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Upright Hot Oil Temperature Control Units Models Covered: TCO-U; 2016U Part Num

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: þ Portable Hot Oil TCU þ Bill of lading þ Packing list þ Operating and Installation packet þ Electrical schematic and panel layout drawings þ 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 ............................................. 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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 uploads/Industriel/ user-guide 16 .pdf