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USERGUIDE
UGH002-0514

Thermolator ® heaTrac Series

Oil Temperature Controller HTR1-500 with TH-1
or TH-2 controls

Corporate Office: 724.584.5500 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861
Please record your equipment’s It’s a good idea to record the model and serial number(s) of your equipment and
model and serial number(s) and the date you received it in the User Guide. Our service department uses this
the date you received it in the information, along with the manual number, to provide help for the specific
spaces provided. equipment you installed.

Please keep this User Guide and all manuals, engineering prints and parts lists
together for documentation of your equipment.

Date:

Manual Number: UGH002-0514

Serial Number(s):

Model Number(s):

DISCLAIMER: Conair shall not be liable for errors contained in this User Guide or for incidental, consequential
damages in connection with the furnishing, performance or use of this information. Conair makes no warranty
of any kind with regard to this information, including, but not limited to the implied warranties of merchantability
and fitness for a particular purpose.

Copyright 2014 l Conair l All rights reserved

INTRODUCTION . . . . . . . . . . . . . . . . . . .1-1 TABLE OF
Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . .1-2
How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . .1-2 CONTENTS
Your responsibility as a user . . . . . . . . . . . . . . . . . . . . . . .1-2
ATTENTION: Read this so no one gets hurt . . . . . . . . . . .1-3

DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1
What is the Thermolator heaTrac? . . . . . . . . . . . . . . . . . . .2-2
Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
How it works: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Features and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

INSTALLATION . . . . . . . . . . . . . . . . . . . .3-1
Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Connecting the cooling water supply . . . . . . . . . . . . . . . . .3-4
Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . .3-6
Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Initial setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Changing temperature units . . . . . . . . . . . . . . . . . . . . . . . .3-9
Enabling and disabling passcode protection . . . . . . . . . . .3-10
Selecting the temperature control point (TH-2 ) . . . . . . . . . .3-12
Entering setpoint deviation parameters . . . . . . . . . . . . . . .3-14
Activating SPI communication . . . . . . . . . . . . . . . . . . . . .3-15
Enabling the Auto Start feature (TH-2 ) . . . . . . . . . . . . . . .3-16

OPERATION . . . . . . . . . . . . . . . . . . . . . .4-1
TH-1 control features . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
TH-2 control features . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Positioning the control panel . . . . . . . . . . . . . . . . . . . . . . .4-4
Entering passcodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Starting the Thermolator . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Stopping the Thermolator . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Performing an Auto Tune . . . . . . . . . . . . . . . . . . . . . . . . .4-10

MAINTENANCE . . . . . . . . . . . . . . . . . . . .5-1
Preventative maintenance schedule . . . . . . . . . . . . . . . . . . .5-2
To access the Thermolator enclosure . . . . . . . . . . . . . . . . .5-3
Checking fluid level in the reservoir . . . . . . . . . . . . . . . . .5-4

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 i

TABLE OF MAINTENANCE . . . . . . . . . . . . . . .(continued)
Performing System Tests . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
CONTENTS The Key/Display Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Input Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Disabling and Enabling Outputs . . . . . . . . . . . . . . . . . . . . .5-9
Calibrating Temperature Sensors . . . . . . . . . . . . . . . . . . .5-10
Logging Operating Hours . . . . . . . . . . . . . . . . . . . . . . . .5-12

TROUBLESHOOTING . . . . . . . . . . . . . . . .6-1
Before Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
A Few Words of Caution . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
How to Identify the Cause of a Problem . . . . . . . . . . . . . . .6-3
DIAGNOSTICS
Shut Down Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Warning Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
System Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
Thermolator Will Not Power Up . . . . . . . . . . . . . . . . . . .6-12
REPAIR
Checking and Replacing Fuses . . . . . . . . . . . . . . . . . . . . .6-13
Resetting and Replacing Overloads . . . . . . . . . . . . . . . . .6-14
Replacing the Motherboard . . . . . . . . . . . . . . . . . . . . . . .6-15
Replacing the Heater Contactor . . . . . . . . . . . . . . . . . . . .6-16
Checking and Replacing Thermocouples . . . . . . . . . . . . .6-17
Repairing Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . .6-18
Replacing Heater Elements . . . . . . . . . . . . . . . . . . . . . . .6-20
Removing the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21

APPENDIX
Customer Service Information . . . . . . . . . . . . . . . . . . . . . .A-1
Warranty/Guarantee Information . . . . . . . . . . . . . . . . . . . .A-2
MP Pumps HTO Series Operation and Maintenance . . . . .B-1
Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Thermolator SPI commands . . . . . . . . . . . . . . . . . . . . . . .D-1
Material Safety Data Sheets . . . . . . . . . . . . . . . . . . . . . . . .E-1

PARTS/DIAGRAMS
Spare Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PD-1
TH-1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PD-5
TH-1 Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .PD-6
TH-1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PD-7
TH-2 Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .PD-8

ii Thermolator heaTrac TH-1 and TH-2 UGH002-0514

 INTRODUCTION
● Purpose of the User Guide . . . .1-2
● How the guide is organized . . . .1-2
● Your responsibilities as a user .1-2
● ATTENTION: Read this so
no one gets hurt . . . . . . . . . . .1-3

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 1-1

PURPOSE OF This User Guide describes the Conair Thermolator® TH-1 and
TH-2 oil temperature controllers and explains step-by-step
THE USER how to install, operate, maintain and repair this equipment.

GUIDE Before installing this product, please take a few moments to

read the User Guide and review the diagrams and safety infor-
mation in the instruction packet. You also should review man-
uals covering associated equipment in your system. This
review won’t take long, and it could save you valuable instal-
lation and operating time later.

HOW THE Symbols have been used to help organize the User Guide and
call your attention to important information regarding safe
GUIDE IS installation and operation.

ORGANIZED Symbols within triangles warn of conditions that could

be hazardous to users or could damage equipment.
Read and take precautions before proceeding.
Numbers within shaded squares indicate tasks or steps
1 to be performed by the user.
◆ A diamond indicates the equipment’s response to an
action performed by the user.
❒ An open box marks items in a checklist.
● A shaded circle marks items in a list.

You must be familiar with all safety procedures concerning

YOUR installation, operation and maintenance of this equipment.
Responsible safety procedures include:
RESPONSIBILITY ● Thorough review of this User Guide, paying particular
AS A USER attention to hazard warnings, appendices and related dia-
grams.
● Thorough review of the equipment itself, with careful
attention to voltage requirements, intended uses and
warning labels.
● Thorough review of instruction manuals for associated
equipment.
● Step-by-step adherence to instructions outlined in this
User Guide.

1-2 INTRODUCTION Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

We design equipment with the user’s safety in mind. You can
avoid the potential hazards identified on this machine by ATTENTION:
following the procedures outlined below and elsewhere in the
User Guide.
READ THIS SO NO
ONE GETS HURT
WARNING: Improper installation,
operation or servicing may result in
equipment damage or personal injury.
This equipment should be installed, adjusted,
and serviced by qualified technical personnel
who are familiar with the construction, opera-
tion and potential hazards of this type of equip-
ment.
All wiring, disconnects and fuses should be
installed by qualified electrical technicians in
accordance with electrical codes in your region.
Always maintain a safe ground. A properly
sized conductive ground wire from the incoming
power supply must be connected to the chassis
ground terminal inside the electrical enclosure.
Improper grounding can result in personal
injury and erratic machine operation.
Do not operate the equipment at power levels
other than what is specified on the the equip-
ment serial tag and data plate.

WARNING: Electrical shock hazard

This equipment is powered by three-phase
main voltage, as specified on the machine seri-
al tag and data plate.
Always disconnect and lock out the incoming
main power source before opening the electri-
cal enclosure or performing non-standard oper-
ating procedures, such as troubleshooting or
maintenance. Only qualified personnel should
perform procedures that require access to the
electrical enclosure while power is on.

CAUTION: Hot surfaces

Surface temperatures inside the Thermolator
can exceed 500° F (260° C). Always allow the
unit to cool to below 100° F (38° C) before
opening, servicing or disassembling the unit.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control INTRODUCTION 1-3

 ATTENTION: WARNING: Hazardous substance
READ THIS SO NO The electrical contactors in the
Thermolator have mercury contactors.
ONE GETS HURT Mercury is considered a hazardous sub-
stance and must be dealt with accord-
ingly. Material Safety Data Sheet (#7439-
97) has been included in the instruction
packet. This sheet explains the potential
hazards, how to avoid them and how to
clean up and dispose of the mercury if it
spills.

1-4 INTRODUCTION Thermolator TH-1 and TH-2 UGH002-0514

 DESCRIPTION
● What is the Thermolator
heaTrac? . . . . . . . . . . . . . . . . .2-2
● Typical applications . . . . . . . . . .2-2
● How it works . . . . . . . . . . . . . . .2-5
● Specifications: heaTrac . . . . . . .2-6
● Features and options . . . . . . . . .2-8

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 2-1

 The Thermolator heaTrac circulates oil at a temperature to add
WHAT IS THE or remove heat as needed to maintain a uniform temperature
THERMOLATOR setpoint in the process. The heaTrac offers an enhanced TH-2
control, with additional diagnostic features and autostart capa-
HEATRAC? bilities.

Both the TH-1 and TH-2 models are available in single or

multiple-zone configurations. Multiple-zone models can con-
trol up to two temperatures at different locations in the
process. Two- zone models have common cooling water mani-
folds and electrical connections.
The best model for your application depends on the process
temperature you need to maintain and the quality of the cool-
ing water supply.

TH-1 and TH-2 models separate the cooling water from the
TYPICAL process fluid, which is held in a reservoir. All heaTrac models
are recommended for:
APPLICATIONS ● Process temperatures up to 500°F (260°C).
● Use with chiller water, or with properly treated and filtered
tower or city water..

2-2 DESCRIPTION Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

 Thermolator heaTrac models maintain the process tempera-
ture by heating and cooling fluid for the process circuit. The HOW IT WORKS:
process fluid (heat transfer oil), which is stored in a reservoir,
is isolated from the optional cooling water supplied by a
chiller, tower or other source

1 The temperature of the process fluid is

measured as it leaves the unit’s heater
tank. The fluid then flows through the “To
Process” line A to the mold or process.
The fluid returns to the unit through the
“From Process” line B for reheating or
cooling.

The vent line allows

warm process fluid
to expand to the
reservoir G . The
G reservoir supplies
If the process process fluid
3b temperature is through a make-up
below the set- line as needed.
point, the heater
elements inside
the heater tank The pump moves
are energized. A E
4 process fluid from
the mixing tank to
the heater tank.
Pressure is mea-
sured after the
pump E..
C

B
2 The temperature
of the process
fluid is measured
as it flows into
the suction tank
OPTIONAL
through the “From
Process” line B .
If the temperature is
3a above the setpoint
value, the cooling valve
opens. C Cool water
enters the cooling piping
and circulates through a
tube heat exchanger to
cool the process fluid. B
Note: cooling is optional.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control DESCRIPTION 2-3

 Dimensions and performance characteristics vary according to
SPECIFICATIONS the model, voltage and components selected. See the cabinet
style reference chart to determine dimensional information for
your specific model. Additional technical information can be
found in the Appendix of this User Guide.

HTR1-500 (single zone) HTR2-500 (dual zone) HTR1-500 rear view and connections

MODELS HTR1-500 HTR2-500

Performance Characteristics
Minimum setpoint °F {°C} 70 {21} 70 {21}
Maximum setpoint °F {°C} 500 {260} 500 {260}
Pump Performance
Pump Size Hp {kW} 1 {0.75} 1.5 {1.12} 2 {1.49} 3 {2.24} 1 {0.75} 1.5 {1.12} 2 {1.49} 3 {2.24}
Nominal flow gpm {l/min} 55 {208} 65 {246} 75 {284} 85 {322} 55 {208} 65 {246} 75 {284} 85 {322}
Pressure @ nominal flow psi {bar} 16 {1.1} 21 {1.5} 24 {1.7} 32 {2.2} 16 {1.1} 21 {1.5} 24 {1.7} 32 {2.2}
Dimensions inches {mm}
A -Height 43 {1090} 43 {1090}
B- Width 14 {355} 28 {710}
C- Depth 31.5 {800} 31.5 {800}
Weight Ib {kg}
Operating 300 {136} 305 {138} 310 {141} 320 {145} 600 {272} 610 {277} 620 {281} 640 {290}
Shipping 470 {213} 475 {216} 480 {218} 490 {222} 770 {349} 780 {354} 790 {358} 810 {367}
Water Connections NPT inches (Female)
To/From Process 1.25 1.25
Cooling Water Inlet/Outlet * 0.75 0.75

FULL LOAD AMPS † HTR1-500 HTR2-500

Heater 6 kW 12 kW 18 kW 6 kW 12 kW 18 kW
Voltage 208V 230V 460V 575V 208V 230V 460V 575V 208V 230V 460V 575V 208V 230V 460V 575V 208V 230V 460V 575V 208V 230V 460V 575V
Pump
1 Hp {0.75 kW} 21.2 19.2 9.6 7.7 37.8 34.2 17.1 21.4 54.4 49.2 24.6 19.7 42.2 38.2 19.1 15.3 75.6 68.4 34.2 15.3 109.0 98.6 49.3 39.4
1.5 Hp {1.12 kW} 21.9 19.8 9.9 7.9 38.5 34.8 17.4 13.9 55.0 49.8 24.9 19.9 43.5 39.4 19.7 15.8 76.9 69.6 34.8 15.8 110.3 99.8 49.9 39.9
2 Hp {1.49 kW} 23.6 21.4 10.7 8.6 40.2 36.4 18.2 14.6 56.8 51.4 25.7 20.6 47.1 42.6 21.3 17.0 80.4 72.8 36.4 17.0 113.8 103.0 51.5 41.2
3 Hp {2.24 kW} 26.5 24.0 12 9.6 43.1 39.0 19.5 15.6 59.7 54.0 27.0 21.6 52.8 47.8 23.9 19.1 86.2 78.0 39.0 19.1 119.3 108.0 54.1 43.2

SPECIFICATIONS NOTES:
* For units equipped with optional heat exchanger and cooling circuits.
†All voltages are 3 phase, 60 Hz.
Specifications can change without notice. Check with a Conair representative for the most current information.

2-4 DESCRIPTION Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

 INSTALLATION
● Unpacking the boxes . . . . . . . . .3-2
● Preparing for installation . . . . . .3-3
● Connecting the water supply . .3-4
● Optional purge valve hookups .3-5
● Connecting the main power . . .3-6
● Testing the installation . . . . . . . .3-7
● Initial setup . . . . . . . . . . . . . . . .3-8
● Changing temperature units . . .3-9
● Enabling and disabling
passcode protection . . . . . . .3-10
● Selecting the temperature
control point (TH-2 ) . . . . . . . . .3-12
● Entering setpoint
deviation parameters . . . . . . .3-14
● Activating SPI
communication . . . . . . . . . . . .3-15
● Installing the Auto Start
feature . . . . . . . . . . . . . . . . . .3-16

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 3-1

UNPACKING THE Thermolator heaTrac models come fully assembled. If they
were specified at the time of the order, the optional cooling
BOXES exchanger and valve is factory-installed.

Remote control cord

(TH-2 only)

Thermolator heaTrac

1 Carefully remove the Thermolator and compo-

nents from their shipping containers, and set upright.

2 Remove all packing material, protective paper,

tape, and plastic. Check inside the electrical enclosure
and behind the side panels for accessories or hardware
that may have been placed there for shipping.

3 Carefully inspect all components to make sure no

damage occurred during shipping, and that you have all
the necessary hardware. If damage is found, notify the
freight company immediately.

4 Take a moment to record serial numbers and

specifications in the blanks provided on the back of the
User Guide’s title page. The information will be helpful if
you ever need service or parts.

5 You are now ready to begin installation.

Complete the preparation steps on the next page.

3-2 INSTALLATION Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

The Thermolator heaTrac is easy to install, if you plan the
location and prepare the area properly. PREPARING FOR
1 Position the Thermolator as close to the process INSTALLATION
machine as possible.

Thermolator

Process machine

Alternate
locations

2 Make sure the installation area provides:

❒ A three-phase power source supplying the correct
current for your Thermolator model. Check the serial tag
on the side of the electrical enclosure for the required volt-
age, phase, frequency, full load amps, disconnect fuse size
and minimum wire connection size. Field wiring should be
completed by qualified personnel to the planned location
for the Thermolator. All electrical wiring should comply
with your region’s electrical codes.
❒ A clean, well-ventilated environment.
The room temperature should not exceed 120° F (48° C)
with 95% non-condensing humidity and should not fall
below 32° F (0° C).
10 inches
❒ Minimum clearance for safe operation and (254 mm)
maintenance. The diagram at right shows
minimum clearance for operation. You also
need enough clearance in the rear for
water hookups. For maintenance, you
should move the Thermolator to
12 inches
provide at least 36 inches on any side 12 inches
(305 mm)
of the Thermolator. 20 inches (305 mm)
❒ A source of water for cooling. (508 mm)

City, tower or chiller water may be used, as long as the

supply pressure is at least 15 psi and not more than 85 psi.

3 Install plumbing for process and cooling lines.

You will need two 11/4-inch NPT male fittings for the
process oil inlet and outlet and two 3/4-inch NPT male
fittings for the cooling water inlet and outlet. Larger line
sizes are acceptable as long as they are reduced at the
Thermolator connections. Smaller line sizes are not recom-
mended.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control INSTALLATION 3-3

 Expansion/Fluid Low-watt
FEATURES OF reservoir tank density electric
immersion heater

THE HEATRAC Low level pump

shutoff safety
Sight glass for
visual inspec-
tion of oil level

Venting sole-
noid valve
TEFC Pump
prevents
Totally
trapped air in
enclosed fan
system.
cooled pump
motor

Shell and tube

heat exchanger
cooling circuit
(optional) cools
the unit before
powering it
down.

Air-cooled seal cavity Cooling check valve pre-

no cooling water required vents coolant back flow
into the exchanger.

TH-1 CONTROL

Standard features include:

● Actual temperature display shows the actual temperature of the fluid

entering the
to-process line. ● Setpoint temperature display shows the fluid tem-
perature setpoint during normal operation. Both of these window will
display alarms, error codes modes and parameters if there is a prob-
lem with the temperature controller.
● Status lights indicate the operating status of the device. Green when
the device is on and red when there is a problem.
● RS485 communications utilizing SPI protocol with baud rates and
addresses programmable right on the operator panel.
● Visual and (optional) audible alarms alerts you to alarm conditions
such as high/low deviation, low water pressure, pump overload or high
temperature safety switch.
● Setpoint adjustment buttons Press the up or down arrows to change
temperature and SPI parameters.

TH-2 CONTROL

All the features of the TH-1 plus:

● Autostart capability for convenient preheating of molds. Works with
external timers or switches.
● Choice of temperature control points allows you to monitor and con-
trol from the process supply temperature or the process return temper-
atures or from an average of the two.
● Remote control with 15 foot cables, optional to 50 feet, and magnetic
backs allow you to place the control where you want it.

3-4 INSTALLATION Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

The Thermolator process inlets and outlets must be connected
to the plumbing that will circulate the temperature-controlled
CONNECTING
water or fluid through the process. Optional cooling water
inlets and outlets are connected to the cooling water supply.
PROCESS OIL
AND COOLING
1 Remove the shipping pipe plug from the female
connections on the back of the Thermolator. WATER SUPPLY
2 Install pipe to the rear of the Thermolator.
Use male 11/4-inch NPT piping for process oil connec-
LINES
tions and male 3/4 inch NPT piping for water connections.
Pipe and pipe threads must be clean and new. Clean
threads with solvent, removing all oil, grease and dirt.
Allow the threads to dry before proceeding.

3 Coat the pipe threads with thread sealant.

Follow the sealant manufacturer’s directions.
Tools for installation:
4 Connect the male pipe to the appropriate ❒ Pipe wrench large enough
female connection on the back of the unit. Start for a 2-inch pipe
by hand until the threads engage, then use a pipe wrench
❒ Premium quality Teflon
to tighten the connection only enough to prevent leaks.
thread sealant rated for
Do not over-tighten!
500Þ F oil.

NOTE: We recommend
that you install an
external ball valve on
the cooling water inlet
of the Thermolator. This
valve is useful for ser-
vice when cooling
option is installed.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control INSTALLATION 3-5

CONNECTING WARNING: Electrical shock hazard

THE MAIN This equipment is powered by three-phase main

voltage. Always disconnect and lock out the main
power source before performing any work
POWER SUPPLY involving electrical connections. All wiring,
disconnects and fusing should conform to your
region’s electrical codes and should be installed
only by qualified personnel.

IMPORTANT: Always refer Before beginning, note the electrical specifications on the
to the wiring diagrams that nameplate mounted to the side of the unit. The electrical
came with your temperature hookup must match these specifications with +/- 10% maxi-
control unit before making mum voltage variance. An improper power supply could
electrical connections. The damage the unit as well as seriously injure an operator.
diagrams show the most
accurate electrical compo- The electrical hookup also should run through a fused dis-
nent information. connect sized for the nameplate amperage and conforming to
Article 250 of the National Electrical Code.

1 Open the unit’s electrical enclosure.

2 Insert the main power wire through the knockout

hole in the right side of the enclosure.

3 Secure the power wire with a rubber compres-

sion fitting or strain relief.

4 Connect the power wires to the terminals.

Connect the three hot
wires to L1, L2, and L3
on the terminal block.

5 Connect the ground

wire to the copper
grounding mount.
If you have installed a
disconnect device, follow
the manufacturer’s wiring
instructions.
IMPORTANT! Before initiating
power to the unit:
❒ Check the system for leaks.
❒ Verify that the disconnect fuse and
minimum wire size meet the voltage,
phase,frequency, and amperage
specifications stated on the name-
plate mounted on the side of the unit.
❒ Verify that resistance to ground on
each phase is at least 1 meg ohm.

3-6 INSTALLATION Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

 WARNING: Only qualified personnel
should perform this procedure.
TESTING THE
Parts of this test require opening the unit while it is INSTALLATION
energized. Only qualified personnel who have been
trained in the use of electrical testing devices and
in avoiding the safety hazards involved in safely
troubleshooting this type of equipment should per-
form this test procedure.

1 Turn on the cooling water supply and check for

leaks. If any leaks appear, stop the test and fix the prob-
lem before continuing. The cooling water must be at least
15 PSI or the unit will function slowly during cooling.

2 Apply power to the unit.

◆ Indicator lights on the control panel blink green, then
red, to test operation of the LEDs.
◆ Setpoint and actual windows will display for
three seconds, followed by the software version. The
windows then display the factory default setpoint of
100° F and the actual temperature.

3 Check the rotation of the pump. Remove the top

access panel. Verify that the pump rotation matches the
direction indicated on the rotation sticker on top of the
pump.
NOTE: If the rotation is incorrect, stop the test and
disconnect power to the unit. Open the electrical
enclosure and switch any two of the three power
source wires on the terminal block. Return to Step 2
and check rotation again.

4 Replace the top access panel.

Press the RUN key to start the unit.
5 If everything is working correctly:
◆ The RUN/STOP light turns green.
◆ 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. Indicator
lights will energize when the device is active.
◆ Normal operation begins. The heater turns on if the
actual temperature is below setpoint. The optional cool-
ing valve is active if the actual temperature is above set-
point.

The test is over. Proceed to initial setup if the unit operated

normally; refer to the TROUBLESHOOTING section if it did not.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control INSTALLATION 3-7

INITIAL SETUP WARNING: Electric shock hazard
This equipment is powered by high voltage. Always
disconnect and lock out the main power source
before opening the unit or the electrical enclosure to
modify factory settings. Failure to disconnect and
lock out the main power source can result in severe
personal injury.

The factory-set parameters and operating modes will satisfy

most applications. But you can change some settings and
enable or disable features as needed.
You can modify the parameters for high and low process tem-
perature deviation warnings from the control panel. See
SETTING SETPOINT DEVIATION PARAMETERS.
Dip switches on the motherboard inside the TH-1 and TH-2
electrical enclosure allow you to:
❒ Select the units of measure for tem-
perature displays.
❒ Enable password protection.
❒ Enable the Auto Tune.
❒ Enable the Auto Start feature.
❒ Enable the Test Mode.
❒ Select the source point of tempera-
ture control.

8 7 6 5 4 3 2 1

Dip switch Configuration

No. OFF ON
1 Display units in °F Display units °C
2 Auto Tune disabled Auto Tune enabled
3 Passcode protect Password reset/modify
4* Auto Start disabled Auto Start enabled
5* Control point protect Control point source select
6 Test Mode disabled Test mode enabled
7† Controller type selection Controller type selection
8† Controller type selection Controller type selection
* Available only on TH-2 models.
† Switch 7 must be off and 8 must be ON for heaTrac oil units.
not change these settings.

To change the dip switch settings, see the appropriate topic

on the following pages.

3-8 INSTALLATION Thermolator TH-1 and TH-2 UGH002-0514

 WARNING: Electric shock hazard CHANGING
This equipment is powered by high voltage. Always
disconnect and lock out the main power source TEMPERATURE
before opening the unit or the electrical enclosure to
modify factory settings. Failure to disconnect and UNITS
lock out the main power source can result in severe
personal injury.

The temperature units are factory-set as degrees Celsius or

degrees Fahrenheit, as specified when the unit was ordered.

When the Thermolator is on, the indicator lights to the right

of the Actual temperature display on the control panel will
show which temperature unit has been set.

To change this setting, move Dip Switch 1 on the control

circuit board.

1 Disconnect and lock out main power to the

Thermolator.

2 Open the electrical enclosure.

3 Change Dip Switch 1 to:
OFF for °F ON for °C NOTE: All dip switch illustra-
tions in this manual show
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 switches 7 OFF and 8 set
to ON. Do Not Change
these settings.

4 Close the electrical enclosure and restore main

power to begin operating.

UGH002-0514 Thermolator TH-1 and TH-2 INSTALLATION 3-9

ENABLING AND WARNING: Electric shock hazard
DISABLING This equipment is powered by high voltage. Always
disconnect and lock out the main power source
PASSCODE before opening the unit or the electrical enclosure to
modify factory settings. Failure to disconnect and
PROTECTION lock out the main power source can result in severe
personal injury.

The TH-1 and TH-2 provide the ability to protect system

parameters from unauthorized changes during normal operat-
ing mode. When system passcode protection is enabled, the
following parameters cannot be changed unless you enter the
correct passcode:
● The Process Setpoint
● High Deviation Alarm Setpoint
● Low Deviation Alarm Setpoint
● Baud Rate selection for serial communications
● Address selection for serial communications

When the unit is turned on for the first time, passcode protec-
tion is disabled. To enable passcode protection:

1 Disconnect and lock out main power to the unit.

2 Open the electrical enclosure.

3 Set dip switch 3 to ON 8 7 6 5 4 3 2 1

and switches 5 and 6
to OFF.

4 Close the electrical enclosure and restore

power to the unit.
5 Press any
button when
the control dis-
plays “Pas rSt”
(Passcode Reset).
The control will
NOTE: All dip switch illustra- display the last
tions in this manual show passcode used.
switches 7 OFF and 8 set
to ON. Do Not Change 6 Select a new passcode using the ▲ and ▼
these settings. setpoint adjustment buttons.
Stop pressing the setpoint buttons when the passcode you
want appears in the setpoint display window. Selecting
“OFF” as the passcode will disable the passcode feature.

3-10 INSTALLATION Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

 ENABLING AND
DISABLING
PASSCODE
PROTECTION

7 Press the RUN button to save the passcode.

◆ The control will display “Pr OFF” to prompt you to
remove power to the unit.

IMPORTANT: If RUN is not pressed, the new

passcode will not be saved.

8 Turn off power to the unit. Disconnect and lock out

the main power supply.

9 Open the electrical 8 7 6 5 4 3 2 1

enclosure.

10 Set dip switch 3 to OFF.

11 Close the electrical enclosure and restore
power to the unit.
A passcode now is required to change system parameters.

Disabling Passcode Protection

To disable passcode
protection and allow
universal access to
system parameters:
1 Follow Steps 1
through 5 in the
previous section
on enabling pass-
code protection.

2 Hold down the ▼ setpoint adjustment button

to select “OFF” as the new passcode.
3 Follow steps 7 through 11 in the previous section.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control INSTALLATION 3-11

SELECTING THE WARNING: Electric shock hazard
TEMPERATURE This equipment is powered by high voltage. Always
disconnect and lock out the main power source
CONTROL POINT before opening the unit or the electrical enclosure to
modify factory settings. Failure to disconnect and
lock out the main power source can result in severe
(TH-2 ONLY) personal injury.

MaxTrac models control the process temperature based upon

the average of the temperatures recorded at the supply (to
process) and return (from process) thermocouples.

TH-2 models allow you to select how the unit will measure
and control the process temperature. The control point can be
selected as the supply, the return or the average of the the two
temperatures.

To select the control point source on TH-2 models:

1 Disconnect and lockout power to the unit.

2 Open the electrical enclosure.

3 Set dip switches 3 and
8 7 6 5 4 3 2 1
6 to the OFF position.

4 Set dip switch 5 to the

ON position.

5 Close the electrical enclosure and restore

power to the unit.

6 Press any button when the control displays

“Cnt Pt”.
The controller will
display “Sel CnP”
and flashes the LED
for the current con-
NOTE: All dip switch illustra- trol point.
tions in this manual show
switches 7 and 8 set to ON.
If you have an Isolated 7 Select a new control point using the Display
Circuit model, these switch- button.
es should be set to OFF. Stop pressing the select button until the indicator light next
to the control point you want illuminates.

3-12 INSTALLATION Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

 SELECTING THE
TEMPERATURE
CONTROL POINT
(TH-2 ONLY)

8 Press the RUN button to save the control point.

◆ The control will display “Pr OFF” to prompt you to
remove power to the unit.

IMPORTANT: If RUN is not pressed, the new

control point source will not be saved.

9 Turn off power to the unit. Disconnect and lock out

the main power supply.

10 Open the electrical 8 7 6 5 4 3 2 1

enclosure.

11 Set dip switch 5 to

OFF.
12 Close the electrical enclosure and restore
power to the unit.
The TH-2 will now control the process temperature based
on actual temperatures recorded at the new control point
source.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control INSTALLATION 3-13

 ENTERING You can establish a normal operating range around the process
temperature setpoint using the high and low deviation parame-
SETPOINT ters. If the process temperature exceeds the high deviation
limit, or falls below the low deviation limit for longer than 15
DEVIATION minutes, the Thermolator will alert you to the unacceptable
temperature variation with an alarm light.
PARAMETERS These temperature deviation limits will adjust automatically
relative to the process temperature setpoint.
The factory default setting is the process temperature setpoint
± 25° F (4° C). This parameter is adjustable to establish a nar-
rower or wider acceptable temperature range for normal oper-
ation. The Low Deviation cannot be set to fall below the facto-
ry-set Low Safety temperature. The High Deviation cannot be
set to exceed the factory-set High Safety temperature.
FACTORY DEFAULT SETTINGS
Model HTR1-500
Process Setpoint 100° F (38° C)
High Safety 510° F (266° C)
Low Safety 60° F (16° C)

To change the temperature deviation settings:

1 Press the Setpoint Select

button to select the deviation
parameter you want to
change.
2 Use the ▲ and ▼ setpoint
buttons to enter the deviation
temperature. The setting is
stored in memory even when the
power is turned off. The recom-
mended setting is ± 2-10° F.
NOTE: If you enabled passcode protection, you must
enter the passcode to change this parameter. Too enter
the passcode:
Hold down the Setpoint Select button for 5 seconds.
When the control displays “ 1 PaS”, use the setpoint
adjustment buttons to enter the passcode. Press the
Setpoint Select button again. If the correct passcode
was entered the controller will display ACC PAS for 3
seconds. If the passcode was incorrect, the controller
will display rEJ PAS (rejected passcode).
Access to system parameters remain until power is
cycled or the RUN or STOP button is pressed.

3-14 INSTALLATION Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

The heaTrac series Thermolators provide SPI compatible sup-
port for RS-485 serial communications with a host machine. ACTIVATING SPI
You can use SPI communication to change or monitor the:
COMMUNICATION
● Process temperature setpoint
● High and low temperature deviation alarms
● Process status (run and alarm conditions)
● Machine 1 status NOTE: To disable SPI, use
the setpoint ▲ or ▼ arrow to
● Machine 2 status select Address. Press the ▼
● Actual temperature to process arrow until OFF is displayed in
● Actual temperature from process the setpoint window.
To use the SPI communication option, you must connect the See the APPENDIX for additional
Thermolator to the host machine and set the communication SPI programming information.
baud rate and node address using the setpoint select and
adjustment buttons on the control panel.

1 Connect the host machine to the Thermolator.

Plug the male DB9 connector into the serial communica-
tions port on the Thermolator.
2 Apply power to the Thermolator.
3 Enter the passcode, if necessary.
Hold the Setpoint Select button for 5 seconds. When the
control displays 1 PaS, use the setpoint adjustment but-
tons to enter the passcode.
4 Enter the node address.
Press the Setpoint Select button to choose
Address. Then press the setpoint ▲ or ▼
arrow until the address you want appears in
the setpoint display. The address may be set
to any number from 32 to 254 (a hexadeci-
mal integer between 20 and FE), as long as
that number has not been assigned to another
machine connected to the same network.

5 Set the baud rate to 12, 24, 48 or 96.

The Thermolator must be set to send and
receive data at the same baud rate as the host
machine. Press the setpoint ▲ or ▼ arrow
until the baud rate you want appears in the
setpoint display window.
12 = 1200 bps 48 = 4800 bps
24 = 2400 bps 96 = 9600 bps
The green SPI status light on the control panel should flash
when the unit is communicating. The LED will turn red, indi-
cating an alarm, if SPI communication is not properly set up.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control INSTALLATION 3-15

INSTALLING THE WARNING: Electric shock hazard
AUTO START This equipment is powered by high voltage. Always
disconnect and lock out the main power source
FEATURE before opening the unit or the electrical enclosure to
modify factory settings. Failure to disconnect and
lock out the main power source can result in severe
(TH-2 ONLY) personal injury.

If you have a TH-2 model, you can automatically start and

stop the Thermolator from a remote switching or timing
device that has power contacts rated 110VAC, such as the
process machine control.
Wiring the device to the Thermolator is accomplished through
a dry contact to the appropriate terminals on the motherboard.
After wiring the device to the unit, Auto Start must be
enabled by configuring a dip switch on the motherboard.

1 Disconnect and lockout power to the unit.

2 Open the electrical enclosure.

3 Punch a small hole in the left side of the

electrical enclosure. The hole must be large enough to
accommodate conduit for the power contact wires from
your switching or timing device.

4 Insert the two power leads from the device

through the conduit into the electrical enclosure.

Device contacts
4
3
2
1
6
5
4
3
2
1
LLS/WPS
LLS/WPS
AUTOSTART
AUTOSTART
HPS/LPS
HPS/LPS

OPS
OPS
FSTAT
FSTAT
4
AC IN + 3
2
AC OUT + 1
F1
AC IN

AC OUT

IMPORTANT: Always
refer to the wiring diagrams
that came with your tempera-
ture control unit before mak-
ing electrical connections. The
diagrams show the most
accurate electrical component
information. 5 Connect the 110VAC device contact wires to
the Auto Start terminals. Make sure terminals are
screwed tight.

3-16 INSTALLATION Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

6 Set dip switch 4 to the
ON position.
8 7 6 5 4 3 2 1 INSTALLING THE
7 Close the electrical
AUTO START
enclosure and restore
power to the unit.
FEATURE
(TH-2 ONLY)

NOTE: All dip switch illus-

trations in this manual show
switches 7 and 8 set to ON.
If you have an Isolated
Circuit model, these switch-
es should be set to OFF.

When Auto Start is enabled:

◆ The Auto Start indicator light flashes to indicate that the
Thermolator can start at any time. The Thermolator will
start whenever the remote switching or timing device sends
a signal to start processing.
◆ The Auto Start indicator light is on whenever the
Thermolator is under the control of the remote device.

To disable Auto Start:

Repeat steps 1,2 and 7, setting dip switch 4 to the OFF instead
of the ON position.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control INSTALLATION 3-17

 OPERATION
● TH-1 control . . . . . . . . . . . . . . . .4-2
● TH-2 control . . . . . . . . . . . . . . . .4-3
● Positioning the control panel . .4-4
● Entering a passcode . . . . . . . . .4-5
● Starting the Thermolator . . . . . .4-6
● Stopping the Thermolator . . . . .4-7
● Performing an Auto Tune . . . . . .4-8

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 4-1

TH-1 CONTROL All normal operating functions can be controlled from the
TH-1 control panel. If you have the optional manual mold
purge, the control button is located on the side of the
Thermolator electrical enclosure.

Run/Stop
Setpoint display Press the RUN button to Actual values display
start normal operation.
The window displays the The green window displays the temperature
Press STOP to stop the
setpoints entered for the temperature control unit. at the middle of the mold. This temperature
fluid temperature, the high is calculated as an average of the tempera-
= Running tures of the supply oil and return oil.
and low temperature devia-
tion alarms, the SPI baud = Stopped The lights indicate whether the temperature
rate and the SPI address. = Alarm (flashing) is in degrees Fahrenheit or Celsius.

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
= On or active
= Alarm condition
Test Mode is used for
initial
programming. When test
mode is enabled, nor-
mal operation is
disabled.
Setpoint Select button = Test Mode off
Setpoint adjustment
= Test Mode on; unit
Press repeatedly until a green buttons
light appears next to the parame- disabled
ter you want to program or view. Press ▲ or ▼ to enter tempera-
ture and SPI parameters. Press ▲
NOTE: Default settings for the devia- to increase a value. Press ▼ to
tion setpoints are: decrease a value. Alarm
High = setpoint + 10Þ F
Low = setpoint - 10Þ F TIP: Press and hold the button for Press to acknowledge the
A warning alarm occurs (indicator faster scrolling speed. alarm light and silence the
light turns red) whenever the actual optional audible alarm. The
temperature is outside this setpoint alarm light will flash until the
range. Recommend setting: ± 2-10Þ. cause of the alarm condition
is fixed.

4-2 OPERATION Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

 All normal operating functions can be controlled from the
TH-2 control panel, including the optional mold purge.
TH-2 CONTROL

Run/Stop
Setpoint display Press the RUN button to Actual values display
start normal operation.
The window displays the The green window displays the temperature
Press STOP to stop the
setpoints entered for the temperature control unit. at the middle of the mold. This temperature
fluid temperature, the high is calculated as an average of the tempera-
= Running tures of the supply oil and return oil.
and low temperature devia-
tion alarms, the SPI baud = Stopped The lights indicate whether the temperature
rate and the SPI address. = Alarm (flashing) is in degrees Fahrenheit or Celsius.

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
= On or active
= Alarm condition
Test Mode is used for initial pro-
gramming. When test mode is
enabled, normal operation is
disabled.
= Test Mode off
= Test Mode on; unit disabled

Auto Start allows you to start

Setpoint Select button Alarm and stop the Thermolator® from
Press repeatedly until a green Press to acknowledge the a remote switching or timing
light appears next to the parame- alarm light and silence the device, such as the processing
ter you want to program or view. optional audible alarm. machine control. This feature
The alarm light will flash can only be enabled by configur-
NOTE: Default settings for the devia-
until the cause of the ing a dip switch on the control
tion setpoints are:
High = setpoint + 10Þ F alarm condition is fixed. motherboard.
Low = setpoint - 10Þ F = Disabled; Auto Start not
A warning alarm occurs (indicator available
light turns red) whenever the actual Cool Down On/Off
temperature is outside this setpoint = (flashing) Enabled; unit can
The Cool Down feature resets the start at any time
range. Recommend setting: ± 2-10Þ. setpoint temperature to 100Þ F to
cool the system before stopping. = On and under control of
Press to turn the feature on. Press the remote device
Setpoint adjustment again to turn it off.
buttons
Press ▲ or ▼ to enter tempera- Display Select button
ture and SPI parameters. Press ▲
to increase a value. Press ▼ to Press repeatedly until a green light
decrease a value. appears next to the parameter you want
to program or view in the Actual values
TIP: Press and hold the button for window. See the User Guide for pro-
faster scrolling speed. gramming information.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control OPERATION 4-3

POSITIONING CAUTION: Improper use of the swiveling
control panel can damage the unit.
THE CONTROL
● Do not rotate the control panel 360
PANEL degrees. This will twist and possibly damage
the control wiring and connections to the
motherboard in the electrical enclosure.
● Do not use the control panel handles or
control cables to move the Thermolator. The
handles are designed only for orientation of
the control panel.
● Do not mount the detached TH-2 control
panel to a hot surface.

The control panel on the TH-1 series Thermolators can be

swiveled, raised and lowered to provide easy viewing and
access. The TH-2 control panel also can be mounted up to 50
feet from the unit, using a remote control cable and the mag-
netic back on the back of the panel.

To raise and swivel the control panel:

Grasp the black control panel
handles, and pull upward. Use
the handles to rotate the control
panel. Do not rotate the panel 360
degrees.

To lower the control panel:

Grasp the black control panel
handles, and rotate the control until
it is aligned with the unit. Do not
rotate the panel 360 degrees. Gently
push down on the handles until the
control panel is flush with the unit.

To detach the TH-2 control panel:

The TH-2 control panel may be removed and mounted up to
50 feet from the unit. Do not stretch the cable. The cable is
available in various lengths so that you can order the appro-
priate cable for your installation.
Grasp the black control panel handles and pull upward. Use
the magnetic back to mount the control panel in the remote
location. Connect the remote-mounted control to the unit with
the cable provided.

4-4 OPERATION Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

 ENTERING A
PASSCODE

The TH-1 and TH-2 models have a security feature that pre-
vents accidental or unauthorized changes to the setpoint tem-
perature, high and low deviation limits, SPI address, and baud
rate.

If passcode protection is enabled, you must enter the correct

passcode to change these parameters. To enter the passcode:

1 Press and hold the Setpoint Select button

for 5 seconds. The control will display 1 PaS to indi-
cate a passcode is needed.

2 Press the Select ▲ button until the correct

passcode appears in the display.
3 Press again to enter the passcode.
If the passcode is correct, the control displays ACC PAS
for 3 seconds. If the passcode is incorrect, the control dis-
plays rEJ PAS (rejected passcode).

4 Press Setpoint to select the parameter you

want to change.
You will have access to the system parameters until:
● The power is cycled off and on.
● The RUN or STOP button is pressed.
● No key has been pressed for 30 seconds.

NOTE: Pressing the STOP or RUN key while you are

entering a passcode will abort the passcode entry
sequence

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control OPERATION 4-5

STARTING THE Before starting the Thermolator, verify that the system has
been installed correctly for your application. See the
THERMOLATOR INSTALLATION section.

If Passcode Protection has been enabled, you must enter the

correct passcode before you can change or enter any of the
operating parameters, including the temperature setpoint.
IMPORTANT: If you are Turn on the optional water supply to the
operating the Thermolator
1 Thermolator.
for the first time since The supply must be at least 15 psi. Check for leaks in the
installation, you should cooling water and process fluid lines before continuing.
perform an Auto Tune after
two hours of normal opera- 2 Turn on main power to the Thermolator.
tion. You should perform the The control initiates a brief self test.
Auto Tune periodically to ◆ Indicator lights blink green, then red.
ensure that the control cor- ◆ Setpoint and actual windows will display for
rectly calculates how much
three seconds, followed by the software version. The
heat and cooling should be
applied to maintain the windows then display the factory default setpoint of
process setpoint. See 100° F and the actual temperature.
“Performing an Auto 3
Tune.” Enter the passcode,
if necessary. Hold the
Setpoint Select button for 5
seconds. When the control
displays 1 PaS, use the setpoint
adjustment buttons to enter the
passcode. Press the Setpoint
Select button again.
4 Enter the temperature
setpoint. Press the Setpoint
Select button until the green
light appears next to
Temperature. Press ▲ to
increase or ▼ to decrease the
temperature setting.
5 Press Run to start normal operation.
◆ The RUN/STOP light turns green.
◆ 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 when the
actual temperature is below setpoint. The cooling valve
turns on if the actual temperature is above the setpoint.

If the Alarm light turns on, press to silence the option-

al audible alarm. Then see the TROUBLESHOOTING section.

4-6 OPERATION Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

 WARNING: Electrical shock and
hot surface hazards STOPPING THE
Before attempting maintenance of any kind
on the Thermolator, you must stop the unit; THERMOLATOR
disconnect and lockout the main power
supply; and allow the unit to cool to less than
100° F (38° C).

You must shut down the Thermolator whenever you:

● Change the water hookups.
● Shut down the process machine.
● Purge the process circuit of the oil.
● Run the unit’s diagnostic tests.
● Perform routine or preventative maintenance.
● See an alarm condition that requires troubleshooting.
● Relocate, ship or store the unit.

To shut down the unit for purging the process lines, diagnos-
tic testing, routine maintenance or troubleshooting, press the
Stop button. Then refer to the appropriate topic or section in
this User Guide.

To shut down the unit to change fluid hookups:

1 Press Stop cool and drain

the unit of all oil or fluid.
Drain the unit using the drain
plugs on the back of the heater
casting.

2 Once the unit is cool,

remove the cooling water
hookups.
Drain plug

To shut down the unit for relocation or storage:

1 Press Stop
and drain the unit of all fluid.
Drain the unit using the two drain plugs.

2 Disconnect the power supply and all water feeds.

3 Position the control panel to rest flush with the unit.

In shipment or storage, the Thermolator can withstand an

environment between -40° F (-40° C) and 150° F (65° C)
with 95% relative humidity non-condensing.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control OPERATION 4-7

PERFORMING AN WARNING: Electric shock hazard
AUTO TUNE This equipment is powered by high voltage. Always
disconnect and lock out the main power source
before opening the unit or the electrical enclosure to
modify factory settings. Failure to disconnect and
lock out the main power source can result in severe
personal injury.

You should perform an Auto Tune after the first two hours of
operation and whenever process variables change (changes in
cooling water pressure, piping or molds; large ambient
swings; new setpoint temperature) to ensure that the control
continues to obtain good approximations of the PID constants
used to compensate for the thermal lag of the system.

To ensure a successful Auto Tune, verify that:

❒ The Auto Tune feature has been enabled. Auto Tune is
enabled or disabled via dip switch 2 on the motherboard.
❒ The process value is stable. A fluctuating process value
will fool the software into making inaccurate tuning deci-
sions. The software waits 5 minutes for the process value to
stabilize before it starts the Auto Tune process. If the
process value still fluctuates after 5 minutes, the Auto Tune
terminates and the control displays the “At ti” error.
❒ The control is in STOP mode and the process value is in
ambient temperature. This allows the software to obtain
good approximations of process parameters, which are crit-
ical for performing an accurate tune. If this requirement is
not met, then a good tune cannot be guaranteed.
❒ The setpoint/process deviation is at least 25° F. If the
absolute value of setpoint - process temperature is not
greater than or equal to 25° F, the Auto Tune will terminate.
The control will display an “At dEV” error.

1 Press Stop
to shut down the Thermolator.
2 Disconnect and lock out main power to the unit.
3 Enable Auto Tune.
Open the electrical enclosure.
Set dip switch 2 to ON.
Close the electrical enclosure
and restore power to the unit.

4 Restore power to the unit.

4-8 OPERATION Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

 PERFORMING AN
AUTO TUNE

5 Press Run and (the Setpoint Select button)

simultaneously to begin the Auto Tune.
The Actual display will flash “At” and the current process
temperature to indicate that an Auto Tune is underway.
If Auto Tune is successful, the controller automatically
starts controlling using the new PID parameters.
If you press the STOP button or a fault occurs during the
Auto Tune, the control enters stop mode and Auto Tuning
immediately terminates. The actual display stops flashing
“At.” If a fault occurred, the control will display the appro-
priate error message.

ERROR MESSAGE ERROR DESCRIPTION

Insufficient setpoint/process deviation.
At dEv If the absolute value of (setpoint - process
value) is less than 25° F. The Auto Tune can-
not be started until the temperature
difference is at least 25° F.

Auto Tune timed out. Auto Tune will time out

At tI if a stable process value cannot be obtained
5 minutes into the tune, or if the tuning
process takes longer than 30 minutes. If this
error occurs, verify that you followed every
requirement under “To ensure a successful
Auto Tune” and perform a second tune.

Invalid PID constants were generated.

At bad The most likely causes of this error is a tune
started inappropriately or an external ele-
ment (i.e., loose thermocouple) that upset
the process while tuning was in progress.
Verify that you followed every requirement
under “To ensure a successful Auto Tune”
and perform a second tune.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control OPERATION 4-9

 MAINTENANCE
● Maintenance schedule . . . . . . . .5-2
● Accessing the Thermolator
enclosure . . . . . . . . . . . . . . . . .5-3
● Checking fluid level in the
reservoir . . . . . . . . . . . . . . . . . .5-4
● Performing system tests . . . . . .5-5
● Key/Display Test . . . . . . . . . . . . .5-6
● Input Test . . . . . . . . . . . . . . . . . .5-7
● Output Test . . . . . . . . . . . . . . . . .5-8
● Disabling or enabling
output monitors . . . . . . . . . . .5-9
● Calibrating temperature
sensors . . . . . . . . . . . . . . . . . .5-10
● Logging operating hours . . . . .5-12

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 5-1

 Thermolator heaTrac TH-1 and TH-2 oil temperature con-
PREVENTATIVE trollers are essentially maintenance-free. However, to maintain
the best performance, we recommend the following mainte-
MAINTENANCE nance schedule.
SCHEDULE ● Whenever process variables change
❒ Perform an Auto Tune.
The Auto Tune ensures that the control continues to
obtain good approximations of the PID constants used
to compensate for the thermal lag of the system.. You
should perform an Auto Tune after the first two hours of
operation and whenever the process changes, such as
after a mold change; installation of different pipe sizes;
or change in process setpoint. See the “Performing an
Auto Tune” in the OPERATION section.

● Daily
❒ Check for leaks in cooling and process lines.
Before and during operation, you should inspect the
unit and all plumbing lines for leaks. If a leak develops,
stop the Thermolator and repair it.
❒ Keep the unit and the area around it clean.
Check for and remove lint, dust or other obstructions on
the unit, especially around air intake areas. Keep the
floor around the unit dry.
❒ Check the process fluid level.
HTR1-500’s have an internal reservoir that
contains the process fluid. Check the level indicator on
the back of the unit to make sure the reservoir contains
an adequate amount of process fluid. Refill as needed
with the specified heat transfer fluid.

● Monthly, or as often as needed.

❒ Inspect the fluid in the fluid reservoir.
For at least the first three months of operation, check
the sight glass in the process fluid reservoir for
debris or discoloration that could indicate fluid
contamination or degradation. Replace as required.

● Quarterly (every 3 months)

❒ Inspect power cords, wires and electrical
connections.
Check for loose or frayed wires, burned contacts, and
signs of overheated wires. Check exterior power cords
to the main power source and from the electrical box to
the pump and heating elements. Check the ground wire
and thermocouple connections. Replace any wire that
appears damaged or has worn or cracked insulation.

5-2 MAINTENANCE Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

● Annually (every 12 months)
PREVENTATIVE
❒ Test and calibrate the unit’s control systems.
The Thermolator’s Test Mode checks the operation
MAINTENANCE
of displays, control buttons, inputs and outputs. You SCHEDULE
can also calibrate the supply and return thermocouples.
See “Performing System Tests” in this section.

WARNING: Electrical shock and

hot surface hazards
ACCESSING THE
Before attempting maintenance of any kind
on the Thermolator, you must stop the unit;
THERMOLATOR
disconnect and lockout the main power
supply; and allow the unit to cool to less than
ENCLOSURE
100° F (38° C)

To access the Thermolator enclosure:

Remove the top access panel by lifting straight up.
Remove the side panels by lifting straight up.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control MAINTENANCE 5-3

 The heaTrac TH-1 and TH-2 models separate the cooling
CHECKING THE water from the process
FLUID LEVEL IN fluid, which is held in a
reservoir inside the unit.
THE RESERVOIR This reservoir should be
kept at least three-quar-
ters full of the process
fluid.

You can check the fluid

level in the reservoir
using the sight glass on
the back of the
Thermolator.

To fill the reservoir:

1 Disconnect and lockout power, and remove the

top panel of the Thermolator.

2 Locate the reservoir near the top of the unit.

3 Locate the fill port at the top of the reservoir.

4 Refill the reservoir. Monitor the level using the sight

glass on the back of the unit.

5 Replace the top panel of the Thermolator.

5-4 MAINTENANCE Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

The TH-1 and TH-2 Thermolators provide a Test Mode that
tests displays and keys on the control panel, as well as inputs PERFORMING
and outputs. The Test Mode also allows calibration of the sup-
ply and return line thermocouples.
SYSTEM TESTS
System tests and calibration should be performed annually.

To enable Test Mode:

1 Press Stop to shut down the Thermolator.

2 Disconnect and lock out main power to the unit,

then open the electrical enclosure.

3 Set dip switches 3 and 8 7 6 5 4 3 2 1

5 to OFF.

4 Set dip switch 6 to ON.

5 Close the electrical enclosure and restore

power to the unit.
◆ The control displays “tSt.”
◆ The Test Mode LED lights.

6 Press any button to display the first test menu. IMPORTANT: All normal
Test mode provides the following menus: operating functions are
● Key/Display Test disabled while Test Mode is
● Input Test enabled. To return to normal
● Output Test operation, you must disable
● Calibration Test Mode.
● Total Operating Hours
● Output Monitor Enable/Disable To disable Test Mode,
repeat steps 2 through 5,
7 After performing each test, hold the Setpoint
setting dip switch 6 to OFF
for 3 seconds to index to the next test menu.
The procedure for each test is described on the following instead of ON.
pages.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control MAINTENANCE 5-5

 The Key/Display Test verifies the function of displays, LEDs
KEY/DISPLAY and buttons on the control panel.
TEST 1 Enable Test Mode.

2 Press any key.

3 If necessary, index to the Key/Display menu.

Press and hold the Setpoint key for 3 seconds to index

to each test menu until the controller displays “dSP”.

4 Press any key to clear all displays.

5 Repeatedly press any key to test displays.

With each key press, a new segment of all six 8-segment
LEDs and a select group of LED indicator lights will illu-
minate.

6 Exit the test and enter the next test.

Press and hold the Setpoint key for 5 seconds to exit
and index to the next test.

5-6 MAINTENANCE Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

The Input Test verifies the function of inputs available on the
various models of TH-1 or TH-2 . Not all inputs are used on INPUT TEST
all models. The performance evaluation of the inputs is based
on the voltage sensing device (VSD).

1 Connect all inputs to the system.

2 Press any key to display the first test menus.

3 Select the Input Test menu.

Press and hold the Setpoint key for 3 seconds to index
to each test menu until the controller displays “InP”.

4 Repeatedly press and release any key to test.

With each key press and release, the left display will indi-
cate the number of the input being tested (v1, v2, v3, etc.).
The right display indicates either “1” for voltage present
or “O” for an absence of voltage.

Only inputs that are actually used by the particular model

will be tested.

5 Exit the test and enter the next test.

Press and hold the Setpoint key for 3 seconds to exit
and index to the next test.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control MAINTENANCE 5-7

 The Output Test verifies the function of outputs available on
OUTPUT TEST the various models of TH-1 or TH-2 . Not all outputs are used
on all models. The performance evaluation of the inputs is
based on the output monitors (OM).

1 Connect all outputs to the system.

IMPORTANT: Testing each output requires the fir-
ing of the associated solid state relay. Make sure an
output device is connected to the controller, other-
wise the test result will be erroneous.

2 Enable Test Mode.

3 Press any key to display the first test menus.

4 Select the Output Test menu.

Press and hold the Setpoint key for 3 seconds to index

to each test menu until the controller displays “oUt”.

5 Repeatedly press and release any key to test.

With each key press and release, the left display will indi-
cate the number of the output being tested (oS1= OM1;
oS2 = OM2; etc.). The right display indicates either “1”
for a good output or “O” for a failed output.

Only outputs that are actually used by the particular model

will be tested.

6 Exit the test and enter the next test.

Press and hold the Setpoint key for 3 seconds to exit
and index to the next test.

5-8 MAINTENANCE Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

All output monitors on the Thermolator can be enabled or dis-
abled permanently through the OM Enable/Disable Menu in DISABLING OR
Test Mode.
ENABLING
You need to use this feature if you have replaced the mother-
board, or if dip switches 7 and 8 have been changed erro- OUTPUT
neously. This will enable any required output monitors that
were disabled and give fuse failures.
MONITORS
1 Enable Test Mode.
2 Press any key to display the first test menus.

3 Select the OM Enable/Disable menu.

Press and hold the Setpoint key for 3 seconds to index
to each test menu until the controller indicates “oS1” in
the actual display and the status of the selected output in
the Select display.

4 Press the Setpoint ▲ or ▼ key to change the

status. Each press of the key changes the output status
from ON to OFF or OFF to ON.
OUTPUT MONITOR SELECTION GUIDE
OM1 Pump ON
OM2 Heat ON
OM3 Cool ON
OM4 Vent ON

5 Press the Setpoint to select the next output.

Repeat Step 4 to change the status of the output, or press
any key to continue indexing through the outputs.

6 Save changes and exit the output menu.

Press and hold the Select key for 3 seconds to save the
changes and exit.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control MAINTENANCE 5-9

 The TH-1 and TH-2 Thermolators use type “K” thermocou-
CALIBRATING ples to sense the temperature in the return and supply process
TEMPERATURE lines. These thermocouples should be calibrated annually, or
when a new thermocouple is installed, to ensure correct opera-
SENSORS tion.

The Thermolator’s Calibration Mode provides zero and span

calibration of both the supply and return line thermocouples.
Special Tools Needed: You access the Calibration Mode while in Test Mode.
❒ type K thermocouple
calibrator 1 Enable Test Mode.
See “Performing System Tests.”

2 Press any button to display the first test menu.

3 Select the Calibration Mode menu.

Press and hold the Setpoint key for 3 seconds to index
to each test menu until the controller indicates “SC.L” in
the Actual display.

4 Release the Setpoint key.

You are now in calibration mode. Each press and release
of this key will exit the current calibration and start the
next calibration. The table below lists the calibrations that
will be performed.
SETPOINT ACTUAL
CALIBRATION DISPLAY DISPLAY

Zero Calibrate Supply Sensor 32° F (0° C) SC.L

Zero Calibrate Return Sensor 32° F (0° C) rC.L
Span Calibrate Supply Sensor 510° F (266° C) SC.H
Span Calibrate Return Sensor 510° F (266° C) rC.H

5 Using the thermocouple calibrator, apply the

appropriate temperature to the control input.

5-10 MAINTENANCE Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

6 Press the up ▲ key to begin calibrating. CALIBRATING
The controller displays the name of the current calibration
(examples: 32 SC.L; 32 rC.L; 510 SC.H; or 510 rC.H). TEMPERATURE
SENSORS

7 Wait until the control displays “don” or “bad.”

A “don” message in the Setpoint display indicates the cali-
bration was successful. A “bad” message in the Setpoint
display indicates a bad calibration.
NOTE: The original calibration value stored in
EEProm can be restored for the current calibration
by pressing the STOP key at any time.

8 Press Select to start the next calibration.

Pressing and releasing the Select key at the end of a
calibration tells the controller to perform the next calibra-
tion.

9 Exit Calibration Mode.

Press and hold the Select key for 3 seconds to exit the
Calibration Mode.

You can now proceed to the next test in Test Mode, or

disable Test Mode and resume normal operation.

TO DISABLE TEST MODE, complete steps 2

through 5 in “Performing System Tests”, setting dip
switch 6 to OFF instead of ON.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control MAINTENANCE 5-11

 You can see the total numbers of operation by accessing the
LOGGING Total Operating Hours Log in Test Mode.
OPERATING 1 Enable Test Mode.
HOURS 2 Press any key to display the first test menus.

3 Index through test menus to the operating log.

Press and hold the Setpoint key for 3 seconds to index
to each test menu until the Actual display indicates “Log”.
The Setpoint display indicates the total number of operat-
ing hours in 100-hour units.

4 Exit the Operating Hours Log.

Press and hold the Select key for 3 seconds to exit and
index to the next test.

You can now proceed to another menu in Test Mode, or

disable Test Mode and resume normal operation.
TO DISABLE TEST MODE, complete steps 2
through 5 in “Performing System Tests”, setting dip
switch 6 to OFF instead of ON.

5-12 MAINTENANCE Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

 TROUBLESHOOTING
● Before beginning . . . . . . . . . . . .6-2
● A few words of caution . . . . . . .6-2
● How to identify the cause
of a problem . . . . . . . . . . . . . . .6-3
DIAGNOSTICS
● Shut down alarms . . . . . . . . . . .6-4
● Warning alarms . . . . . . . . . . . . .6-8
● System alarms . . . . . . . . . . . . .6-11
● Thermolator will not power up .6-12
REPAIR
● Checking and replacing fuses .6-13
● Resetting overloads . . . . . . . . .6-14
● Replacing the pump overload .6-14
● Replacing the motherboard . . .6-15
● Replacing the heater
contactor . . . . . . . . . . . . . . . .6-16
● Checking and replacing
thermocouples . . . . . . . . . . .6-17
● Repairing solenoid valves . . . .6-18
● Replacing heater elements . . .6-20
● Removing the pump . . . . . . . . .6-21

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 6-1

BEFORE You can avoid most problems by following the recommended
installation, operation and maintenance procedures outlined in
BEGINNING this User Guide. If you do have a problem, this section will
help you determine what caused it and tell you how to fix it.

Before you begin troubleshooting:

❏ Find the wiring, plumbing and other diagrams
that were shipped with your equipment. These
diagrams are the best reference for correcting a problem.
The diagrams also will note any custom features, such as
special wiring, control or plumbing options, not covered in
this User Guide.
❏ Verify that you have manuals for other equip-
ment in the process line. Solving problems may
require troubleshooting malfunctions or incorrect operating
procedures on other pieces of equipment.
❏ If an alarm is present, note any indicator lights
and messages shown on the control panel. These
indicators will help you discover the cause of the problem
more quickly.

The Thermolator is equipped with many safety devices. Do

A FEW WORDS not remove or defeat them. Improper corrective action can
lead to hazardous conditions, and should never be attempted
OF CAUTION to sustain production.

WARNING: This machines should be

adjusted and serviced only by qualified techni-
cal personnel who are familiar with construc-
tion and operation of this type of equipment.

WARNING: Hot surfaces and liquids

Allow the Thermolator to cool to below
100° F (38° C) before servicing the unit.

DANGER: Voltage hazard.

Troubleshooting the electrical system of this
equipment requires use of precision electronic
measuring equipment, and may require access
to the electrical enclosure while power is on.
Exposure to potentially fatal voltage levels may
be unavoidable. These troubleshooting proce-
dures should be performed only by qualified
electrical technicians who know how to use
this precision electronic equipment and who
understand the hazards involved.

6-2 TROUBLESHOOTING Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

Most Thermolator malfunctions are indicated by an illuminat-
ed alarm light and error codes displayed on the control panel. HOW TO IDENTIFY
A problem can trigger three types of alarms: THE CAUSE OF A
● Shut Down Alarms: The Thermolator detected a problem
that caused it to shut down automatically to prevent equip-
PROBLEM
ment damage or personal injury.
● Warning Alarms: The Thermolator continues to operate,
but warns of a problem that could lead to a condition that
will shut down the unit.
● System Errors: The system error codes indicate a non-
recoverable problem with the microprocessor control.

When the Thermolator control detects a problem, the red

Alarm light is activated and the RUN/STOP light changes
from green to flashing red.

A status light
that turns from
green to red
indicates an
alarm condition.

When an Alarm condition occurs:

1 Press to silence any optional audible
alarm.
◆ The RUN/STOP light changes from flashing red to
steady red.

2 Note any indicator lights or error messages to

help determine the cause of the problem.
WARNING:
3 Find the alarm or error code in the diagnostics Disconnect and lockout
tables in the TROUBLESHOOTING section of this manual. the main power source
before opening the
Thermolator or its electri-
4 Press Stop to clear the alarm and shut down
cal enclosure for servic-
the Thermolator to correct the problem. ing. Disconnect oil and
water lines as needed.
Press Run to resume normal operation after
the problem is corrected.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control TROUBLESHOOTING 6-3

 The Thermolator has detected a problem that could lead to equip-
SHUT DOWN ment damage or personal injury if it is not corrected.
◆ The Alarm LED lights and the STOP/RUN LED flashes red.
ALARMS ◆ The Thermolator automatically shuts down.
◆ The control displays a red LED or alarm code indicating the
source of the problem.

Alarm Possible cause Solution

Pump Is the correct voltage Supply voltage should match
supplied to the pump the rating on the pump name
motor? plate. If voltage is correct,
The pump motor check wiring connections.
overload has
tripped. The Is the required water flow ❒ Review pump sizing
contact is open. greater than the pump’s for the application.
capacity? ❒ Decrease the water flow
from the process.
Is the motor overload Disconnect the power and open
WARNING: faulty or set incorrectly? the electrical enclosure. Verify
Only qualified that the overload is set to trip at
electrical service per- the proper amperage, which
sonnel should examine should not exceed the FLA.
and correct problems Manually trip and reset the
that require opening
the unit's electrical overload. If the problem contin-
enclosure or checking ues, replace the overload. See
electrical current to Resetting and Replacing
diagnose the cause of Overloads.
a problem.
Is the pump working Replace the pump if supply
properly? voltage, wiring and overload
settings are correct, but the
pump continues to draw exces-
sive current.

6-4 TROUBLESHOOTING Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

The Thermolator has detected a problem that could lead to equip-
ment damage or personal injury if it is not corrected. SHUT DOWN
◆ The Alarm LED lights and the STOP/RUN LED flashes red.
◆ The Thermolator automatically shuts down.
ALARMS
◆ The control displays a red LED or alarm code indicating the
source of the problem.

Alarm Possible cause Solution

High Temp. Safety Has oil stopped flowing ❒ Verify that the unit is run-
through the unit or ning and that the pump is
The actual tempera- between the supply outlet working. Verify all process
ture of oil and return inlet? line valves are open.
supplied to the
process exceeds the
510° F safety switch
limit.
Is the electro-mechanical Check the switch setting. A
WARNING: safety switch improperly too-low setting will cause
Only qualified electri- set or defective? nuisance trips. Check the
cal service personnel switch and replace if defective.
should examine and
correct problems that See Checking and Replacing
require opening the Switches.
unit's electrical
enclosure or checking Has the heater contactor Replace the contactor if
electrical current to failed? defective. See Replacing
diagnose the cause of
a problem.
the Heater Contactor.

Has oil stopped flowing ❒ Verify that the unit is run-

Hi SAF through the unit or ning and that the pump is
between the supply outlet working.Verify all process
The actual tempera-
and return inlet? valves are open.
ture of oil
supplied to the
process exceeds the
programmed 510° F
safety limit.
Has the heater contactor Replace the contactor if
WARNING: failed? defective. See Replacing
Only qualified electri- the Heater Contactor.
cal service personnel
should examine and
correct problems that
require opening the
unit's electrical
enclosure or checking
electrical current to
diagnose the cause of
a problem.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 TROUBLESHOOTING 6-5

 The Thermolator has detected a problem that could lead to equip-
SHUT DOWN ment damage or personal injury if it is not corrected.
ALARMS ◆ The Alarm LED lights and the STOP/RUN LED flashes red.
◆ The Thermolator automatically shuts down.
◆ The control displays a red LED or alarm code indicating the
source of the problem.

Alarm Possible cause Solution

Is the cooling valve stuck Disassemble the cooling valve
Lo SAF open? and check for particles block-
ing the valve seat. Check the
Actual temperature valve seat for excessive wear.
of oil supplied to Replace parts as required using
the process is below a valve repair kit. See
the programmed Repairing Solenoid Valves.
50° F safety limit.
Has the heater failed? Check for a bad heating
element, or a heater contactor
that failed in the open position.
See Replacing the Heater
Contactor and Replacing
Heater Elements.

Is the thermocouple Check for a loose thermocou-

Pbr Err loose? ple or loose wire connections
to the thermocouple.
The thermocouple
in the process Has the thermocouple Check the thermocouple and
return line failed. failed? replace if necessary. See
Checking and Replacing
Thermocouples.

Is the thermocouple Check for a loose thermocou-

PbS Err loose? ple or loose wire connections
to the thermocouple.
The thermocouple
in the process Has the thermocouple Check the thermocouple and
supply line failed. failed? replace if necessary. See
Checking and Replacing
Thermocouples.

6-6 TROUBLESHOOTING Thermolator heaTrac TH-1 and TH-2 UGH002-0514

The Thermolator has detected a problem that could lead to equip-
ment damage or personal injury if it is not corrected.
SHUT DOWN
◆ The Alarm LED lights and the STOP/RUN LED flashes red.
◆ The Thermolator automatically shuts down.
ALARMS
◆ The control displays a red LED or alarm code indicating the
source of the problem..

Alarm Possible cause Solution

Is the pump rotating in Check pump rotation against
PHS Err the wrong direction? the arrow stamped on the
pump. If the pump is rotating
The incoming in the wrong direction, discon-
power is out of nect and lockout the main
phase. A leg may power source. Open the electri-
have failed or is cal enclosure, and reverse
disconnected. any two leads on the power
connection.
NOTE: This alarm
is available only on Has one of the main sup- Disconnect power and open
TH-2 models. ply wire leads become the electrical enclosure. Check
disconnected? for loose connections in main
supply and on motherboard.

Has the indicated device Disconnect and lockout the

FUS 002 blown a fuse? main power. Open the electri-
Pump fuse. cal enclosure. Check for loose
wires and incorrectly installed
jumpers or terminal blocks
FUS 003 associated with the fuse error.
Heater fuse. Replace the fuse, if necessary.
See Checking and Replacing
Fuses.
FUS 004
Cooling valve fuse. Is the correct device Replace the fuse, then enter
being used for this fuse Test Mode. Turn off the Output
location? Monitor associated with the
FUS 005 fuse location and test outputs.
Vent valve fuse. See Performing System Tests
and Disabling or Enabling
Output Monitors in the
MAINTENANCE section.

Has the motherboard Replace the motherboard. See

output channel at the Checking and Replacing the
designated fuse failed? Motherboard.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 TROUBLESHOOTING 6-7

 The Thermolator has detected a problem that could lead to a shut
WARNING down condition if it is not corrected.
ALARMS ◆ The Alarm LED lights.
◆ The Thermolator continues operating.
◆ The control displays a red LED or alarm code indicating the
source of the problem.

Alarm Possible cause Solution

Low Deviation Is the cooling valve stuck Disassemble the cooling valve
open or leaking water? and check for particles block-
The Thermolator ing the valve seat. Check the
will not heat to the valve seat for excessive wear.
setpoint temperature, Replace as required using a
or takes too long to valve repair kit. See Repairing
reach the setpoint Solenoid Valves.
temperature. The
actual temperature of Did a heater element fail? With the unit powered down:
fluid supplied to the Check for loose connections.
process is lower than Check resistance between the
the setpoint devia- phase legs on the output side
tion allows. of the heater contactor.
Readings should be within
WARNING: 0.25 ohms of each other.
The Thermolator should Replace the heater, if neces-
be tested and repaired sary. See Replacing Heater
only by qualified techni- Elements.
cians equipped with the
correct tools and trained Did a heater contactor With power on and the
in the maintenance and fail? Heater LED lit: Check the
repair of electrical sys- amp draw on each of the three
tems and industrial phase legs to the heater. All
appliances. should match the FLA listed
for the heater on the unit
nameplate. Replace the heater
contactor if there is a voltage
imbalance greater than 10%.
See Replacing the Heater
Contactor.

Is the low deviation tem- Increase the low deviation set-

perature set too low? ting. The recommended setting
is 2° F to 10° F below the
process setpoint.

Is the Thermolator cor- Review specifications and

rectly sized for the appli- selection guidelines that apply
cation? to heater and pump sizes in
temperature control units.

6-8 TROUBLESHOOTING Thermolator heaTrac TH-1 and TH-2 UGH002-0514

The Thermolator has detected a problem that could lead to a shut
down condition if it is not corrected. WARNING
◆ The Alarm LED lights.
◆ The Thermolator continues operating.
ALARMS
◆ The control displays a red LED or alarm code indicating the
source of the problem.

Alarm Possible cause Solution

High Deviation Has oil stopped flowing Check for a plugged pipe or
between supply outlet closed valve.
The Thermolator and return inlet?
will not cool down,
or takes too long to Did the cooling valve fail? Check the cooling valve. See
cool down. The actu- Repairing Solenoid Valves
al temperature of
fluid supplied to the
process is higher
than the setpoint Is the temperature differ- The temperature difference
deviation allows. ence between the cooling should be at least 25° F to
water supply and the set- achieve proper cooling. Increase
point too small? the process setpoint, decrease
WARNING: the cooling water supply tem-
The Thermolator should perature. or increase cooling
be tested and repaired water supply pressure.
only by qualified techni-
cians equipped with the Did a heater contactor With power on and the Heater
correct tools and trained fail? LED lit: Check the amp draw
in the maintenance and on each of the three phase legs
repair of electrical sys- to the heater. All should match
tems and industrial the FLA listed for the heater on
appliances. the unit nameplate. Replace the
heater contactor if there is a
voltage imbalance greater than
10%. See Replacing the Heater
Contactor.

Is the high deviation tem- Increase the high deviation set-

perature set too low? point. The recommended setting
is the setpoint + 2° F to 10° F .

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 TROUBLESHOOTING 6-9

 The Thermolator has detected a problem that could lead to a shut
WARNING down condition if it is not corrected.
ALARMS ◆ The Alarm LED lights.
◆ The Thermolator continues operating.
◆ The control displays a red LED or alarm code indicating the
source of the problem.

Alarm Possible cause Solution

SPI Communication Is the unit connected to a If the Thermolator is not con-
host machine? nected to a host device, set the
The SPI communica- SPI address to OFF using the
tion link has failed. Setpoint adjustment buttons on
the control panel.

Are the network address ❒ Check the network address.

and baud rate correct? The address may be set to
any number from 32 to 254
(a hexadecimal integer
between 20 and FE), as long
as that number has not been
assigned to another machine
connected to the same net-
work.
❒ Make sure the baud rate
(9600, 4800, 2400, or 1200)
matches the host machine.

Is something wrong with Check the communication

the cable? cable condition and connec-
tions. The cable must conform
to SPI standards. Check for
loose connections on the
motherboard.

6-10 TROUBLESHOOTING Thermolator heaTrac TH-1 and TH-2 UGH002-0514

The Thermolator has detected a non-recoverable error involv-
ing he microprocessor control. SYSTEM
◆ The Alarm LED lights and the STOP/RUN LED flashes red.
◆ The Thermolator shuts down or will not start.
ALARMS
◆ The control displays an error code indicating the source of
the problem.

Alarm Cause Solution

ERR 001 Electrical noise or failed Make sure all connections on
CPU on the motherboard the motherboard are solid.
RAM hardware caused system write tests Operate unit in a noise free
failure. do fail during power up. environment. If error persists,
contact Conair service.

The CPU and/or PROM Make sure the CPU and PROM
ERR 002 chips are seated correctly in the
chip (U1 or U2) is not
making good contact with sockets. If error persists, contact
ROM, checksum its socket, or the PROM Conair service.
failure. chip has failed.

A failed CPU, failed moth- Cycle power to the unit. If the

ERR 003 erboard, software bug or problem persists, contact Conair
electrical noise caused an service technicians. You may
ERR 004 internal software error. need to replace the mother-
board.
COP failures.

The CPU tried to execute Make sure all connections to

ERR 005 an illegal software instruc- the motherboard are solid and
tion due to electrical noise that the unit is operating in a
Illegal Opcode. or a failed motherboard. noise free environment. If error
persists, contact Conair service.

A failed CPU, failed moth- Cycle power to the unit. If the

ERR 006 erboard, software bug or problem persists, contact Conair
electrical noise caused an service technicians. You may
through internal software error. need to replace the mother-
ERR 014 board.

The memory has exceeded Cycle power to the unit.

ERR 015 its usable life or there is a Contact Conair service if an
software bug. This error operating parameter such as the
ERR 016 occurs only after changes setpoint is not being saved or if
have been made to non- this error persists.
Software cannot volatile memory either
write to CPU non- through the operator panel
volatile memory. or SPI.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 TROUBLESHOOTING 6-11

THERMOLATOR If you apply power to the Thermolator and the control panel does
not light, you have a problem with the main power circuit or the
WILL NOT unit’s microprocessor board.

POWER UP WARNING: Electrical Shock Hazard

Disconnect and lockout the main power supply
before proceeding.
Symptom Possible cause Solution
Applying power Is power reaching the ❒ Verify that the main power
does not turn on Thermolator? supply and any customer-
the Thermolator or installed electrical discon-
light the control nect or emergency stop
panel. devices are in the ON posi-
tion.
❒ Verify correct electrical con-
nections between the unit
and the control, and
between the unit and the
power supply. Replace any
damaged wires or cables.

Has the unit blown a Check Fuse 1 on the mother-

fuse? board and any fuses or breakers
associated with customer-
installed disconnect devices.
Replace or reset as required.
Identify the cause of the ground
fault and correct it. See Check-
ing and Replacing Fuses.

Is the correct voltage Check the electrical require-

reaching the ments on the unit nameplate.
Thermolator? Verify correct main supply
voltage to the unit and the sec-
ondary voltage supply from the
transformer to unit compo-
nents. Replace the transformer,
if necessary.

The control panel is Is the unit in Test Mode? If the Test Mode LED is lit,
lit, but the you must disable Test Mode on
Thermolator will the motherboard before resum-
not operate when ing operation. See Performing
RUN is pressed. System Tests in the
MAINTENANCE section.

6-12 TROUBLESHOOTING Thermolator heaTrac TH-1 and TH-2 UGH002-0514

This procedure covers the factory-installed fuses on the unit’s
motherboard. If you have installed an electrical disconnect or CHECKING AND
emergency stop switch, additional fuses and/or breakers may
have been used elsewhere in the in the main power circuit. REPLACING
To replace a blown fuse: FUSES
1 Disconnect and lockout the main power.
2 Open the electrical enclosure door. Turn the screw
on the front panel counterclockwise to open.
WARNING:
Shock Hazard
3 Replace the fuse. The fuses are located on the mother-
board and are labeled and identified on the orange shield. Only qualified service
personnel familiar with
4 Close the electrical enclosure and restart the unit. electrical testing and
industrial equipment
If fuses continue to fail: should examine and
❒ Verify that the unit is receiving the correct voltage. correct problems that
Check the voltage, phasing and amperage ratings on require opening the
the unit’s nameplate. unit with power on to
❒ Verify that the unit’s transformer is operating correctly. diagnose the cause of
Check for proper voltage (120V 10%) to the voltage a problem.
sensing device for the fuse location.
❒ Check all wiring referencing the fusing location for
loose connections, damage or improper grounding.
Verify that the correct device is being used for this fuse
location. See Disabling or Enabling Output
Monitors in the MAINTENANCE section.
4
3
2
1
6
5
4
3
2
1

Fuse 1
LLS/WPS
LLS/WPS
AUTOSTART
AUTOSTART
HPS/LPS
HPS/LPS

OPS
OPS
FSTAT
FSTAT

L1

L2

L3

Control
4
AC IN + 3
2
AC OUT + 1
F1

3 PHASE INPUT
AC IN

AC OUT

power

F5
UNLDR 1/ VENT 2 SOL +
Fuse 5
4
UNLDR 1/ VENT 2 SOL
UNLDR 2/ COOL 1 SOL +
3
2
Vent valve
UNLDR 2/ COOL 1 SOL 1

F4
Fuse 4
PUMP 4
PUMP
PUMP OL
3
2
Cooling valve
PUMP OL 1
F2 Fuse 2
PMP AUX
PMP AUX
6
5
Pump IMPORTANT: Always
OFF 1 2 3 4 5 6 7 8
1FS/ COMP AUX
1FS/ COMP AUX
PUMPDOWN
4
3
2
refer to the wiring dia-
ON
PUMPDOWN

HEAT/COMP
HEAT/COMP
1

4
grams that came with
CONFIGURATION
DIP SWITCH
HTS/COMP OL
HTS/COMP OL
3
2
1
your Thermolator to
Fuse 3
F3
N
C
6
5
4 Heater
locate specific electrical
ALARM
NC
NO
C
3
2
1
components. Illustrations
110V
in the User Guide are
OPER PNL CABLE

LLS/PURGE 3SOL 4
(-2) CONTROL

LLS/PURGE 3SOL + 3
+ 120 Ohm

120 Ohm

PURGE 4SOL
PURGE 4 SOL +
2
1
intended to be represen-
GND
GND

F6
+ TR

+ TR
TR

TR

TCPL'S
SUP RET
tative only.
Y
R
R
Y

1 2 3 4 5 6 7 8 1 2 3 4

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 TROUBLESHOOTING 6-13

 The pump motor overload is located inside the unit’s electri-
RESETTING cal enclosure.
OVERLOADS 1 Disconnect and lockout the main power.

2 Open the electrical enclosure door. Turn the

screw on the front panel counterclockwise to open.

3 Check the overload.

If the yellow button is out, the
overload has tripped. Press the
blue button to reset the overload.
Verify that the overload trip point
does not exceed the FLA for the
pump.

REPLACING THE 1 Disconnect and lockout the main power.

PUMP OVERLOAD 2 Open the electrical enclosure door. Turn the screw
on the front panel counterclockwise to open.

3 Locate the pump overload module attached

to the pump motor starter.

4 Disconnect the three power leads from the over-

load module to the pump motor. Note the placement of
each lead and label as needed.

5 Disconnect auxiliary wiring on

the overload module.

6 Remove the overload module.

Loosen the three screws that connect
the overload module to the motor con-
tactor. Pull the overload module down
to release it from the starter.

7 Reverse these steps to install

the new overload module.

8 Set the module reset mode to

M for manual.
Motor contactor
9 Set the proper FLA trip point.
Do not exceed the FLA for the pump
motor.
Motor overload

6-14 TROUBLESHOOTING Thermolator heaTrac TH-1 and TH-2 UGH002-0514

1 Disconnect and lockout the main power supply. REPLACING THE
2 Open the electrical enclosure door. Turn the screw MOTHERBOARD
on the front panel counterclockwise to open.

4
3
2
1
6
5
4
3
2
1
3 Mark or label each wire
IMPORTANT: Always

LLS/WPS
LLS/WPS
AUTOSTART
AUTOSTART
HPS/LPS
HPS/LPS

OPS
OPS
FSTAT
FSTAT

L1

L2

L3
connected to the mother-

4
AC IN + 3
2
AC OUT + 1
F1
3 PHASE INPUT

AC IN

AC OUT
board. The orange shield is refer to the wiring dia-
labeled with the connection F5
grams that came with
your Thermolator to locate
UNLDR 1/ VENT 2 SOL + 4

information. You must label the

UNLDR 1/ VENT 2 SOL 3
UNLDR 2/ COOL 1 SOL + 2
UNLDR 2/ COOL 1 SOL 1

wires to ensure they are con-

F4

PUMP
PUMP
4
3
specific electrical compo-
nents. Illustrations in the
PUMP OL 2

nected to the correct terminals

PUMP OL 1
F2

on the new motherboard. PMP AUX

PMP AUX
6
5
User Guide are intended
to be representative only.
1FS/ COMP AUX 4
1FS/ COMP AUX 3
OFF 1 2 3 4 5 6 7 8 PUMPDOWN 2
PUMPDOWN 1
HEAT/COMP

4 Disconnect the wires

4
ON HEAT/COMP
3
CONFIGURATION HTS/COMP OL
2
DIP SWITCH HTS/COMP OL
1

from the motherboard by

F3
6
N
5
C
4
NC
ALARM 3
NO

pulling the terminal

2
C
1
110V

OPER PNL CABLE

LLS/PURGE 3SOL 4

(-2) CONTROL
LLS/PURGE 3SOL + 3

blocks up.
+ 120 Ohm

120 Ohm
PURGE 4SOL 2
PURGE 4 SOL + 1
GND
GND

F6
+ TR

+ TR
TR

TR

TCPL'S
SUP RET

Y
R
R
Y
5 Loosen the screws hold- 1 2 3 4 5 6 7 8 1 2 3 4

ing the orange shield. 4

3
2
1
6
5
4
3
2
1

6
LLS/WPS
LLS/WPS
AUTOSTART
AUTOSTART
HPS/LPS
HPS/LPS

OPS
OPS
FSTAT
FSTAT

Remove the mother- L1

L2

L3
4
AC IN + 3
2
AC OUT + 1
F1

3 PHASE INPUT
AC IN

AC OUT

board and shield from the

electrical enclosure as a unit.
F5 4
3
UNLDR 1/ VENT 2 SOL + 2

7
UNLDR 1/ VENT 2 SOL

Remove the mother-

1
UNLDR 2/ COOL 1 SOL +
UNLDR 2/ COOL 1 SOL

board from the shield

F4 4
3
PUMP 2
PUMP 1
PUMP OL

and replace with the new F2

PUMP OL

motherboard. PMP AUX

6
5
4
PMP AUX 3
1FS/ COMP AUX 2
1FS/ COMP AUX 1
OFF

8
PUMPDOWN

Reattach the shield and ON

1 2 3 4 5 6 7 8 PUMPDOWN

HEAT/COMP
4
3
2

new motherboard in the

HEAT/COMP
CONFIGURATION HTS/COMP OL 1
DIP SWITCH HTS/COMP OL 6
F3 5

electrical enclosure. Tighten ALARM

N
C
NC
4
3
2
1

the screws. NO
C
110V
4
OPER PNL CABLE

3
LLS/PURGE 3SOL 2
(-2) CONTROL

LLS/PURGE 3SOL + 1
+ 120 Ohm

120 Ohm

PURGE 4SOL
PURGE 4 SOL +

9
GND
GND

Reconnect the terminal F6

+ TR

+ TR
TR

TR

TCPL'S
SUP RET
Y
R
R
Y

blocks and wires to the 1 2 3 4 5 6 7 8 1 2 3 4

new board.
Make sure you align the terminal blocks with the correct
pins on the board. Push the terminal blocks onto the pins,
taking care not to bend any pins.

10 Set dip switches 7 and 8 to the correct unit type.

Set Dip switch 7 to OFF and dip switch 8 to ON.

11 Program output monitors on the new board.

See Disabling or Enabling Output Monitors in the
MAINTENANCE section.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control TROUBLESHOOTING 6-15

REPLACING THE WARNING: Electrical Shock Hazard
Only qualified service personnel who have been
HEATER trained on electrical testing and the procedures for
avoiding the hazards should diagnose or correct prob-
CONTACTOR lems that require opening the unit with power on.

Thermolators use mercury displacement heater contactors.

IMPORTANT: Always The heater contactors should be replaced if:
refer to the wiring dia- ● You have checked the amp draw on each of the three-phase
grams that came with legs and discovered a voltage imbalance greater than 10%.
your Thermolator to ● You have checked the continuity and found that ohms at
locate specific electrical the coil equal zero.
components. Illustrations
in the User Guide are To replace the heater contactor:
intended to be represen-
tative only. 1 Disconnect and lockout the main power.

2 Open the electrical enclosure door. Turn the

screw on the front panel counterclockwise to open.

3 Disconnect the wires from the heater contactor

contactor. Make sure you label the wires to ensure you
can connect them correctly to the new contactor.

4 Remove the contactor

by removing the screws that
hold it in place.
Heater contactor
5 Discard the old contac-
tor using the proper
disposal procedure. See
Material Safety Data Sheet
#7439-97 in the APPENDIX.

6 Reverse this procedure

to install the new con-
tactor. Make sure the wires
are connected correctly.

WARNING: Hazardous Substance

Thermolators use mercury displacement contac-
tors. Mercury is considered a hazardous substance
and must be dealt with accordingly. See Material
Safety Data Sheet #7439-97-6 for information on
the how to avoid the potential hazards and how to
clean up and dispose of mercury if it spills.

6-16 TROUBLESHOOTING Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

The Thermolator uses two type ‘K’ thermocouples
to monitor supply and return process temperatures. One ther- CHECKING
mocouple is installed in the wall of the heater tank at the “to
process” outlet. The other thermocouple is installed in the wall THERMOCOUPLES
of the cooling tank at the “from process” inlet.
To check a thermocouple after a probe error:
1 Disconnect and lockout the main power.
2 Open the electrical enclosure door. Turn the screw
on the front panel counterclockwise to open.

3 Unplug the appropriate thermocouple from the

motherboard and install a jumper on the leads.
Refer to the wiring diagrams that came with your unit.

4 Restart the Thermolator.

◆ If error message disappears, replace the thermocouple.
◆ If error message does not disappear, replace the mother-
board. See Replacing the Motherboard.

To replace a thermocouple: REPLACING

1 Disconnect and lockout the main power. THERMOCOUPLES
2 Shut off the process valves (if installed) and
drain the unit. Drain all oil using the drain plugs locat-
ed the bottom of the unit. WARNING:
Hot surfaces
3 Remove the unit’s top panel Allow the Thermolator
and open the electrical enclo- to cool to below 100° F
sure (38° C) before servicing
the unit.
4 Remove the thermocouple.
Loosen the compression nut to slide
the thermocouple out of the casing. Nut
Disconnect the thermocouple wires
at the motherboard.

5 Install the new thermocouple.

Insert the tip of the new thermocou- Thermocouple
ple at least 1 inch into the tank.
tighten the compression nut. Thread
the leads through the raceway lead-
ing to the electrical enclosure. Attach
the thermocouple leads to the moth-
erboard.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control TROUBLESHOOTING 6-17

REPAIRING Every Thermolator has a solenoid valve assembly that controls
the cooling water out flow.
SOLENOID
VALVES
WARNING: Electrical shock and
hot surface hazards
Before attempting maintenance of any kind
on the Thermolator, you must stop the unit;
disconnect and lockout the main power supply;
and allow the unit to cool to 100° F (38° C)

1 Shut off the cooling water infeed.

2 Drain the unit of all water through the manual lever
on the pressure relief valve.

3 Remove the cooling water inlet feed.

4 Disconnect and lockout main power.

5 Remove the top and side panels of the

Thermolator. Lift the top panel straight up, then lift the
side panels up.

6 Remove the solenoid valve

from the cooling water inlet
line.
7 Disassemble the solenoid
valve.
(see exploded views on next page.

8 Inspect and clean or repair

the valve body assembly.
Remove foreign particles and
replace damaged parts as necessary.

9 Reassemble the valve and other components.

Reassemble in reverse order. Seal all pipe fittings
with pipe sealant. Check that all flows are in the correct
direction. Check for leaks before resuming operation.

6-18 TROUBLESHOOTING Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

*Indicates Parts Supplied
in Solenoid Enclosure Kit REPAIRING
or
Retaining Clip*
SOLENOID
Nameplate Retaining Cap*
VALVES
Cover*

Sleeve*
Grounding Wire
Yoke* (Not present on all constructions)

Insulating Washer
Housing*
7/8" Dia. Hole
for 1/2" Conduit
Coil
Solenoid Base
Sub-Assembly Insulating Washer
0.9375-26 UNS-2A Sleeve*
Thread
Core (AC) Tapped Hole in Core
0.250-28 UNF-2B
0.38 Minimum Full Thread

Alternate Construction with or Retaining Clip*

Nameplate on Housing
*Indicates Parts Supplied
in Solenoid Enclosure Kit Cover*

Spring
Washer*

Yoke* Sleeve*

Housing* Grounding Wire

with Nameplate* (Not present on all constructions)

7/8" Dia. Hole

for 1/2" Conduit
Coil
Solenoid Base
Sub-Assembly Sleeve*
0.9375-26 UNS-2A
Thread
Core (AC) Tapped Hole in Core
0.250-28 UNF-2B
0.38 Minimum Full Thread

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control TROUBLESHOOTING 6-19

REPLACING WARNING: Electrical shock and
hot surface hazards
HEATER Before attempting maintenance of any kind
on the Thermolator, you must stop the unit;
ELEMENTS disconnect and lockout the main power
supply; and allow the unit to cool to less than
100° F (38° C)

1 Disconnect and lockout the main power.

2 Remove the top panel of the Thermolator.
3 Remove the heater cap.
Use a 1/4-inch open-end wrench Heater
cap
to remove the three bolts that
hold the cap to the heater tank.

4 Remove the heater wiring

harness.
Label the wiring layout of the
IMPORTANT: Always heater terminals; wires are
refer to the wiring dia- labeled 2T1, 2T2, 2T3 and
grams that came with GND. Then unscrew the lock-
your Thermolator to ing screws on the wiring harness
locate specific electrical and remove the wires.
components. Illustrations
in the User Guide are 5 Shut off the cooling water in feed.
intended to be represen-
tative only. 6 Drain the Thermolator using the drain plugs
located at the rear of the unit.
7 Remove the four bolts
Heater cap
that hold the heater ele-
ment in place. Use a 15/16-
inch socket with 1/2-inch drive. Heater element

8 Lift the heating element Heater

out of the heater tube. gasket
Lift the element straight up.

9 Replace the heater gasket

Use a high temperature Teflon
paste to ensure a good seal.
10 Reverse these steps to
install the new heater
element and reassemble
the unit.

6-20 TROUBLESHOOTING Thermolator heaTrac TH-1 and TH-2 control UGH002-0514

 WARNING: Electrical shock and
hot surface hazards
REMOVING
Before attempting maintenance of any kind THE PUMP
on the Thermolator, you must stop the unit;
disconnect and lockout the main power
supply; and allow the unit to cool to less than
100° F (38° C)

1 Disconnect and lockout the main power.

2 Shut off the cooling water in feed.

3 Remove the top and side panels of the

Thermolator.

4 Drain the unit of all fluid. Remove the drain plugs at

the rear of the heater casting.

5 Remove the seal flush line. Use a 1/2-inch open-end

wrench to remove the vent line from the connection on the
pump adapter.
Pump
6 Remove the pump
assembly bolts. Use a
assembly
bolts
9/16-inch open-end box
wrench to remove the bolts
holding the pump to the
volute case. The bolt in the
rear will require a 9/16-inch
crows foot wrench.

7 Lift the pump assembly

straight up to remove. Pump seal flush line
The pump can now be replaced
or disassembled for repair.

8 Reverse the steps to

reassemble the unit.

NOTE: Before restarting,

close all drain openings using
sealant on the threads and
refill the unit with fluid. Do not
start the the pump when the
unit is dry.

UGH002-0514 Thermolator heaTrac TH-1 and TH-2 control TROUBLESHOOTING 6-21

We’re Here to Help Additional manuals and prints for
your Conair equipment may be
ordered through the Customer
Conair has made the largest investment in customer support in the plastics Service or Parts Department for a
nominal fee.
industry. Our service experts are available to help with any problem you might
have installing and operating your equipment. Your Conair sales representative
also can help analyze the nature of your problem, assuring that it did not result
from misapplication or improper use.

How to Contact Customer Service

To contact Customer Service personnel, call:

NOTE: Normal operating hours are 8:00 am - 5:00 pm EST. After hours emergency
service is available at the same phone number.

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.

Before You Call...

If you do have a problem, please complete the following checklist before calling Conair:

r Make sure you have all model, control type from the serial tag, and parts list numbers for your
particular equipment. Service personnel will need this information to assist you.
r Make sure power is supplied to the equipment.
r Make sure that all connectors and wires within and between control systems and related
components have been installed correctly.
r Check the troubleshooting guide of this manual for a solution.
r Thoroughly examine the instruction manual(s) for associated equipment, especially controls.
Each manual may have its own troubleshooting guide to help you.
r Check that the equipment has been operated as described in this manual.
r Check accompanying schematic drawings for information on special considerations.

UGH002-0514 SERVICE INFORMATION APPENDIX A-1

 Equipment Guarantee
Conair guarantees the machinery and equipment on this order, for a period as defined in the quotation
from date of shipment, against defects in material and workmanship under the normal use and service for
which it was recommended (except for parts that are typically replaced after normal usage, such as
filters, liner plates, etc.). Conair’s 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.

Performance Warranty
Conair warrants that this equipment will perform at or above the ratings stated in specific quotations
covering the 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 misapplication, 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 subject to prior notice by the customer at
which time a Return Goods Authorization Number (RGA) will be issued by Conair’s 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.

Warranty Limitations
Except for the Equipment Guarantee and Performance Warranty stated above, Conair disclaims
all other warranties with respect to the equipment, express or 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 UGH002-0514

B-1
B-2
B-3
B-4
 PUMP
CURVES

UGH002-0514 TECHNICAL INFORMATION APPENDIX C-1

The SPI commands supported by Conair Thermolator® mold
temperature controllers are listed in the following tables. SPI COMMANDS
The standard required commands and three optional com- SUPPORTED BY
mands are listed in the SPI Command Pairs table, along with
the Select and Poll command pairs in hexadecimal format. THE CONAIR
Select commands set or change Thermolator functions. Poll
commands retrieve information from the Thermolator. THERMOLATOR®
SPI Command Pairs
Mold temperature controllers Device ID: hex 20

Commands Select Poll

Echo 0x20 0x20
- Select stores 4 bytes of information at the Thermolator; Poll retrieves it. 0x21 0x20
Setpoint Process Temperature 0x20 0x20
- Sets and retrieves the process temperature setpoint. 0x31 0x30
Alarm, High Temperature Deviation* 0x20 0x20
- Sets the alarm band temperature; retrieves setpoint + alarm band value. 0x33 0x32
Alarm, Low Temperature Deviation* 0x20 0x20
- Sets the alarm band temperature; retrieves setpoint + alarm band value. 0x35 0x34
Mode, Machine 0x20 0x20
- Start/stops the Thermolator; acknowledges alarms; retrieves run status 0x49 0x48
Version 0x20
- Retrieves 4 bytes of SPI version information. 0x22
Process Status 0x20
- Retrieves run status and alarm conditions. 0x40
Status, Machine 1 0x20
- Retrieves run status and alarm conditions. 0x42
Status, Machine 2 0x20
- Retrieves run status and alarm conditions. 0x44
Temperature, from Process 0x20
- Retrieves the actual temperature of fluid returning to the Thermolator. 0x72

* NOTE: Both High and Low Temperature Deviation commands set the
same variable. Use only one of these commands to avoid problems.

See the tables on the following pages for the SPI status words
and BIT positions for Process Status, Machine 1 Status and
Machine 2 status.

For more information on the SPI protocol, you can obtain the
SPI Communication Protocol Manual by contacting:
The Society of the Plastics Industry, Inc.
1801 K Street, NW
Suite 600K
Washington DC 20006
(202) 974-5200 Fax: (202) 296-7005
www.plasticsindustry.org

UGH002-0514 THERMOLATOR SPI COMMANDS APPENDIX D-1

SPI STATUS WORDS
Status, Process
Poll: 0x20 0x40

Alarm, High temperature deviation

Alarm, Low temperature deviation
Alarm, High pressure condition
Alarm, Low pressure condition
Alarm, Low flow

Alarm, Machine

Alarm, Process

Alarm, System

Processing
Reserved

Reserved

Reserved

Reserved

Reserved
Open

Open

SPI STATUS WORD

Word BIT position 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

EEprom error
A/D converter error
SET SET
*
CJC Error
SET SET
*
RAM hardware
SET SET
*
ROM checksum
SET SET
*
Probe Failure
SET SET
*
SET SET
*
E/M Hi temp safety
Prog. Hi temp safety
*
Output monitor failure
*
Low water pressure
SET SET
*
High deviation alarm
SET SET SET
*
Low deviation alarm
SET SET SET
*
Prog. Lo temp safety
SET SET SET
*
*
Pump overload
Low water level
SET SET
*
Test Mode
SET SET
*
Phase error
*
*
NOTES:
*Elsewhere
The SPI I/O list defines the Processing bit as being cleared if the unit is not processing; otherwise it is SET.
on the chart:
● If a bit is not shown to be SET, it is cleared.
● The System Alarm bit is SET if an alarm is present. It is the logical OR of Process alarm and Machine alarm.
● Processing, System Alarm, Process Alarm and Machine Alarm bits are repeated for Process Status, Machine 1
Status and Machine 2 Status.

APPENDIX D-2 THERMOLATOR SPI COMMANDS UGH002-0514

SPI STATUS WORDS
Status, Machine 1
Poll: 0x20 0x42

Alarm, Low temperature safety limit

Alarm, High temperature safety limit

Alarm, High pressure safety limit
Alarm, Low pressure safety limit
Alarm, High current
Alarm, Low current

Alarm, High volts

Alarm, Low volts

Alarm, Machine

Alarm, Process

Alarm, System
Alarm, Phase

Processing
Reserved

Reserved
Open

SPI STATUS WORD

Word BIT position 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

EEprom error
A/D converter error
SET SET
*
CJC Error
SET SET
*
RAM hardware
SET SET
*
ROM checksum
SET SET
*
Probe Failure
SET SET
*
*
E/M Hi temp safety
Prog. Hi temp safety
SET SET SET
*
Output monitor failure
SET SET SET
*
Low water pressure
SET SET
*
High deviation alarm
SET SET SET
*
Low deviation alarm
*
Prog. Lo temp safety
*
SET SET SET
*
Pump overload
Low water flow
SET SET
*
Low water level
SET SET
*
Test Mode
SET SET
*
Phase error
*
SET SET SET
*
NOTES:
*Elsewhere
The SPI I/O list defines the Processing bit as being cleared if the unit is not processing; otherwise it is SET.
on the chart:
● If a bit is not shown to be SET, it is cleared.
● The System Alarm bit is SET if an alarm is present. It is the logical OR of Process alarm and Machine alarm.
● Processing, System Alarm, Process Alarm and Machine Alarm bits are repeated for Process Status, Machine 1
Status and Machine 2 Status.

UGH002-0514 THERMOLATOR SPI COMMANDS APPENDIX D-3

SPI STATUS WORDS
Status, Machine 2
Poll: 0x20 0x44

Alarm, Machine

Alarm, Process

Alarm, System
Fault, Sensor

Processing
Fault, CAL
Reserved

Reserved

Reserved

Reserved

Reserved

Reserved

Reserved

Reserved
Open

Open

SPI STATUS WORD

Word BIT position 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

EEprom error
A/D converter error
SET SET
*
CJC Error
SET SET
*
RAM hardware
SET SET
*
ROM checksum
SET SET
*
Probe Failure
SET SET
*
SET SET SET
*
E/M Hi temp safety
Prog. Hi temp safety
*
Output monitor failure
*
Low water pressure
SET SET
*
High deviation alarm
*
Low deviation alarm
*
Prog. Lo temp safety
*
*
Pump overload
Low water level
SET SET
*
Test Mode
SET SET
*
Phase error
*
*
NOTES:
* The SPI I/O list defines the Processing bit as being cleared if the unit is not processing; otherwise it is SET.
Elsewhere on the chart:
● If a bit is not shown to be SET, it is cleared.
● The System Alarm bit is SET if an alarm is present. It is the logical OR of Process alarm and Machine alarm.
● Processing, System Alarm, Process Alarm and Machine Alarm bits are repeated for Process Status, Machine 1
Status and Machine 2 Status.

APPENDIX D-4 THERMOLATOR SPI COMMANDS UGH002-0514

 Material Safety Data Sheet
An explanation of the terms used in this document may be found in OSHA 29 CFR 1910.1200,
MSDS:
which is available from OSHA regional or area offices.
7439-97-6
1. Chemical Identification
Substance: Mercury
Chemical name: Mercury
CAS-Number: 7439-97-6
Synonyms: Quicksilver; Liquid silver
MERCURY
Formula: HG Molecular weight: 200.59
Trade name: Not applicable Chemical family: Metal
Supplier of MSDS information: Emergency contact:
The Conair Group Inc. For CHEMTREC assistance call
One Conair Drive 800-424-9300 (in the U.S.)
Pittsburgh, PA 15202 703-527-3887 (international)
412-312-6000
2. Composition and Exposure Limits
Material Weight (%) Exposure Limits
3
Mercury 100 0.05 mg/m Threshold Limit Value(skin)/TWA
3
0.1 mg/m Permissible Exposure Limit (PEL)
3. Hazards Identification
Hazard Ratings (0 = no hazard; 4 = extreme hazard):
Health - 4 Extreme (Poison) Carcinogenic: NTP – No
Flammability - 0 None IARC – No
Reactivity - 1 Slight Z List – No
Contact - 3 Severe (Life) OSHA Reg – No
Personal Health Effects:
WARNING Mercury is a dangerous poison and an extreme contact
hazard. Mercury may be absorbed by the skin or through
the eyes. It may be fatal if swallowed or inhaled. It emits
toxic vapors, especially when heated. Do not get mercury
in your eyes, on your skin or on your clothing. Do not
breathe mercury dust. Keep mercury in a tightly closed
container. Use with adequate ventilation. Wash
thoroughly after handling.
Effects of overexposure Mercury causes skin, digestive tract and severe
respiratory tract irritation. It may affect the central
nervous system and cause severe eye irritation.
Inhalation of vapors may cause coughing, chest pains,
nausea and vomiting.
Chronic effects of overexposure may include kidney
and/or liver damage, and central nervous system
depression. Chronic effects of mercury poisoning include
a buildup of the metal in the brain, liver and kidneys.
Symptoms include headache, tremors, loose teeth, loss
of appetite, blisters on the skin and impaired memory.
This substance has caused adverse reproductive and
fetal effects in animals.
Target organs Eyes, skin, respiratory system, central nervous system,
kidneys and liver.
Routes of entry Inhalation, absorption, eye contact, skin contact.
4. Emergency and First Aid Measures
Call a physician immediately.
If swallowed: Immediately induce vomiting, if person is conscious.
If inhaled: Immediately remove exposed person to fresh air. If the person
is not breathing, give artificial respiration. If breathing is
difficult, give oxygen.
In case of contact: Immediately flush eyes or skin with plenty of water for at least
15 minutes, while removing contaminated clothing and shoes.
Wash clothing before using again.

UGH002/1199 Material Safety Data Sheets E-1

MSDS: 5. Fire and Explosion Data
Fire and explosion Mercury presents a slight fire and explosion hazard when

7439-97-6 hazards: exposed to heat or flame. Mercury vapors are heavier

than air and may travel a considerable distance to a
source of ignition and flash back.

MERCURY Firefighting media: Dry chemical, carbon dioxide, water spray or foam.
For larger fires, use water spray, fog or alcohol foam.
(1984 Emergency Response Guidebook, DOT P 5800.3).
Firefighting Use agents suitable for type of fire. Use water in flooding
procedures: amounts as a fog. Avoid breathing corrosive and
poisonous vapors. Keep upwind. Move containers from
the fire area if possible. Cool containers exposed to
flames with water from side until well after fire is out.
(1984 Emergency Response Guidebook, DOT P 5800.3).
6. Spill and Disposal Procedures
EPA Hazardous Waste Number: U151 (Toxic Waste)
If spilled or discharged: Wear self-contained breathing apparatus and full
protective clothing. Clean up the spill immediately.
Collect and store using a suction pump with a capillary
tube. Calcium polysulfide with excess sulfur should be
sprinkled into cracks or inaccessible sites. Keep collected
mercury in a tightly closed bottle for recovery or disposal.
Disposal procedure: Dispose in accordance with all applicable federal, state,
and local environmental regulations.
7. Storage and Handling Precautions
Mercury should be stored in a secure poison area inside a tightly closed container.

8. Exposure Control and Protective Equipment

Ventilation: Use general or local exhaust ventilation to meet TLV
requirements.
Respiratory protection: None required where appropriate ventilation conditions
exist. If the TLV is exceeded, a self-breathing apparatus
is advised.
Eye/skin protection: Safety goggles and face shield, uniform, protective suit
and rubber gloves are recommended.
9. Physical and Chemical Properties
Appearance and odor: Silver-white, heavy, mobile liquid metal; odorless
Boiling point: 675° F (357° C) Melting point: -38° F (-39° C)
Specific gravity: 13.5 Vapor pressure: 0.002 mm HG
Vapor density: 1.01 Solubility in H20: negligible, less than 0.1%
Solubility in solvents: Sulfuric acid, nitric acid, lipids
10. Stability and Reactivity Data
Stability: Stable Hazardous polymerization: Will not occur
Conditions to avoid: Heat
Incompatibles: Strong acids

IMPORTANT: Users of this equipment should study this MSDS carefully to

become aware of and understand the hazards associated with the product. If
necessary or appropriate, the reader should consider consulting reference works or
individuals who are experts in ventilation, toxicology and fire prevention to use and
understand the data in this MSDS. To promote safe handling, the reader should
furnish this information to anyone whom he or she knows or believes will use this
equipment.

E-2 Material Safety Data Sheets UGH002/1199

Material Safety Data Sheet Paratherm Corporation
NP Heat Transfer Fluid
L ,111111 •IIR••
Manufacturer's Name Paratherm Corporation CAS Number: 8042-47· 5
Address 1050 Colwell Road
Conshocken, PA 19428 TSCA Inventory Status: Included
Emergency Telephone No. (610) 941-4900 NFPA Hazard Identification
Trade Name Paratherm m-e
Revision Date April 3, 1996 Degree of Hazard Hazard Ratings
0-Least
Health: 0 1-8light
I. RIIEFEII Fire: 1 2-Moderate
Reactivity: 0 3-High
COMPONENT CAS HAZARDOUS PERCENTAGE COMPONENT 4-Extreme
NAME NUMBER IN BLEND Min. Max. EXPOSURE LIMITS UNITS
Hydrotreated OSHA PEL None established (see item m below)
8042-47-5 No tOO.OO
Natural Hydrocarbon ACGIH TLV None established (see item m below)

11. ma.m•1nmm111
ACUTE EFFECTS CHRONIC EFFECTS
EYE CONTACT On rare occasions, prolonged and repeated exposure to oil mist poses a
Paratherm Nre is non-irritating to the eyes upon direct contact. risk of pulmonary disease such as chronic lung inflammation. This con­
SKIN CONTACT dition is usually asymptomatic as a result of repeated small aspirations.
Paratherm Nre is not expected to cause any skin irritation upon direct Shortness of breath and cough are the most common symptoms.
single or repeated and prolonged contact; however, similar chemical Aspiration may lead to chemical pneumonitis which is characterized by
composition products applied to the skin of laboratory animals resulted pulmonary edema and hemorrhage, and may be fatal. Signs of lung
in minimal to slight dermal irritation. involvement include increased respiration rate, increased heart rate,
INHALATION and a bluish discoloration of the skin. Coughing, choking, and gagging
Paratherm Nre has a low vapor pressure and is not expected to present are often noted at the time of aspiration. Gastrointestinal discomfort
an inhalation hazard at ambient conditions. Caution should be taken to may develop, followed by vomiting, with a further risk of aspiration.
prevent aerosolization or misting. The permissible exposure limit (PEL) CARCINOGENICITY
and threshold limit value (TLV) for the fluid as oil mist is 5 mg/m3. NTP: No
Exposures below 5 mg/m3 appear to be �thout significant health risk. IARC: No
INGESTION OSHA: No
Ingestion is relatively non-toxic unless aspiration occurs. Paratherm Nre
has laxative properties and may result in abdominal cramps and diar­
rhea. See Personal Health Protection section below.

LI. E• IBID I RIii .....

EYE CONTACT an inhalation hazard at ambient conditions. If vapor or mist is generat­
Immediately flush eyes with large amounts of water and continue flush­ ed when the fluid is heated or handled, remove victim from exposure. If
ing for 15 minutes. If fluid is hot, treat for thermal burns and take victim breathing has stopped or is irregular, administer artificial respiration
to hospital immediately. and supply oxygen if it is available. If victim is unconscious, remove to
SKIN CONTACT fresh air and seek medical attention. Do not use compressed oxygen in
Remove contaminated clothing. If fluid is hot, submerge injured area in hydrocarbon atmospheres.
cold water. If victim is severely burned, take to a hospital immediately. INGESTION
INHALATION May act as a laxative. Do not induce vomiting due to possible aspira­
Paratherm Nre has a low vapor pressure and is not expected to present tion. If vomiting occurs, lower head below knees to avoid aspiration.
Seek immediate medical attention.

EYE PROTECTION organic vapor respirator with a dust and mist filter. All respirators must
Eye protection is not required under conditions of normal use. If the be NIOSH certified. Do not use compressed oxygen in hydrocarbon
fluid is handled such that it could be splashed into eyes, wear plastic atmospheres.
face shield or splash-proof safety goggles. VENTILATION
SKIN PROTECTION If vapor or mist is generated when the fluid is heated or handled, ade­
No skin protection is required for single, short duration exposures. For quate ventilation in accordance with good engineering practice must be
prolonged or repeated exposures, use impervious synthetic rubber provided to maintain concentrations below the specified exposure or
clothing (boots, gloves, aprons, etc.) over parts of the body subject to flammable limits.
exposure. If handling hot fluid, use insulated protective clothing (boots, OTHER
gloves, aprons, etc.) Consumption of food and beverages should be avoided in work areas
RESPIRATORY PROTECTION where hydrocarbons are present. Always wash hands and face with
Respiratory protection is not required under conditions of normal use. soap and water before eating, drinking or smoking.
If vapor or mist is generated when the fluid is heated or handled, use an

E-3
E-4
 PARTS/DIAGRAMS
● Spare Parts Lists . . . . . . . . . .PD-1
● TH-1 Wiring . . . . . . . . . . . . . . .PD-5
● TH-2 Wiring . . . . . . . . . . . . . . .PD-7

UGH002-0514 Thermolator TH-1 and TH-1 Plus PD-1

RECOMMENDED TH-1 and TH-2 Thermolators
SPARE PARTS 208-230/460V 9kW & 12kW units
1 HP through 3 HP

PUMP ASSEMBLIES
Air cooled mechanical seal, Totally enclosed fan cooled motor
Part No. Description
09003669 1 HP pump model
09003670 1-1/2 HP pump model 1
09003671 2 HP pump model
09003672 3 HP pump model

PD-2 RECOMMENDED SPARE PARTS UGH002-0514

TH-1 and TH-2 Thermolators RECOMMENDED
208-230/460V, 6kW, 12kW & 18kW units, 1HP through 3HP
SPARE PARTS
REPLACEMENT HEATERS
Part No. Description
09002018 6 KW 208V/3/60 MS
09001579 6 KW 230/460V/3/60 MS
09002019 12 KW 208V/3/60 MS
09002017 12 KW 230/460V/3/60 MS
25917401 Heater flange gasket

COOLING SOLENOID OVERHAUL KITS

Part No. Description
09004614 1/2 inch solenoid overhaul kit, 4.0 CV
09004554 3/4 inch solenoid overhaul kit, 5.0 CV

COOLING SOLENOID VALVES

Part No. Description
09002969 1/2 inch solenoid valve, 4.0 CV
09004510V 3/4 inch solenoid valve, 5.0 CV

UGH002-0514 RECOMMENDED SPARE PARTS PD-3

RECOMMENDED TH-1 and TH-2 Thermolators
SPARE PARTS 208-230/460V, 6kW ,12kW & 18kW units, 1 HP through 3 HP
HEATER CONTACTORS
Part No. Description
20004401 Heater contactor for 6kW 208/230/460V
20004401 Heater contactor for 12kW 230/460V
09000417 Heater contactor for 12kW 208V
REPLACEMENT BOARDS for TH-1 , TH-2
Part No. Description
09003732 TH1 operator board
09003731 TH1 motherboard
09003735 TH1 flat ribbon cable
09003734 TH2 operator board
09003733 TH2 motherboard
09003737 15 feet coiled control cable - TH-2
02001186PH 30 feet coiled control cable - TH-2
02001187 50 feet coiled control cable - TH-2
PUMP OVERLOADS
Part No. Description
20003909 Pump overload for: 1 HP 460V
20003910 Pump overload for: 1 HP 230V and 2 HP 460V
20003911 Pump overload for: 1 HP 208/230V
20003912 Pump overload for: 3 HP 460V
20003913 Pump overload for: 2 HP 208/230V
20003914 Pump overload for: 3 HP 208/230V

PUMP CONTACTORS
Part No. Description
20003801 Pump contactor for: 3 HP 208/230/460V

MISCELLANEOUS
Part No. Description
11001213 Thermolator transformer
11000400 Thermocouple, standard temp unit, 6 feet
09002602 Process pressure gauge 0-60PSI
09000328 Water pressure relief valve, 150 PSI
09040000 Caster
09000686 Handle
09002254 Level Switch 500 Deg F rated

MANUALS
Part No. Description
UGH002-0514 User Guide, Thermolator TH-1 Series
QCH003/1197 Quick Card, Thermolator TH-1
QCH004/1197 Quick Card, Thermolator TH-2

PD-4 RECOMMENDED SPARE PARTS UGH002-0514

 Ref: 33405309-A
TH-1 WIRING

UGH002-0514 TH-1 230/460V WIRING DIAGRAM PD-5

 R
R R
M
XF M
M R
O XF
FR M

S
S
O

LL
LL
FR

L1

L2

L3
2

3
4
1

6
5
4
3
2
1
4
3
2
1

4
3
2
1
LLS/WPS
LLS/WPS
AUTOSTART
AUTOSTART
HPS/LPS
HPS/LPS

OPS
OPS
FSTAT
FSTAT

L1

L2

L3
4
AC IN + 3
2
AC OUT + 1
F1
3 PHASE INPUT
AC IN

AC OUT

TH-1 F5

CIRCUIT BOARD UNLDR 2/ VENT 2 SOL

UNLDR 2/ VENT 2 SOL
+ 4
3
10
2
VENT SOL
VENT SOL
UNLDR 1/ COOL 1 SOL + 2 2 COOL SOL
UNLDR 1/ COOL 1 SOL 1 9 COOL SOL

F4

PUMP PUMP
WARNING! 4 2
PUMP 3 6 PUMP
IT IS VERY IMPORTANT THAT
PUMP OL 2 6 PUMP OL
SWITCHES #7 AND #8 BE SET TO PUMP OL
PUMP OL 1 5
THE PROPER UNIT TYPE BEFORE
OPERATING THIS UNIT F2

THERMOLATOR
sw Hot Oil Unit
8 ON PMP AUX 6 4 PUMP AUX
PMP AUX 5 7 PUMP AUX
7 OFF
1FS/ COMP AUX 4
1FS/ COMP AUX 3 11 1FS or JUMPER 4
OFF PUMPDOWN 2
1 2 3 4 5 6 7 8
PUMPDOWN 1

HEAT/COMP
4 2 HEAT
ON HEAT/COMP
3 8 HEAT
CONFIGURATION HTS/COMP OL 2 12 HTS
DIP SWITCH HTS/COMP OL 1 8 HTS

F3 ALARM
6 2
N 5
C 4
NC 3 22 ALARM
ALARM
NO 2
C 1
110V
OPER PNL CABLE

NOT USED 4
(-2) CONTROL

NOT USED 3
+ 120 Ohm

120 Ohm

NOT USED 2
NOT USED 1
GND
GND

F6
+ TR

+ TR
TR

TR

TCPL'S
SUP RET
Y
R
R
Y

1 2 3 4 5 6 7 8 1 2 3 4
12
12

0
0

Y
R
R
Y
O
O

hm
hm

R UR TC L
R PPL TC
SU
SU PL
JU

ET N P
JU

ET Y P
D 9 (4
D
B .8

P
B

U T L
M

9 )

R C
PE
PE

(5

N P
.9

R
R

TC L
)

PL

PD-6 HEATRAC CIRCUIT BOARD UGH002-0514

 Ref: 33405310-A
TH-2 WIRING

UGH002-0514 TH-2 230/460V WIRING DIAGRAM PD-7

 R
R R
M
XF M

ST RT
RT
M R

TO STA
A
O XF
FR M

AU TO
AU S
S
O

LL
LL
FR

L1

L2

L3
15
4
2

3
4
1

6
5
4
3
2
1
4
3
2
1

4
3
2
1
LLS/WPS
LLS/WPS
AUTOSTART
AUTOSTART
HPS/LPS
HPS/LPS

OPS
OPS
FSTAT
FSTAT

L1

L2

L3
4
AC IN + 3
2
AC OUT + 1
F1

3 PHASE INPUT
AC IN

AC OUT

TH-2 F5

CIRCUIT BOARD UNLDR 2/ VENT 2 SOL

UNLDR 2/ VENT 2 SOL
+ 4
3
10
2
VENT SOL
VENT SOL
UNLDR 1/ COOL 1 SOL + 2 2 COOL SOL
UNLDR 1/ COOL 1 SOL 1 9 COOL SOL

F4

PUMP PUMP
WARNING! 4 2
PUMP 3 6 PUMP
IT IS VERY IMPORTANT THAT
PUMP OL 2 6 PUMP OL
SWITCHES #7 AND #8 BE SET TO PUMP OL
PUMP OL 1 5
THE PROPER UNIT TYPE BEFORE
OPERATING THIS UNIT F2

THERMOLATOR
sw Hot Oil Unit
8 ON PMP AUX 6 4 PUMP AUX
PMP AUX 5 7 PUMP AUX
7 OFF
1FS/ COMP AUX 4
1FS/ COMP AUX 3 11 1FS or JUMPER 4
OFF PUMPDOWN 2
1 2 3 4 5 6 7 8
PUMPDOWN 1

HEAT/COMP
4 2 HEAT
ON HEAT/COMP
3 8 HEAT
CONFIGURATION HTS/COMP OL 2 12 HTS
DIP SWITCH HTS/COMP OL 1 8 HTS

F3 ALARM
6 2
N 5
C 4
NC 3 22 ALARM
ALARM
NO 2
C 1
110V
OPER PNL CABLE

LLS/PURGE 3SOL 4
(-2) CONTROL

LLS/PURGE 3SOL + 3
+ 120 Ohm

120 Ohm

PURGE 4SOL 2
PURGE 4SOL + 1
GND
GND

F6
+ TR

+ TR
TR

TR

TCPL'S
SUP RET
Y
R
R
Y

1 2 3 4 5 6 7 8 1 2 3 4
12
12

0
0

Y
R
R
Y
O
O

hm
hm

R UR TC L
R PPL TC
SU
SU PL
JU

ET N P
JU

ET Y P
D (4
D
B .8

P
B

U T L
M

9 )
9

R C
PE
PE

(5

N P
.9

R
R

TC L
)

PL

PD-8 TH-2 CIRCUIT BOARD UGH002-0514