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USERGUIDE

Thermolator
Oil Temperature Controller
Start-Up Guide

microTrac 3 Control
microTrac 1 Control

WARNING - Reliance on this Manual Could Result in Severe Bodily Injury or Death!
This manual is out-of-date and is provided only for its technical information, data and capacities. Portions of this manual
detailing procedures or precautions in the operation, inspection, maintenance and repair of the product forming the subject
matter of this manual may be inadequate, inaccurate, and/or incomplete and cannot be used, followed, or relied upon.
Contact Conair at info@conairgroup.com or 1-800-654-6661 for more current information, warnings, and materials about
more recent product manuals containing warnings, information, precautions, and procedures that may be more adequate
than those contained in this out-of-date manual.

Corporate Office: 412.312.6000 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861
When attempting maintenance of any kind on the Thermolator, press the STOP
(RES) button and disconnect thepower supply and let the unit cool to_ less than
12SF before any other action is taken. ~

To change rotation direction;

Disconnect and lock out the power at the fused disconnect.

Open the electrical access panel. the door will fold open exposing the electrical
compnents and mother board (MT3 ).

Reverse any two incoming leads at the powerte:rn:riilal block. Donat switch leads at the
motor or motor starter.
Power

Check your work. close the electrical acc~ss

panel. reconnect the power suppiy, and proceed
to Start Ihe unit.
!131
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Note:

Cooling on a Thermolaror Oil Temperarure Conrrol Unit is optional

TC-400 Oil Temperature controllers are designed to operare from 70F to 400F. TQ-500 Oil
Temperature Control Untis are deigned to operate from 70F to 500F. T-C-500s require 2GPM of 85F
pump seal cooling water.

Conair Tempro tests with, and recommends the use of Parathenn NF Heat Transfer Fluid in their
Thermolator Oil Temperamre Conn-oilers. If an alternate hear transfer fluid is used, all of the
manufactures recommendations for flushing the piping system of the Thennolaror must followed to
prevent failure of the equipment.

TheThermolatorsphysicald.imensionsare33" deep, 15" wide,and43" tall Tnepipingprotruding:from

the back of the unit must be considered when locating the unit. In addition, 6" around the sides, and a
minimum of 12" of top clearance should be allowed in order to dissipate heat

Only the TC-500 Thermolaror Oil Temperanrre Controllers have an absolute minimum requirement of
2 GPM@ 85F of cooling warerforthe pump seal cooling. For those TC-400 or TC-500 Tnermolarors
that were purchase with a hear exchanger option, a minimum of 25 PSI and a maximum 85 PSI must e.
supplied to the unit to achieve proper cooling. Cooling water lines must be 711Il full size to the unit i.i.J.
ord..."'T t0 reduce line pressffi"e drops.

TC-500s must have seal cooling water flowing whenever the process temperature is above 150F,
inciuding when the unit is shut down. Failure to do so will damage these.al immediately.

TEE::Z~\:iC)L:\TOR C~ - 0:1 :-.:mper:J.Lure c:nntrailer .. S:::u--r-C (~ude

P:!ge ::
microTrac 1 Control Panel
The microTrac 1 control panel has 3 function areas; Display Screens, Action L.E.D.s,
and Control Buttons.

Display Screens The Process Display continuously displays the process oil temperature of the
Thennolator.

The Set Point Display shows the oil temperature SET POINT selected by the
operator.

Action L.E.D.s There are 2 categories of L.E.D.s; Action Monitoring, and Waring.

Action Monitorjn~

Pump - Indicates the pump is working.

Vent - Indicates that the Thermolator vent se-

Heat

Cool - indicates the cooling solenoid, for units

equipped with a water cooling heat ex
changer, has been opened by the controller.
t.:

Warnjn2 L.E.D.s
Low Oil Level - Indicates that the process oil level'is low.
Check oil level in tank.
Check oil lines and process machinery for oil leaks.

Pump Overload - Indicates that current drawn by any of the three power
source lines (phases) exceeds factory specifications.
Inspect pwnp for jaming of obstruction of impeller.

THEJ, _.:)LATOR Oil Temperature Controllers Start-up Guide

Pa2e7
microTrac 3 Control Panel
The microTrac 3 Control Panel consists of five areas that provide process information
and control.
PROCESS DISPLAY UNITS DISPLAY CONTROL BUTION

ACTION L.E.D.

Process Area The Process area contains, a display screen, and elevenL.E.D .s which indicate trouble
conditions.

The Process display screen shows the process oil tempera-

ture.

The eleven L.E.D. indicators in this area are used to indicate

any alarm condition th :nay occur. Mc
.. tors , . covered in tht roublt! Shoot
mar: ..il.

THER. LATOR - Oil Temperature Controllers Start-up Guide

Pa2e 9
microTrac 3 Control Panel

Heat
The HeatL.E.D. will light indicating the heater hasbeen rurned on by the comroller.

Ramp ~
The Ramp L.E.D. will light when the control is raising or lowe..'1.ng the process
temperature to the Set Point.

Comm
The Comm LE.D. will flash on indicating that communication with a host machine
has been enabled. When the host machine makes a change to rhe micro Trac 3 control
paramerers, the Comm LE.D. will fla..sh off. The display L.E.D. for any parameter
that has been. changed throu~ communication will also flash when selected.

Cable
The Cable L...ED. will light indicating the conrrol panel cable that links the con.rrol
panel to rhe mother board is improperly connected., or is not a proper cable rype.

Test
The Test L..E..D. will light indica.cing the unir is in the diagnostic test: mcce. The
process display s~.n. will also show "SEL'' and rhe display screen will indic:ue .e
numbe: of the spe:-:..:5.c test :illour to be preformed.. For IiJ.Ore on diagnostic ~s'li:.g,
see Chapter 8, System.Test. The Test L.E.D. must be off for proper operntion i:O
occur.

~ Locked.
~ The Locked L.E.D. will li;:-n1 wnen ille lockiilg key has C;ee.n e::;.aOied.. .:.ne Co::::::-ol
Panei Locking Key is a use: option as well as a focto:ry insialled oprion. ::=-or =ore.
on die lo:king key option, s:::: C1apte:- 5, Basic 0~-::::-auons & =xua ?~a.ru.:.-es.

Auto
Tne Amo LE.D. will flash ';;.D.en dJ.e aurostart c3.paoiliry is es.abled. Tne I.. ::-D. '.:..:i11
remain 5.asbing when the ur.i[ is sta.i."1ed. or swpped. by L.1e 2.UtOSta.i."1: oprion. :::or :::.ci~
on c.he aumsra:: option, see i2apr~: S, Basic ()pe:c.rions & :=.~::c.. F~2.rJi~s.
microTrac 3 Control Panel
Ramp (White)
At anytime the Thennolator Oil Temperature controlleris operati.ng:in amode where
it is gaining or losing temperature the RAMP function may be activated. This'.function
allows the ope..atorto establish a serrate at which the unit will heat or cool the'process.
This is done be setting :into the MT-3 control a value of time, :in seconds, that the
controller must allow to time out before it can raise or lower the process temperature
10 F.

The default value forthe RAMP function is 300 seconds orfive minutes per 1 F. This
means that ifthe unitisinaheat:ingmode, everynveminures. (300 seconds), the MT-
3 control will raise the temnerature 1F.

Wben the RAMP burron. is pressed the con.rrol will ramp me process to the tempe:ramre
set point.

To change u.~e RA1\1P time value;

When attempting maintenance of any kin.don the Thennolator, press the Stop
(Red) button an then disconnect the power supply and let tb.e unit cool to less
than 125 F before any other action is taken.

Ope~ tie elecrrical access panel by rurnlilgthe icdci.11g

.. sc:-ews counre:rclocbvise. T.:le
elec..-~cai. access panel will foid down exposi..'1g :.:.~e elec:rical components and. moce:-
.
'ocarc...

Gsmg 2. :;w point pen1 smrc!J. C:Jili.::giJ..i.-ati.on S",.;riLch l~ labeled "S ysrem ~es! YioC.e
;i'

012 the =:i.oilie: board :o t.i-ie "ON" ?Ositiorr. "ON'' w111 be ~ndic:ned. by an arrow on :2::
svvi.rc:: Jloc.k.
ON
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..,.____.. L2

- FUSED DISCONNECT
BY OTHERS
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L3 1
1 1l L1
lrr
----------------------~
r I I I I I
L2

L3
2Ml 2Tl

GROUND

\./IRE PRIMARY SIDE OF TRANSFORMER L_~~~~~~~-------,

~: :::: ~ HEATER I
PER CHART

t x6 . X5 . xy x2 x1 I
~ 1
X12

.,!.
3 X14 GND 2 HEATER
CONNECTIONS
2
TERMINAL CONNECTIONS
51 I 52 I 531 54 I 55 2.0;230V/3PH/~Z cTl
3.________..__ ~ L------~------<. 55 GROUND 2T2

L--~---------,54 2T3
FS [___ _ _ _ _ _ _ _ _ _ _ _ ~ 53
0 0
r------~-------------, 52 TERM!NAL CONNECT!ONS
I OPTIONAL I 460V/3PH/60HZ :~~
: KEY S\./ITCH : 51
I 3 __k I
+-~-------+--<(?------'-~ 9'----~-t----~~------------~---~ 103 VSD 7 2T3

L--------------------~

.-----~>------<~>------<12
3 3 12 12 AUX ALARM 2
0

CR

2 J LEVEL HI TEMP
-~~-----~4~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 104 VSD 6
CONTROL TRANSFORMER
PRIMARY VIRING CHART

LM" ,11
1 O'LOADS
4 ~ 5 5 6 6 2
f------~>----<~- ~ - - - / > - - - - - - < E - - - - - - - - - - - 1 PUMP

~---< 106 VSD 1 1M4 1.1

t_ .~___l 240 VOLT
4
1-------i>----<~>------<<
7 7
r
7 7
, HEATER

4 " . , _ ~---1
1--------i>----<~>------<~---------------ll--------------___J
9 9
'--------<(107
9

'------< 109
VSD 2

VSD 3
lSOL

2SOL
I 2
COOL J.1 JtJl
480 VOLT
I I

4 t_ ~
~------l>----<~>------<~--------------_.
__ _lo 10 10 10_ _ _ _ _ _ _ _ _ _ _ _ _ ____J\ 2
VENT
CCLOSED
'-----<110 VSD 4 CIRCU!Tl

CONAIR 117:i1Ji\V'I3Ril'D
ELGJN.~~ISU.S.A.
TEMPRO C3l.2) SS8-813QQ

B I cow-LI<T TO DtL sctiDIA nc

A I GENERAL F"OR COJ.0.U:RCIALIZATIDN

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'SYMBOL! DESCRIPTION
PUMFf: I OIL PUMP- Scot with seal cavity vent
,;,:
HTR j: I OIL IMMERSION HEATER
SOLi!' I' SQLENOID VALVE, VENT
FILL: PRY!: I PRESSURE RELIEF VALVE
BY t , . SQUARE HEAD, COCK VALVE
FLsw; ' I SE;LA COOLING WATER FLOW SWITCH
3 GALLON FLT l I OIL; FLOAT SW.ITCH
., RESERVOIR
I TAS j:1
I OVERTEMPERATURE SAFTEY
TC s:i I T'~.PL.(K)UNG,6",304SS p ,W /6'LEAD
VENT/OVERFLOW SG FLT TCTR r f'CPl..,(K)UNGJ)"]o4ssP:W/18'LEAD
(PIPE TO AN APPROPRIATE
COVERED,VENTED,METAL RECEPTACLE.) SG '.! I SIGHT GLASS,3/ 4,500 DEG
PG i PRESSURE GAUGE, 60 --P-.S-.1-.- - - - - - <
* HTX ij, HEAT EXCHAN\;ER (OPTIONAL)
SOL
~ * CLSOL , SOLENOID VLV, COOLING (OPTIONAL)
N.C.
.:.:n. fi(\l~'i" re * CK ii, C~ECK VLV . (OPTIONAL)
TO r~ I ~ * OPTIONAL ON ALL UNITS. - - - -
PROCESS -c
TAS Ii
T PRY
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COOLING WATER i ~
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INLET ''
SEAL COOLING ,,
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COOLING WATER SOL ii i:;
ii
OUTLET

FROM PROCESS c
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C'ONATI10 ,. ,
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. 1175 DAVIS ROAD
ELGIN, ILLINOIS U.S.A.
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T1EM1PRO <708~~~;~8800
N
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HTX HTR
OPTIONAL
'.OIL: THERMOLATORS 1 :.

I1~/~;gsl ~IoN'E
DRAVN. BY, . 1APPROVED BY
WJS TW
.JOBlt,i DRA'w'ING NUMBE:Ri- CHECKED BYr -REV
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09003066A 96
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; _ _ _ _ -- _ .. 1

SYMBOL DESCRIPTI01\: ) ;
FILL
PUMP OIL PUMP- HT0-80 with seal __C~\fil2' vent
HTR OIL IMMERSION HEATER
SOIJ . SOLENOID VALVE, VENT
3 GALLON ----
RESERVOIR PR\/, PRESSURE RELIEF VALVE
BV;L SQUARE HEAD COCK VALVE
i
VENT/OVERFLOW ~ I
COVER~D.VENTED,METAL ~
PIPE TO AN APPROPRIATE SG N.o. FLT FLT OIL FLOAT SWITCH
RECEPTACLE.) I I TAS, OVERTEMPERATURE SAFTEY
re: s T'CPL.(K)UNG,6",304SS P,W/6'LEAD
1
TCI R T CPL,(K)UNG,6",304SS P,W/18'LEAD
..- SG' SIGHT GLASS,3/ 4,500 DEG
. TO PG.: PRESSURE GAUGE, 60 P.S.I.
PROCESS *I HTx: HEAT EXCHANGER. 4.3 SQ FT (OPTIONAL)
PRV *I CLSOL
,,
SOLENOID VLV, COOLING (OPTIONAL)
(OPTIONAL)
*
~\
OPTIONAL ON ALL UNITS.
!;'
HTR
COOLING WATER PUMP )1
INLET
~ I '

COOLING WATER ~CLSOL

OUTLET .l
FROM PROCESS c
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N '. , CONFIDENTIAL
N
G 'This drawing, information and design are the
G propi!rty of Conoir Inc.. This drawing and information
ore confidential and must not be copied or mode
HTX HTR public witho'ul prior written approval from Conoir.
Acc!lptonce or possession of this drawing constitutes
OPTIONAL lfull ogreemenl with the above conditions.
:1.
"
CUSTOMER NAME
'~--::Jr
CUSTOMER LQCATIO~I
PURCHASE ORDER:OOOOOO~OOO
Cf!#.IVAIR
ONE CON!llR ORIVE, PITTSBURGH, PA 15202, (412)312-6000

ti("/} I t4< MODEL NUMBER HEATRAC

ll---+----------"--1---l---11VOLTAGE
~=~ BY:l~Jfo 97
480/3 60 SCALE'
FLUID HEAT TRANSFER GROUP

REVISIONA ~
F.L. AMPS 1---n-'o-'-n.c;:.e_ _,___ __,--'--1
A ADAPTED FOR HT0-80' 10/97
REV DESCRIPTION DATE
IWJSllHEATER
BY
KW
Pl l!AP J.lP
16.12,18
1 ? .l
I Q 9 QQ 3 Q 6 6
OWG. NO.
 ,

AMP AtllJ IOLOWAH CAl'ACllY .~llAflr roll JIU WAllJl llEAUllS

.
WHll 6'fl.lMf:lilS
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[ ==i = TllE llEATER'S RAlED AMPS ANO l<ILOWAT(S DllR =oo NOT wmE 1WA1rns ;ron 111EsE vALUEs
Pl\RT NUMBER: 90015'10 DESC: GKW, 300V . TYPE: OIL SINGl.I: ELEMENT "ES.ISTl\NCE:
'\\ \:
150
;
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SERIES DELTA llAlf- DEi.TA SERIES WYE llALF WYE PAflALLEL DELTA:: ' PAIV\LLEL WYE ' WYE DELTA
VOLTS REG= 179.0219 llEO= 09.[i781 flHl= 537.2 nr:o"' :wn.o llHI= 'l'l.319,,' nr:o~: 13'1.3' nEn= 61.778
KW fl. KW A l<W A 1(w A KW I\ l<W. I\ KW A
208 0.36 1.00 0.04 2.32 0.14 0.39 0.20 0.77 l.69 4.69 " 0.5~: 1.55 ': 1.21 3.37
230
aoo
0.44
t.20
l.10
1.02
1.02
2.10
2.57
4.24
0.17
0.47
. 0.43
0.11
0.34
o.93
0.00
1.41
2.07
--- - . ,, __
6.04
,. - 6. lU
'
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- .....,,, i

0.67 : ' t.oo

0.00'
' : '
1.71
2.03
1.48
4.05
3.72
6.16
415 1.43 1.99 3.33 4.03 0.66 0.77 1.11 Ui6 6.73, 9.36 ' 2.22: 3.09 4.63 6.72
460 1.70 2.21 4.09 6.14 0.68 0.06 1.36 1.71 0.27 10.30 ' 2.13' 3.43 6.93 7.46.
675 2.76 2.76 6.39 6.42 1.07 1.07 2.13 2.14 12.92 12.97 '. 4,20; 4.28 9.27 9.31 ..

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SERIES DELTA SERIES WYE PARAU..EL DELTA DELTA WYE

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llALF DELTA llALFWYE PARALLEL WYE
'-----_.;_~--- ..:..L'

T,;
-----'
:r:
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:jJ ti
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 , \ j I l - I1 . lt;I I '.J/, l .'l'. IJ.'ll V1:\li.I( 111./lll.h,> \/11110 1.1.l;ltltlllJj.
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L '=HIE llE/\IEH'S IV\1[0 /\MPS ANIJ l<ILOWAllS Jii~~~-lii!~~liln .. (JO NO l WIHE llEA fo:>I rd1t 11 IESE VALUES
I :lr .\ :
PART NUMBER: 9002010 OESC: 61<W, 200V lYrE:. OIL SINGLE ELEMENT RE~l~TANCE: 42.6
srn1Es DEUI\ I
111\LF DHTf\. SEntES WYE' llAlf WY~ P/\11AllEl DELTA WYE DELTA
VOLTS I REQ= '10.26793 , l?EQ::: 2'1.15207,~Q,,, 144.0'1 UEQ,,, 72.'12 UEQ~ 11EQo 16.6566
-- KW I\ l<W I\ l<W A l<W A KW KW A
200 l.55 4.31 3.10 0.61 0.52 1.4~ 1.03 2.07
230 l.90 4.77 3.79 9.52 0.63 1.5/;I 1.27 3,.10
300
415
5.10
6.10
7.0 7 '~' ~~~.~~'.,; aJ.\ ~~ 7. ~~1~::.
1.1\2,j!J:11 '. 11 lJ,fo.'Li
1.73. 2.6~ 3.45 d.w
0.60
'160
575
:!( 7.591::
~ .' 11 '.06'!';
I ,: . 'r. ,.. ~.rt' I ~;} ~, j, . .,'.!I, ! ', I. I
i:19.u3; 1J ,1u.17 1ii .; .19.0o,1;,
: ;!';_.;:

' ..f1 \ \ il 1'';;;; 't ,~, ;1 "I\'!"' '': 1 .i.. o' 1 ;j~.'.'
Y ... ~ 3 ./ :
1
I 2 J. 1.r
2.06
2.53
3.95
2.07
3.10
3.97 .
11.12
!Hl6 I 5.73
6.35
IWJ!rn~ 1'.iii~:;:11 ~1113~'1R1.1ri:~);
: I ml.' 't. . .Ni'.~~1t ,,J~~ ,J)''l.1,.~1 .

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SERIES DELTA SERIES WYE PARAll.EL DELTA DELTA WYE

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:)
_1,_

i.
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HALF DELTA HALF WYE PARALLEL WYE
I' '

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l\IYll "1 lll IUl u v'//\ II l. Al' AC II V LI !Alli I Ull ()II HJ WAIW lll:AIU!S Wllll 6 u'.u.11.111!.i
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I . : .
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[ .. , ) = JllE llEAlEn'~ llATED AMPS AND KllOWATlS: =DO NOl WlllE llE~ l~ns Fpn 11 lf:SE VALUES .i
l ;;' '. i '
PART NUMBER:

VOLTS I l<EQ=
srnrEs DELTA
60.044705
9001579 OESC:

l<EQ=
61<W,
llAl.F nr:uA
30.'14522
I
230/466V ___

2~Q:::
iVrE:-~oii.

~ srn1Es wvr:
102.50
I ltAl.F WYE
UEQ= 91.29
I
_________ i ___ -- siHGi.E EiEMEIH fi~s.isiAtj~E:
PAnAUH DEi.TA
nEQ::: 15.0620~ ~Q.=
'I PAlt/\LLH WYE
53.7

45.6'15"
I WYE DELTA
UEQ= 20.9967
KW A l<W A l<W A KW A KW A : t<.W A KW A
200 1.23 JJ12 2.46 6.o3 0.41 1.1 tt 0.02 2.20 _j_'.97 I 13:~ 1.61 4.56 3.s1 9.91
230 l.51 3,70 .,?91 .. ' 7.~~., ;
I I 0,50 1.26 1.00 ~,52 6,06 15,27 ': 2,0~ : 5,04 . ~.~-~,. .'?9~
.~_f_:i_;~_.l.tl.~_'.~_~: 1~---~_:_~rn!_.~~1\~ .~_-._ 1~J_; _.l,'1 ~. ,~,-~t_ _ J~Y_)~~~~~ll.an_9!1
11
1
JOO
415
4.11
4.90
6.2s
6.02 ,ii.,9~00 i :';~'IJ:6a,1n~1
1.37.
1.63
2.00
2.27
2.14
3.27
4.16
4.55
._,- 1no.1.,._ ,1_~ 1
,11rtr'~1~ 1 i.L'.~'-.1.,. 1~ -1 6.54
5Ao
9.09
o.33
. : .~ 1 ~f~~ ~i~)irJ.f
460 - - - - - ' - - - 1 1 t f t"~'f:' 1q~\!.l11$''~
6.02 7.56
1
1',J:?uit : ~';~: t>J li;j 2.01 2.52 4.01 5.0tl :;~~~~~
i ".)'_ J . -I.I
;
_l!L~ft
uo! '~' _~1.~~~~l''ll"il~'
1
;1, !l~1,QuJ.11ni'.t.' ~Mt-1~'6'U11l
~~:i:7 o. u.~m t~l.f .~.t-1' 5,\i,~d,. -~['!> o
~.. ..,,~y
~~ 1' L ~r !.'.t~'~/ i1'1~-if l:!t.~ .~ -~, '. 1,i 1~!. ~3' ,J11JB. \-t~f,1!! :: !. t{lit;J:.f~,J~ ~I !1J u~j ti ~ r~" .'itfit1o!i ( : ,/'~tit~ .;; f.
575 ::li:(,.,Y.'l~,t.':'i! :: I~~ l',li~ J\.,i UL Jfi 3.14 3.15 6.27 6.30 j,H,~,,,lf4,: ,ifJ~!Jl]d' ;J:.l 2v5l)I;' :0 ll:~V.'f ~- 7/1.7.h; :i~i2f1~9i .'

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SERIES DELTA SERIES WYE PARAI..l.EL DELTA OELTA~YE
., '
1

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HALF DELTA llALFWYE \ ~ARAU.Et; WYE
., :
i ~
 " , ,. .. Ht , ' " ' I .. . ' : < " ' ' . "''' ;111\ll.h lll./ .. t,1,.1 1111111) lti: h'.11.fll,t, i: ,

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f =HIE llE/\1En'S iV\l[I) /\MPS /\NO l<llOW/\llS .: tllft(r~i = 00 NOT WlllE llEAii::Hs t:Olt'.lltESE V/\LUES
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 TROUBL OTING
If there is a problem, the Thermolator activates the red Alarm light
and changes the RUN/STOP light from green to flashing red. Thermolator
D Press
fJ toCheck
to silence the optional audible alarm.

the indicator lights and messages -

heaTrac
help determine the cause of the problem. '
Oil Temperature Controller
& WARNING: Before servicing the Thermolator with TH-2 Microprocessor
Allow the unit to cool to below 1 oo
F. Disconnect and lockout
the main power source. Disconnect water and air supply lines .

Actual temperature of oil supplied to the

Shut down alarms
The Thermolator has shut down automatically to prevent
damage to equipment or personnel. To resume normal
operation, press E, fix the problem, then press mmJ.
Pump
The pump overload has tripped. Contact is open.
1. Verify that the correct voltage is supplied to the motor.
2. Fluid flow may be more than the pump can handle.
Check current draw against motor rating. Decrease flow.
mold higher than the programmed 51 o F
safety limit.
1. Oil has stopped flowing between supply outlet and return
inlet. Check for closed valve or plugged line.
2. The heater contactor failed. Replace contactor.
Actual temperature of oil supplied to the
mold is below the programmed 60' F
safety limit.
1. The cooling valve is stuck open. Clean valve.
2. The heater has failed. Check for a bad heating element,

Low Oil Alarm
The oil level in the unit reservoir is too low.
1. Check reservoir and add oil as needed.
Low Water Flow Alarm
There is not enough cooling water at the pump seal.
1. Check the water-jacketed seal chamber at the pump.
High Temp. Safety
The actual temperature of oil supplied to the mold
exceeds the temperature safety switch limit.
1. The unit is not running. Start the Thermolator.
2. Oil has stopped flowing between supply the outlet and
return inlet. Check for closed valve or plugged line.
3. The heater contactor failed. Replace contactor.
or a heater contact that failed in the open position.
The incoming power is out of phase. A
leg may have failed or is disconnected.
1. The pump is rotating in the wrong direction. Reverse any
two leads on the power connection.
2. Check fuses or circuits at the main power supply.
The return line temperature probe failed.
Check for loose connections, or replace.
The supply line temperature probe failed.
Check for loose connections, or replace.
The pump fuse failed.
Replace the fuse on the motherboard.
NOTE: See the Thermolator User Guide for additional alarm mes-
sages regarding fuses and controller errors.

Warning alarms
~
~ High Deviation
Actual temperature of oil supplied to the mold is
The Thermolator continues operating, but this problem higher than the setpoint deviation limit allows.
could lead to a shutdown condition if not corrected. 1. High deviation temperature is set too low. Increase. The Conair Group, Inc.
2. Oil has stopped flowing between supply outlet and return One Conair Drive
Low Deviation
inlet. Check for plugged pipe or failed cooling valve. Pittsburgh, PA 15202
Actual temperature of oil supplied to the mold is lower 3. The heater contact failed. Replace the contactor. Phone: (412) 312-6000
than the setpoint deviation limit allows. 4. The heater and lines may be too large for this application. Fax: (412) 312-6001
1. Low deviation temperature is set too low. Increase.
2. The heater failed. Check for a bad heating element or a SPI Communication
heater contact that failed in the open position. The SPI communication link has failed. QCH004/1197 1997
3. The cooling valve is stuck open. Clean valve as needed. 1. Check SPI device, cables and cable connections.

Setpoint display
The window displays the
setpoints entered for the
fluid temperature, the high
~
Run/Stop. Starting the Thermolator.
Press the RUN button to
start normal operation.
Actual values display 0 Turn on main power to the Thermolator.
Press STOP to stop the
The green window displays the temperature
at the middle of the.mold. This temperature
+ Setpoint and actual windows display llliJ
for
temperature control unit. three seconds, then display the most recently
is calculated as an average of the tempera- entered setpoint temperature and the current
8;::;: Running

*
and low temperature devia-
tion alarms, the SPI baud
rate and the SPI address.
tures of the supply oil and return oil.
.=stopped The. lights indicate whether the temperature
'is in degrees Fahrenheit or Celsius.
= Alarm (flashing)
.Status lights
The lights indicate the operating
status of the listed components.
Except in Test Mode and Auto
Start, the lights indicate:
= Off or inactive
G = On or active
.e ~ Alarm condition
:Tes(Mode.is used for initialpro-
;'gramming. When test mode is
'enabled, normal operation is
idisabled.
,e :::Test j\Aode off .. , ...
fe =Test Mode on; unit disabled
'Auto St~~allows you to start
actual temperature.
+ Indicator lights blink green, then red.
fJ Turn on the water supply to the unit.
If the water supply is on, go to Step 3 .
BJ Enter the temperature setpoint.
Press the Setpoint. until the green light appears
next to Temperature. Press A to increase the set-
point or T to decrease.
IJ Press ml.
+ The RUN/STOP light turns green.
+ If fluid temperature is 21 o F or lower, the unit
initiates a 60-second venting sequence. Cool-
ing and venting valves are active for 60 sec-
onds. The pump runs for the final 30 seconds.
+ Normal operation begins. The heater turns on
if the actual temperature is below setpoint.
The cooling valve remains active if the actual
temperature is above setpoint.
If the Alarm light turns on, press to silence an

Setpoint Select button Alarm '' \and stop the Thermolator from
audible alarm and go to the Troubleshooting section.

Press repeatedly until a green
light appears next to the parame-
ter you want to program or view.
NOTE: Default settings for the devia3 i
tion setpoints are:
High= setpoint + 10 F
Low = setpoint - 1o F
A warning alarm occurs (indicator
light turns red) whenever the iictual
temperature is outside this setpoint
range. Recommend setting: 2-10.
Setpoint adjustment
buttons
Press .A or Y. to enter tempera-
ture and SPI parameters. Press A ~
to increase a value. Press Y to
decrease a value. .' ... .... > ;>
TIP: Press and hold the button for :
faster scrolling speed.
Pre~s to ackrioWi1dge the
alarm light and silence the
optional audible alarm,.
The alarm light will flash
untilJhe cause of the
alarm condition.is.fixed.\
C~ol D~~~ ~~g~~i{
:The Cool o'Jwn feat~re resets
setpoint ternperatur~JoJoo F to
. cool the system before stopping.
Press to turn the feature on. Press
again to turn it off.
[)i~p1ay Select buttoh
~t:>ress repeatedly. until a g~een .light ...
~.appears next to the parameteryo.u want ,
:. to program or view in the }\ctual values,,, .
.window. See the User Guide for.pro-
;gramming intor.mation;
. . a remote switching or timing
~device, such as the processing
fmacJ'line control. This feature
;can only be enabled by configur-
[ing a dip switch on the control
: motherboard.
. '7 Disabled; Auto Start not
'. .available
~ ;f (t1ashing) Ena~led; unit can
tti';< [ . ,, . >start at any time. . .
1$.. ::;on arid under. ~ontrol of
the remote device
Cooling the Thermolator.
If your setpoint is over 250' F, you should cool the
unit and fluid before stopping. The Thermolator
must be running to use the Cool Down feature.
D Press the button to begin cooling.
+ The green Cool Down light turns on.
+ The temperature setpoint changes to 100' F.
+ The heater indicator light turns off.
+ The cooling valve indicator light turns green
and stays on until the actual temperature
reaches 1oo F.
fJ Press the II button again to stop cooling.
+ The setpoint temperature stays at 1oo F until
a new setpoint is entered.
Stopping the Thermolator.
D Pressm .
+The RUN/STOP light turns red.
 r-. re,
TROUBLE COTING
If there is a problem, the Thermolator activates the red Alarm light
and changes the RUN/STOP light from green to flashing red. Thermolator
0 Press to silence the optional audible alarm.

FJ toCheck the indicator lights and messages -

heaTrac
help determine the cause of the problem. '
Oil Temperature Controller
Lt WARNING: Before servicing the Thermolator with TH-1 Microprocessor
Allow the unit to cool to below 1 oo
F. Disconnect and lockout
the main power source. Disconnect water and air supply lines .

Actual temperature of oil supplied to the

Shut down alarms
The Thermolator has shut down automatically to prevent
damage to equipment or personnel. To resume normal
operation, press li'IJ,
fix the problem, then presslimiJ.
Pump
The pump overload has tripped. Contact is open.
1. Verify that the correct voltage is supplied to the motor.
2. Fluid flow may be more than the pump can handle.
Check current draw against motor rating. Decrease flow.
Low Oil Alarm
The oil level in the unit reservoir is too low.
1. Check reservoir and add oil as needed.
Low Water Flow Alarm
mold is higher than the programmed
510 F safety limit.
1. Oil has stopped flowing between supply outlet and return
inlet. Check for closed valve or plugged line.
2. The heater contactor failed. Replace contactor.
Actual temperature of oil supplied to the
mold is below the programmed 60 F
safety limit.
1. The cooling valve is stuck open. Clean valve.
2. The heater has failed. Check for a bad heating element,
or a heater contact that failed in the open position.
The incoming power is out of phase. A
leg may have failed or is disconnected.
1. The pump is rotating in the wrong direction. Reverse any
two leads on the power connection.

2. Check fuses or circuits at the main power supply.
There is not enough cooling water at the pump seal .
1. Check the water-jacketed seal chamber at the pump. The return line temperature probe failed.
Check for loose connections, or replace.
High Temp. Safety
The supply line temperature probe failed.

The actual temperature of oil supplied to the mold
exceeds the temperature safety switch limit.
1. The unit is not running. Start the Thermolator.
2. Oil has stopped flowing between supply outlet and return
inlet. Check for closed valve or plugged line.
3. The heater contactor failed. Replace contactor.
Check for loose connections, or replace.
The pump fuse failed.
Replace the fuse on the motherboard.
NOTE: See the Thermolator User Guide for additional alarm mes-
sages regarding fuses and controller errors.

Warning alarms High Deviation

The Thermolator continues operating, but this problem

Actual temperature of oil supplied to the mold is
higher than the setpoint deviation limit allows.
~
could lead to a shutdown condition if not corrected. 1. High deviation temperature is set too low. Increase. The Conair Group, Inc.
2. Oil has stopped flowing between supply outlet and return One Conair Drive
Low Deviation
inlet. Check for plugged pipe or failed cooling valve.
Actual temperature of oil supplied to the mold is lower Pittsburgh, PA 15202
3. The heater contact failed. Replace the contactor.
than the setpoint deviation limit allows. 4. The heater and lines may be too large for this application. Phone: (412) 312-6000
1. Low deviation temperature is set too low. Increase. Fax: (412) 312-6001
2. The heater failed. Check for a bad heating element or a SPI Communication
heater contact that failed in the open position. The SPI communication link has failed. QCH003/1197 1997
3. The cooling valve is stuck open. Clean valve as needed. 1. Check SPI device, cables and cable connections.
 OPERATION

Starting the Thermolator.

Setpoint display
The window displays the
setpoints entered tor the
fluid temperature, the high
and low temperature devia-
tion alarms, the SPI baud
. rate and the SPI address.
Run/Stop/: ..j,1.'.
Press the RUN button(g::
start normal operationf ?1f'
Press STOP to.stop the;.
temperature control u?ik
e =Running . ,.. .,;
*
=Stoppea . \r.+' JtieJight$ il'l~icatff;Whli)ther. the temp~rat!Jre
= Alarm. (flashing)
fA~~~'12~#J~e~~~'spr~v{}t~1.E;e: ,~.
[The''6reen ;V\l;~aow:ciisplays the)~mp~rature~
1
,at th~ llli.ddle<()ft~~. rnold. This temp~rature
(is caJpulated,a~ arr.average ofttieternpera-
,ture~ ontie.~.upplY,'oil (indreturn oil . . . ..
; is in,degr~es Fahrenheit orCelsius. '
Status Ugh!s
The lights indicate the op~ratlrtg
$fatus of the listed.components.
Except in Test Mode and~u~g
~t~fl. th~ lighf! ind!cate: :;),,
IJ =.Off c:>r in~tiw + > ~ttct
G .::::On or active . .;:
e = Alarm cohdition
Test Mode is used for initial pro-
gramming. When test rnode is
.enabled, normal operation is
disabled.
e= Test Mode off
e = Test Mode on; unit disabled
D Turn on main power to the Thermolatoi4.
+ Setpoint and actual windows display mJ for
three seconds, then display the most recently
entered setpoint temperature and the current
actual temperature.
+ Indicator lights blink green, then red.
fl Turn
on water supply to the unit.
If the water supply is on, go to Step 3.
fD Enter the temperature setpoint.
Press the Setpoint until the green light appears
next to Temperature. Press A to increase the set-
point or T to decrease.
I) Pressm!ll.
+ The RUN/STOP light turns green.
+ If the fluid temperature is 210 F or lower, the
unit initiates a 60-second venting sequence.
Cooling and venting valves are active for 60
seconds. The pump is active for the final 30
seconds.
+ Normal operation begins. The heater turns on
if the actual temperature is below setpoint.
The cooling valve remains active if the actual
temperature is above setpoint.
If the Alarm light turns on, press to silence an
audible alarm and go to the Troubleshooting section.

Setpoint Select button Setpoint adjustment Alarm

Press repeatedly until a green
light appears next to the parame-
ter you want to program or view.
NOTE: Default settings for the devia-
tion setpoints are:
High= setpoint + 10 F
Low= setpoint - 1o F
A warning alarm occurs (indicator
light turns red) whenever the actual
temperature is outside this setpoint
range. Recommend setting: 2-10'.
buttons
Press A. or .. to enter tempera-
ture and SPI parameters. Press A
to increase a value. Press .. to
decrease a value.
TIP: Press and hold the button for
faster scrolling speed.
Press to acknowledge the alarrn light
and silence the optional audible alarm ..
The .alarm light will flash until the
, cause. of the alarm conditiortJs. ~xed.
Stopping the Thermolator.
D Press B.
+ The RUN/STOP light turns red.
NOTE: If your setpoint temperature was 250 F or
higher, you should cool the system to 1oo F before
stopping the unit for a long time. To cool, enter a
temperature setpoint of 1oo F. Allow the unit to
continue running until the actual temperature
reaches 1oo F.
Conair has made the largest investment in customer support in
the plastics industry. Our service experts are available to help WERE HERE
with any problem you might have installing and operating
your equipment. Your Conair sales representative also can help TO HELP
analyze the nature of your problem, assuring that it did not
result from misapplication or improper use.

To contact Customer Service personnel, call:

HOW TO CONTACT
CUSTOMER
SERVICE
From outside the United States, call: 814-437-6861
You can commission Conair service personnel to provide on-
site service by contacting the Customer Service Department.
Standard rates include an on-site hourly rate, with a one-day
minimum plus expenses.

If you do have a problem, please complete the

following checklist before calling Conair: BEFORE YOU
Make sure you have all model, serial and parts list num- CALL ...
bers for your particular equipment. Service personnel will
need this information to assist you.
Make sure power is supplied to the equipment.
Make sure that all connectors and wires within and
between loading control and related components have been
installed correctly.
Check the troubleshooting guide of this manual
for a solution.
Thoroughly examine the instruction manual(s)
for associated equipment, especially controls. Additional manuals and
Each manual may have its own troubleshooting prints for your Conair
guide to help you. equipment may be
ordered through the
Check that the equipment has been operated as Customer Service or
described in this manual. Parts Departments for
a nominal fee.
Check accompanying schematic drawings for
information on special considerations.

SERVICE INFORMATION APPENDIX A-1

 Conair guarantees the machinery and equipment on this
EQUIPMENT order, for a period as defined in the quotation from date of
GUARANTEE shipment, against defects in material and workmanship
under the normal use and service for which it was recom-
mended (except for parts that are typically replaced after
normal usage, such as filters, liner plates, etc.). Conairs
guarantee is limited to replacing, at our option, the part or
parts determined by us to be defective after examination.
The customer assumes the cost of transportation of the
part or parts to and from the factory.

Conair warrants that this equipment will perform at or

PERFORMANCE above the ratings stated in specific quotations covering the
WARRANTY equipment or as detailed in engineering specifications,
provided the equipment is applied, installed, operated and
maintained in the recommended manner as outlined in our
quotation or specifications.

Should performance not meet warranted levels, Conair at

its discretion will exercise one of the following options:
Inspect the equipment and perform alterations or
adjustments to satisfy performance claims. (Charges
for such inspections and corrections will be waived
unless failure to meet warranty is due to misapplica-
tion, improper installation, poor maintenance practices
or improper operation.)
Replace the original equipment with other Conair
equipment that will meet original performance claims
at no extra cost to the customer.
Refund the invoiced cost to the customer. Credit is sub-
ject to prior notice by the customer at which time a
Return Goods Authorization Number (RGA) will be
issued by Conairs Service Department. Returned
equipment must be well crated and in proper operating
condition, including all parts. Returns must be prepaid.

Purchaser must notify Conair in writing of any claim and

provide a customer receipt and other evidence that a claim
is being made.

Except for the Equipment Guarantee and Performance

WARRANTY Warranty stated above, Conair disclaims all other war-
ranties with respect to the equipment, express or
LIMITATIONS implied, arising by operation of law, course of dealing,
usage of trade or otherwise, including but not limited to
the implied warranties of merchantability and fitness for
a particular purpose.

APPENDIX A-2 WARRANTY INFORMATION UGE015/0499