RTD (input U8)
Return "From Proc" RTD Temperature Probe, units always in °C.
Spare RTD
Spare RTD (input U9)
Spare RTD Temperature Probe, units always in °C.
Spare
Spare (input U10)
Input not used.

9
Table 3 –Diagnostic Screens (continued)
Category
Screen
Number
Parameter
Device
Description
Digital
Relay
Outputs
4/18
Pump
Pump Contactor (output
NO1)
Pump contactor coil output.
Heat
Heater Contactor (output
NO2)
Heater contactor coil output.
Spare
Spare (output NO3)
Output not used.
5/18
Cool
Cooling Solenoid Valve
(output NO4)
Cooling solenoid valve coil output.
Purge
Purge Solenoid Valve
(output NO5)
Purge solenoid valve coil output.
Alarm
Alarm Active Output
(output NO6)
Alarm active output.
Runtime
Statistics
6/18
Pump
Pump
Pump motor runtime displayed in units of x100 hours. Pump contactor
actuations displayed in units of x100 operations.*
Heater
Heater
Heater runtime displayed in units of x100 hours. Heater contactor
actuations displayed in units of x100 operations.*
CV Open
Cooling Solenoid Valve
Cooling solenoid valve runtime displayed in units of x100 hours. Cooling
solenoid valve actuations displayed in units of x100 operations.*
7/18
Pres Switch
Pressure Switch
Pressure switch input actuations displayed in units of x100 operations.*
Mold Purge
Mold Purge Solenoid
(optional)
Mold purge solenoid valve coil actuations displayed in units of x100
operations.*
8/18
Pump OL
Pump Motor Overload
Pump overload input trips. The input transitioning to OFF is considered
an operation.
Alarm
Alarm Output
Alarm output actuations. The alarm output transitioning to ON is
considered an operation.
High Temp
High Temperature Input
High temperature input trips. The input transitioning to OFF is
considered an operation.
9/18
Cooling
Water
Cooling Water
Temperature
The cooling water temperature as measured at the end of the valve vent
during normal TCU startup. Value is saved through power cycles and is
overwritten at startup during the venting sequence.
Cooling LTS-
%
Cooling Long Term
Average Percent
Displays the average used cooling capacity after the unit reached
setpoint. This value resets if power is cycled or the setpoint is changed.
Heating
LTA-%
Heating Long Term
Average Percent
Displays the average used heating capacity after the unit reached
setpoint. This value resets if power is cycled or the setpoint is changed.
Runtime
Statistics
9/18
Lst Alm Dur-
s
Last Alarm Duration in
Seconds
How long the machine was in an alarm state. It counts from the initiation
of an alarm to the remedying of the condition or manual reset of the
alarm (for non-auto-resetting alarms).
Low Pres-hrs
Low Pressure Hours
The number of hours the machine was in a running mode but the pump
was turned off due to insufficient pressure to the unit.
10/18
Mem @-
x10000
Memory Writes
The number of times the memory has been written to. Shown in units of
x10000.
Loop Time-
ms
PLC Loop Time
How long it takes the controller to run the entire program and loop back
around to begin again. PID loop is updated only once per second
regardless of this value.
Max Lp
Time-ms
Max PLC Loop Time
The maximum recorded controller loop time once the controller had
loaded all initial parameters.
PS Volts-V
Power Supply Voltage
Incoming power supply voltage.
OS Freq-Hz
Power Supply Frequency
Incoming power supply frequency for AC supply. In the case of a DC
supply, this is shown as "0".

10
Table 3 –Diagnostic Screens (continued)
Category
Screen
Number
Parameter
Device
Description
Alarm/
Warning
Counts
11/18
Sup Probe
Srt
Supply "To Proc" RTD
Temperature Probe
Shorted Alarms
Note: Warnings that result from this condition are not counted.
Ret Probe
Srt
Return "From Proc" RTD
Temperature Probe
Shorted Alarms
Note: Warnings that result from this condition are not counted.
12/18
Sup Probe
Opn
Supply "To Proc" RTD
Temperature Probe Open
Alarms
Note: Warnings that result from this condition are not counted.
Ret Probe
Opm
Return "From Proc" RTD
Temperature Probe Open
Alarms
Note: Warnings that result from this condition are not counted.
13/18
Sup Probe
Err
Supply "To Proc" RTD
Temperature Probe
Channel Error Alarms
Note: Warnings that result from this condition are not counted.
Ret Probe
Err
Return "From Proc" RTD
Temperature Probe Chan-
nel Error Alarms
Note: Warnings that result from this condition are not counted.
14/18
Pmp Stuck
Clsd
Pump Contactor Stuck
Closed Alarms
Number of times pump contactor auxiliary contacts remained actuated
when the coil was de-energized.
Pmp Stuck
Open
Pump Contactor Stuck
Open Alarms
Number of times pump contactor auxiliary contacts remained open when
the coil was energized.
Htr Stuck
Clsd
Heater Contactor Stuck
Closed Alarms
Number of times heater contactor auxiliary contacts remained actuated
when the coil was de-energized.
Htr Stuck
Open
Heater Contactor Stuck
Open Alarms
Number of times heater contactor auxiliary contacts remained open
when the coil was energized.
15/18
Low Pres
Time
Low Pressure Shutdown
Alarms
Number of times the running TCU has remained in a low-pressure
paused state for so long that it created an alarm to turn itself off.
Low Pres
Evnt
Low Pressure Events
Alarms
Number of times the TCU had an alarm due to too many low-pressure
events within the selected time period.
Pump
Overload
Pump Overload Alarm
Alarms
Note: Warnings that result from this condition are not counted.
Overtemp
Over Temperature Alarms
Number of times the TCU has alarmed due to lack of signal on external
high-temperature input.
16/18
Tmp Ovr
Limit
Temperature Over Factory
Limit Alarms
Number of times the TCU has alarmed due to the process temperature
exceeding the factory high limit.
Tmp Und
Limit
Temperature Under
Factory Limit Alarms
Number of times the TCU has alarmed due to the process temperature
dropping below the factory low limit.
Tmp Ovr
Setng
Temperature Over User
Limit Alarms
This is a user-influenced alarm since the user picks the alarm trip points.
Tmp Und
Setng
Temperature Under User
Limit Alarms
This is a user-influenced alarm since the user picks the alarm trip points.
17/18
Flash
Memory
Flash Memory Warnings
Number of times an "excessive number of memory writes" were
detected.
Brownout
Brownout Alarms
Number of times the machine lost power while running. This will only
register if user turns this alarming on. Note: This functionality is not
available on all TCU models.
Electric
Power
Electric Power Alarms
Number of times the machine detected incorrect incoming power phase
rotation or unequal phase legs. Note: This functionality is not available
on all TCU models.

11
Table 3 –Diagnostic Screens (continued)
Category
Screen
Number
Parameter
Device
Description
Temperature
Loop
Monitoring
18/18
P:
Proportional Output
Contribution
The component of the PID output generated from proportional control.
I:
Integral Output
Contribution
The component of the PID output generated from integral control. A ↕
symbol means this value is free to change because the integrator is
active; alternatively a Ä symbol means the integrator value is frozen due
to output saturation (anti-windup), or a large difference between process
value and setpoint.
D:
Derivative Output
Contribution
The component of the PID output generated from derivative control.
X:
Output Multiplier
This multiplier is applied to the sum of the P, I, and D contributions to
generate the output percentage. It dynamically changes in proportion to
the difference between cooling water temperature and process
temperature. The aggressiveness of this multiplier is set by the factory
parameter "Cool-Heat Rto".
→
Output Percentage
The final output of the PID loop. This value drives the PWM generator for
either the cooling valve or heater. PWM generator outputs under 5% are
rounded to 0%, and outputs above 95% are rounded to 100%.
To: / From: /
Avg:
Process Value
The current process value. By default, the controlling process value, as
determined by user parameter "PV Source," will be shown. Temporarily
view the other RTD temperature probe values by pressing the key (this
will not alter which RTD is actually controlling the PID loop). The display
reverts back to the controlling RTD after several seconds.
SP:
Setpoint
Process setpoint. This can be modified by pushing the ↑ or ↓ keys.
Err:
Error Signal
This is the difference between the process value and the setpoint. The
goal of the control loop is to reduce this to 0° during operation.
Start-up
Every unit is factory set to deliver water in
accordance with the standard operating
specifications for that particular unit. Due to
variables involved with different applications and
different installations, minor adjustments may be
required during the initial start-up to ensure proper
operation. Use a qualified technician to perform the
start-up procedure in sequence. The following serves
as a checklist for the initial start-up and for
subsequent start-ups if the unit is out of service for a
prolonged time.
WARNING: This equipment contains hazardous
voltages that can cause severe injury or death.
WARNING: This equipment contains hot water or
coolant under pressure. Accidental release of hot water
or coolant under pressure can cause personal injury
and or property damage.
WARNING: This equipment may contain fan blades or
other sharp edges. Make sure all fan guards and other
protective shields are securely in place.
WARNING: The exposed surfaces of motors, piping,
and other fluid circuit components can be very hot
and can cause burns if touched with unprotected
hands.
CAUTION: Disconnect and lock out incoming power
before installing, servicing, or maintaining the
equipment. Connecting power to the main terminal
block energizes the entire electric circuitry of the unit.
Electric power at the main disconnect should be shut
off before opening access panels for repair or
maintenance.
CAUTION: Wear eye protection when installing,
maintaining, or repairing the equipment to protect
against any sparks, debris, or fluid leaks.
CAUTION: Wear protective gloves when installing,
maintaining, or repairing the equipment to protect
against any sparks, debris, or fluid leaks.
CAUTION: Wire the unit ground in compliance with
local and national codes.

12
Step 1 –Connecting Main Power
Connect main power properly ensuring it matches
the voltage shown on the nameplate of the unit.
Check the electrical phase sequence prior to start-
up. Operation of the unit with incorrect electrical
phase sequencing will cause damage to
components. Check the phasing prior to applying
power. The proper sequence is “ABC.” If the phasing
is incorrect, open the main power disconnect and
switch two line leads on the main power terminal
blocks (or the unit mounted disconnect). All
electrical components are in-phase at the factory. Do
not interchange any load leads that are from the unit
contactors or the motor terminals. After making
proper power connection and grounding, turn the
main power on.
Step 2 –Fill Coolant Circuit
Check to make sure all piping connections are secure
and that all lines are suitable for water or the coolant
in the system at the maximum set point temperature
and cumulative pressure rating of the maximum
pump pressure and the unit fill fluid pressure.
Make sure that the cooling source is the appropriate
temperature and pressure for your application. In
most cases, the cooling source is between 40°F and
85°F. The cooling source fluid pressure must be
above the set point of the pressure switch in order
for the unit to start. For most applications, the
design cooling source supply pressure is between 25
psi and 50 psi. Units with the 300°F operating range
option require an inlet cooling source pressure of 75
psi. If the total pressure in the unit (cooling source
inlet pressure plus the pump pressure) exceeds 150
psi, the pressure relief valve in the unit will open. If
this becomes an issue, install a pressure-regulating
valve (Part #9616548 available from our Parts
Department) on the supply line to help regulate the
pressure to ensure it does not exceed the pressure
rating of the pressure relief valve. For further
assistance in installing a pressure-regulating valve,
please contact our Customer Service Department.
System Fill Water Chemistry Requirements
The properties of water make it ideal for heat
transfer applications. It is safe, non-flammable, non-
poisonous, easy to handle, widely available, and
inexpensive in most industrialized areas.
When using water as a heat transfer fluid it is
important to keep it within certain chemistry limits to
avoid unwanted side effects. Water is a “universal
solvent” because it can dissolve many solid
substances and absorb gases. As a result, water can
cause the corrosion of metals used in a cooling
system. Often water is in an open system (exposed
to air) and when the water evaporates, the dissolved
minerals remain in the process fluid. When the
concentration exceeds the solubility of some
minerals, scale forms. The life giving properties of
water can also encourage biological growth that can
foul heat transfer surfaces.
To avoid the unwanted side effects associated with
water cooling, proper chemical treatment and
preventive maintenance is required for continuous
plant productivity.
Unwanted Side Effects of Improper Water Quality
•Corrosion
•Scale
•Fouling
•Biological Contamination
Cooling Water Chemistry Properties
•Electrical Conductivity
•pH
•Alkalinity
•Total Hardness
•Dissolved gases
The complex nature of water chemistry requires a
specialist to evaluate and implement appropriate
sensing, measurement and treatment needed for
satisfactory performance and life. The
recommendations of the specialist may include
filtration, monitoring, treatment and control devices.
With the ever-changing regulations on water usage
and treatment chemicals, the information is usually
up-to-date when a specialist in the industry is
involved. The table below shows the list of water
characteristics and quality limitations.

13
Fill Water Chemistry Requirements
Water Characteristic
Quality Limitation
Alkalinity (HCO3-)
70-300 ppm
Aluminum (Al)
Less than 0.2 ppm
Ammonium (NH3)
Less than 2 ppm
Chlorides (Cl-)
Less than 300 ppm
Electrical Conductivity
10-500µS/cm
Free (aggressive) Carbon Dioxide (CO2)†
Less than 5 ppm
Free Chlorine(Cl2)
Less than 1 PPM
HCO3-/SO42-
Greater than 1.0
Hydrogen Sulfide (H2S)
Less than 0.05 ppm
Iron (Fe)
Less than 0.2 ppm
Manganese (Mn)
Less than 0.1 ppm
Nitrate (NO3)
Less than 100 ppm
pH
7.5-9.0
Sulfate (SO42-)
Less than 70 ppm
Total Hardness (dH)k
4.0-8.5
† Dissolved carbon dioxide calculation is from the pH and total
alkalinity values shown below or measured on the site using a test
kit. Dissolved Carbon Dioxide, PPM = TA x 2[(6.3-pH)/0.3] where TA =
Total Alkalinity, PPM as CaCO3
CAUTION: When your application requires the use of
glycol, use industrial grade glycol specifically
designed for heat transfer systems and equipment.
Never use glycol designed for automotive
applications. Automotive glycols typically have
additives engineered to benefit the materials and
conditions found in an automotive engine; however,
these additives can gel and foul heat exchange
surfaces and result in loss of performance or even
failure of the chiller. In addition, these additives can
react with the materials of the pump shaft seals
resulting in leaks or premature pump failures.
WARNING: Ethylene Glycol is flammable at higher
temperatures in a vapor state. Carefully handle this
material and keep away from open flames or other
possible ignition sources.
Step 3 –Initial Unit Operation
Enter the set point temperature. Refer to the Control
Panel Operation section for further information.
Changing the set point temperature requires the unit
display shows the Home Screen. Once the Home
Screen shows, press the run soft key (the under
the “Run” box on the screen). Pressing the run
button enables the microprocessor control functions,
initiates an auto-vent sequence, and turns on the
Run indicating light, which is amber when the unit is
running.
The vent sequence removes air that may have
separated out from the water or been entrapped in
the water circuit for some reason. Air in the system
can lead to improper operation and premature
heater failure. When initiated, the auto-vent
sequence opens the cooling valve for the first half of
the sequence (30 seconds is the default value for
this) to allow the majority of the air to escape from
the system. During this part of the sequence, “VALVE
VENT” shows on the display.
For further air purging, the vent sequence energizes
the pump for the second half of the auto-vent
sequence (30 seconds is the default value for this)
while the cooling valve is open to remove any
remaining air from the system. During this part of
the sequence, “VALVE/PUMP VENT” shows on the
display.
Once the vent sequence is complete, the cooling
valve is closed, the pump remains energized, and
normal operation initiates.
Check the rotation of the pump by visually
confirming the motor shaft rotation matches the
directional arrow sticker on the motor case. If the
pump is running backwards, switch two of the main
power leads, after shutting off the disconnect switch.
The unit is now ready for service.

14
Preventive Maintenance
Once the unit is in service, we suggest following the
maintenance procedures as closely as possible. The
importance of a properly established preventive
maintenance program cannot be overemphasized.
Taking the time to follow these simple procedures
will result in substantially reduced downtime,
reduced repair costs, and an extended useful lifetime
for the unit. The following is a list of suggested
periodic maintenance.
Once a Week
1. Check to make sure that the To Process
temperature is reasonably close to the Set Point
temperature. If the temperature stays more than
2°F away from the set point, there may be a
problem with the unit. If this is the case, refer to
the Troubleshooting section of this manual or
contact our Customer Service Department.
2. Check the pump discharge pressure. Investigate
further if the pressure starts to stray away from
the normal operating pressure.
3. Check the pump for leaks in the seal area.
Replace pump seal if necessary.
Once a Month
Repeat items 1 through 3 listed above and continue
with the following.
4. With the main power shut off, check the
condition of electrical connections at all
contactors, starters, and controls. Check for
loose or frayed wires.
5. Check the incoming voltage to make sure it is
within 10% of the design voltage for the
temperature control unit.
6. Check the amp draws to each leg of the pump
motor and heater to confirm that they are
drawing the proper current.

15
Troubleshooting
Problem
Possible Cause
Remedy
Alternating
overheating and
overcooling or
rapid cycling from
heat to cool
Poor water flow
Check connectors and increase size if necessary. If there are
a large number of hoses and/or they are long, try to shorten
hose runs and use as large of a hose as possible to
minimize water-circuit pressure drop. If quick disconnects
with check valves are used, remove the check valves to
reduce pressure drop through water circuit.
Poor connection or failure of RTD
Check connection, replace if necessary
Failure of the microprocessor
Replace controller
Unable to heat
properly
Cooling valve is stuck in the open position
Flush out the cooling valve by adjusting the Set Point up
and down several times to open and close the cooling valve.
If this does not work, stop the unit and turn off the electric
power, shut off the cooling source, and take the valve apart
for cleaning or replacement.
Leaking connection and/or the manual pressure relief valve
is in an open condition
Check for leaks and replace any faulty valves
Immersion heater is inoperative
Have a qualified electrician check to see if the heater and/or
heater contactor are functioning correctly and replace any
defective components.
Controller failure
Replace controller
Failure of RTD
Replace RTD
Unable to cool
properly
Cooling water supply is not sufficient
Check to make sure the cooling water supply is of sufficient
temperature, volume and pressure for the unit.
Drain (cooling water return line) is not sufficient
Check the drain (cooling water return line) to ensure there is
no restriction preventing water flow to the drain (cooling
water return line).
Cooling valve is inoperative
Check the drain (cooling water return line) and see if you
can feel or hear a change in the flow as the cooling valve
opens and closes. If you cannot hear or feel the flow it is
likely the valve has failed. Replace valve if necessary.
Plugged heat exchanger (only on models with heat
exchanger option)
Clean or replace heat exchanger
High backpressure in the cooling water system
Reduce backpressure
Heater failure
Unit not filled with water
Fill unit with water
Faulty heater
Replace heater
Plugged heater tube / flow restriction
Clear obstruction
Pressure relief
valve leaks
The combined pressure of the incoming cooling water
pressure and the unit pump pressure exceeds the pressure
rating of the pressure relief valve
Install a pressure-reducing valve on the incoming cooling
water line. Review the start-up procedure for cooling water
pressure requirements at various operating temperatures.
Pressure relief valve stuck in open position
Replace valve
Drawings
We have prepared a custom set of drawings for your unit and placed them on top of the unit prior to shipment.
Please refer to these drawings when troubleshooting, servicing, and installing the unit. If you cannot find these
drawings or wish to have additional copies, please contact our Customer Service Department and reference the
serial number of your unit.

16
Notes