Regal G500 Series Temperature Control Unit User manual

I.O.M. #149 updated : 04/24/2020

INSTRUCTION MANUAL • INSTALLATION • OPERATION • MAINTENANCE

ADVANTAGE ENGINEERING, INC.

525 East Stop 18 Road Greenwood, IN 46142

317-887-0729 fax: 317-881-1277

Service Department fax: 317-885-8683

www.AdvantageEngineering.com

[email protected]

Model:

Serial Number :

TEMPERATURE CONTROLLER

For Units with the G500 Series Control Instrument

INSTRUCTION MANUAL

Regal RK with

G500 Series Instrument

COVERING

INSTALLATION

OPERATION

MAINTENANCE

ADVANTAGE ENGINEERING, INC. 525 East Stop 18 Road Greenwood, IN 46142

317-887-0729 fax: 317-881-1277 Service Department fax: 317-885-8683

www.AdvantageEngineering.com E-mail: [email protected]

TEMPERATURE CONTROLLER

Temperature Control Unit : Regal with G500 Series Instrument

Page: 4

Advantage Engineering, Inc.

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-0729 Fax: 317-881-1277

Service Department Fax: 317-885-8683www.AdvantageEngineering.com

TABLE OF CONTENTS

1.0 GENERAL 7

1.1 Receiving Instructions 8

1.2 Introduction 8

1.3 Safety 8

1.4 Components 10

2.0 INSTALLATION 13

2.1 General 14

2.2 To and from process connections 14

2.3 Water supply connection 15

2.4 Drain connection 15

2.5 Electrical connection 17

3.0 START UP SEQUENCE 19

3.1 General 20

3.2 System Fill / Operations 20

3.3 Instrument : Quick Start 24

3.4 Instrument : Basic Navigation 25

3.5 Instrument : Operating Screens 26

3.6 Instrument : Fault Screens 27

3.7 Instrument : Main Menu 28

3.8 Instrument : Setpoints Menu 28

3.9 Instrument : Utilities Menu 29

3.10 Instrument : Network Menu 30

3.11 Instrument : Options Menu 32

3.12 Instrument : Machine Menu 32

3.13 Shut Down / Disconnect 33

4.0 TROUBLESHOOTING 35

4.1 Unit will not start (Display is not Illuminated) 36

4.2 Unit will not start (Display is Illuminated) 36

4.3 Unit Stops 36

4.4 Unit Overheats 37

4.5 Unit Underheats 38

4.6 Pressure Relief Valve Leaks 38

5.0 MAINTENANCE 41

5.1 Preventative Maintenance 42

5.1 Pump Seal Replacement 43

5.2 Heater Replacement 45

5.3 Cooling Valve Service 46

5.4 Pressure Switch Service 47

5.5 Electronic Instrument Repair Policy And Procedure 48

Temperature Control Unit : Regal with G500 Series Instrument

Page: 5

Advantage Engineering, Inc.

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-0729 Fax: 317-881-1277

Service Department Fax: 317-885-8683 www.AdvantageEngineering.com

6.0 COMPONENTS 49

6.1 Mechanical system 50

6.2 Electrical system 50

7.0 RELATED DRAWINGS 53

7.1 Physical 12 kW Heaters & 1 - 3 HP Pumps 54

7.2 Physical 16-24 kW Heaters & 1 - 3 HP Pumps 55

7.3 Physical 36-48 kW Heaters & 5 - 7.5 HP Pumps 56

7.4 Circuit Schematic with Cooling Circuit 57

8.0 APPENDIX 59

8.1 Model # And Suffix Coding 60

8.2 Water Cooled Process Pumps 61

8.3 Mold Purge 62

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Temperature Control Unit : Regal with G500 Series Instrument

Page: 7

Advantage Engineering, Inc.

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-0729 Fax: 317-881-1277

Service Department Fax: 317-885-8683 www.AdvantageEngineering.com

1.0 GENERAL

1.1 Receiving Instructions

1.2 Introduction

1.3 Safety

1.4 Components

Temperature Control Unit : Regal with G500 Series Instrument

Page: 8

Advantage Engineering, Inc.

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-0729 Fax: 317-881-1277

Service Department Fax: 317-885-8683www.AdvantageEngineering.com

1.1 RECEIVING INSTRUCTIONS

A. Temperature control units are generally shipped skid mounted, boxed and wrapped in

plastic prior to shipment.

B. Unbox the unit before accepting delivery. Check for visible damage and document any

evident damage on the delivery receipt or refuse the shipment. Shipping damage is the

responsibility of the carrier.

C. In order to expedite payment for damages, should they occur, follow proper procedures

and keep detailed records. Take photographs of any suspected damage.

1.2 INTRODUCTION

A. This manual covers temperature control units from 12 to 48 kW of heating capacity

using the G500 Series microprocessor control instrument. The standard uid operating

temperature range for this temperature control unit is 100°F to 500°F. Consult the factory

if you have questions about the operating range of your temperature control unit.

B. The intent of this manual is to serve as a guide in the installation, operation and

maintenance of your temperature control unit. Improper installation can lead to equipment

damage and poor performance. Failure to follow the installation, operation and

maintenance instructions may result in damage to the unit that is not covered under the

limited warranty. This manual is for standard products. The information contained in this

manual is intended to be general in nature. The information is typical only and may not

represent the actual unit purchased.

C. When calling for assistance from the Manufacturer’s Service Department, it is important

to know the model and serial number of the particular unit. The model number includes

critical unit information which is helpful when troubleshooting operating difculties. The

serial number allows the service team to locate manufacturing and testing records which

can have additional information relating to a particular unit.

1.3 SAFETY

A. It is important to become thoroughly familiar with this manual and the operating

characteristics of the unit.

B. It is the owner’s responsibility to assure proper operator training, installation, operation,

and maintenance of the unit.

C. Observe all warning and safety placards applied to the unit. Failure to observe all

warnings can result in serious injury or death to the operator and severe mechanical

damage to the unit.

WARNING: This equipment contains hazardous voltages that can cause severe injury or

death. Disconnect and lock out incoming power before installing or servicing the equipment.

Temperature Control Unit : Regal with G500 Series Instrument

Page: 9

Advantage Engineering, Inc.

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-0729 Fax: 317-881-1277

Service Department Fax: 317-885-8683 www.AdvantageEngineering.com

D. Observe all safety precautions during installation, startup and service of this equipment

due to the presence of high voltage. Only qualied personnel should install, startup and

service this equipment.

E. When working on this equipment, observe precautions in literature and on tags, stickers

and labels located on the equipment. Wear work gloves and safety glasses.

F. Before installing and operating the unit, be aware of and follow any local laws and codes

that apply to the installation.

G. Samples of Warning Labels applied to typical temperature control units.

1. Alerts users to the danger of high voltage.

2. Alerts the user to possible explosive danger.

3. Alerts the user to a hot surface danger due to high operating temperatures.

CAUTION

WARNING

J5318-BF

Temperature Control Unit : Regal with G500 Series Instrument

Page: 10

Advantage Engineering, Inc.

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-0729 Fax: 317-881-1277

Service Department Fax: 317-885-8683www.AdvantageEngineering.com

1.4 COMPONENTS

WARNING: Improper fluid quality will void unit warranty.

From Process Valve and Connection

Process Pump

Fluid Drain Valve

Water Drain Connection

Water Supply Connection

To Process Valve and Connection

Sight Glass

Heat Cylinder

Expansion Tank

Typical unit with lift-off cabinetry.

Temperature Control Unit : Regal with G500 Series Instrument

Page: 11

Advantage Engineering, Inc.

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-0729 Fax: 317-881-1277

Service Department Fax: 317-885-8683 www.AdvantageEngineering.com

From Process Valve and Connection

Process Pump

Fluid Drain Valve

Water Drain Connection

Water Supply Connection

To Process Valve and Connection

Sight Glass

Heat Cylinder

Expansion Tank

Typical unit with clam shell cabinetry.

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Temperature Control Unit : Regal with G500 Series Instrument

Page: 13

Advantage Engineering, Inc.

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-0729 Fax: 317-881-1277

Service Department Fax: 317-885-8683 www.AdvantageEngineering.com

2.0 INSTALLATION

2.1 General

2.2 To and From Process Connections

2.3 Water Supply Connection

2.4 Drain Connection

2.5 Electrical Connection

Temperature Control Unit : Regal with G500 Series Instrument

Page: 14

Advantage Engineering, Inc.

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-0729 Fax: 317-881-1277

Service Department Fax: 317-885-8683www.AdvantageEngineering.com

2.1 GENERAL

A. Care should be taken to use materials (hose, rigid piping, valves or filters) rated for

the temperature and pressure duty of your unit. Most units have a maximum operating

temperature of 500°F or less and a maximum pressure of 75 PSI. The unit is most

efficient when full size plumbing is run from the unit connections to and from the process.

If necessary, reduce the plumbing size at your process, not at the unit.

B. Be certain all process piping materials have the equivalent or larger diameter of the

particular process connection.

2.2 TO AND FROM PROCESS CONNECTIONS

A. Connect the unit’s To Process port to the Fluid In port on the process manifold.

B. Connect the unit’s From Process port to the Fluid Out port on the process manifold.

C. Please note: Process piping circuitry should be designed to avoid an excessive use of

elbows and/or lengths of pipe or hose. If hose is the material of choice, avoid tight twists

or curls and excessive lengths.

.

2.3 WATER SUPPLY CONNECTION

A. Connect the unit’s Water Supply port to the plant’s city water, well water, tower water or

chilled water supply.

B. If unit is a Heating Only Unit, the water supply must be a minimum of 1/2 GPM at a

maximum temperature of 100°F for efcient component cooling. If the unit is a Heating

and Cooling Unit including a heat exchanger, the water supply must be a minimum of

3 GPM at a minimum temperature of 100°F. High water ow may be required for your

application depending on the process cooling requirement.

To process connection:

Connect to “fluid in” on process manifold

Compressed air connection:

Connect to plant compressed air source

when purging fluid from mold to unit for

storage

From process

connection:

Connect to “fluid out” on

process manifold

Fluid fill port:

Use when manually

adding fluid to the unit

Fluid fill/drain connection:

Use when adding fluid from a

pressurized source or when draining

majority of fluid volume from unit

Water drain connection:

Connect to one of the following:

• Plant’s open water drain

• Tower water system return

• Chilled water system return

Water supply connection:

Connect to one of the following:

• Plant’s city water source

• Well water source

• Tower water supply

• Chilled water supply

Temperature Control Unit : Regal with G500 Series Instrument

Page: 15

Advantage Engineering, Inc.

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-0729 Fax: 317-881-1277

Service Department Fax: 317-885-8683 www.AdvantageEngineering.com

C. The factory recommend minimum operating water supply pressure requirement is a

minimum of 20 PSI. To protect the unit from operating without adequate supply water, a

water pressure switch is plumbed into the supply manifold. If the supply pressure is not

sufcient, the pressure switch will prevent unit operations.

D. On all units, cooling water circulates to the supply manifold, through the pump adapter

cooling jacket, and is then rejected to the drain manifold. This action maintains proper

pump seal cavity temperatures.

E. On units with the installed cooling option, a tube and shell heat exchanger for process

uid cooling is supplied and mounted to the expansion tank.

1. The purpose of the heat exchanger is to cool the process uid. Cooling water

from plant water supply circulates through the “tube” side of the heat exchanger.

The process uid circulates through the “shell” side. Cooling water ow is

controlled by the solenoid valve.

2. A 1/2” ball valve is placed in the heat exchanger water supply line after the

solenoid valve. The ball valve should be open during operations from 100°F to

200°F. During operations with temperatures over 200°F, this valve should be

closed. In such cases, the necessary cooling water is proportioned to the heat

exchanger through the small capillary line, which some water “steams off” to cool

the process uid. The steam and water mixture is then rejected to drain.

2.4 WATER DRAIN CONNECTION:

A. Connect the unit’s Water Drain port to one of the following, determined by the water

supply source:

1. Open water drain for well or city water supply.

2. Tower water system return for tower system water supply.

3. Chilled water system return for chilled water system supply.

B. The factory recommends a minimum of 20 psi pressure differential between the water

supply and water drain line for proper cooling.

1. For units equipped with the cooling feature, the amount of cooling provided by

the unit depends on:

a. Cooling heat exchanger size.

b. The cooling valve size

c. The pressure differential across the valve

d. The temperature difference between the unit set point and the cooling

water temperature

2. Consult factory when selecting the correct cooling valve for your application.

Temperature Control Unit : Regal with G500 Series Instrument

Page: 16

Advantage Engineering, Inc.

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-0729 Fax: 317-881-1277

Service Department Fax: 317-885-8683www.AdvantageEngineering.com

3. In general, the cooling capacity of the standard 3.5 sq ft heat exchanger is 6,000

Bth/hr (2 kW) for every 20°F difference between the cooling water temperature

and the uid temperature.

C. CAUTION: The unit must never be operated with a closed drain line valve. A closed

drain line valve prevents adequate system cooling and will lead to unit overheating.

Overheating of the unit may lead to unit damage and/or serious personal injury.

2.5 ELECTRICAL CONNECTION

A. Standard Models

1. Electrical power supply requirements for standard units are identied on the

equipment data tag. Verify that available voltage supply is the same as the unit’s

voltage requirements.

WARNING: DO NOT CONNECT THE UNIT TO A VOLTAGE SUPPLY SOURCE

NOT EQUAL TO THE UNIT’S VOLTAGE REQUIREMENTS AS SPECIFIED ON

THE UNIT’S DATA PLATE.

Use of incorrect voltage will void the unit’s warranty and cause a signicant

hazard that may result in serious personal injury and/or unit damage.

2. For standard units with 12 kW heaters and up to 3 horsepower pumps, a four

conductor cable, 10 foot in length, is provided for connection to an operator

supplied fused disconnect.

3. For units with 16 kW to 48 kW heaters, the owner must provide a four conductor

power cable and the fused disconnect.

4. The owner supplied fused disconnect must be sized and installed according to

the unit’s power supply requirements and local electrical codes.

B. Models With Factory Included Disconnect Switch and Other Custom Features

1. Some units may be customized and include a factory supplied power disconnect

switch and/or higher specication electrical enclosure. Electrical power supply

requirements are identied on the equipment data tag. Verify that available

voltage supply is the same as the unit’s voltage requirements.

WARNING: Never operate the Temperature Control Unit with a closed water drain.

WARNING: Do not connect the unit to a voltage supply not equal to the unit’s voltage

requirements as specified on the unit’s data plate. Use of incorrect voltage will void the unit’s

warranty and cause a significant hazard that may result in serious personal injury and unit

damage.

Temperature Control Unit : Regal with G500 Series Instrument

Page: 17

Advantage Engineering, Inc.

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-0729 Fax: 317-881-1277

Service Department Fax: 317-885-8683 www.AdvantageEngineering.com

WARNING: DO NOT connect the unit to a voltage supply source not equal

to the unit’s voltage requirements as specied on the unit’s data plate. Use

of incorrect voltage will void the unit’s warranty and cause a signicant

hazard that may result in damage to the unit or serious personal injury.

2. Appropriate conduit and ttings should be selected which will maintain the

integrity of the cabinet.

3. Supply a power conductor sized according to the unit’s power supply

requirements. Connect the power conductor to the unit’s power supply entry

terminal block.

C. Control Circuit Wiring

1. The unit’s supplied control circuit is 110 volt, 1 phase, 60 cycle. The control circuit

is supplied by the factory installed transformer. A control circuit fuse is provided.

D. General

1. Make certain all ground connections to the unit are properly afxed. A proper

connection to earth ground is required. A conduit ground is not a reliable

conductor!

2. Make certain the power conductor, disconnecting means, and fusing are properly

sized according to the unit’s power supply requirements.

3. Make certain all electrical connections are tightly afxed. Any loose wiring

connections must be tighten before engaging the power supply.

4. Make certain no moisture or standing water is present inside the electrical

cabinet.

WARNING: Electric Shock Hazard. High Voltage is present in the electrical cabinet.

Disconnect power before servicing. Follow all facility lock-out tag-out procedures.

Temperature Control Unit : Regal with G500 Series Instrument

Page: 18

Advantage Engineering, Inc.

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-0729 Fax: 317-881-1277

Service Department Fax: 317-885-8683www.AdvantageEngineering.com

WARNING: Check that all electrical connections are tight before starting.

Disconnect power before servicing. Follow all facility lock-out tag-out procedures.

Typical Electrical Panel shown as reference of a RK-1230H model. Refer to the electrical drawing available for specific model.

A

B

C

D

E

F

G

H

I

A High temperature limit. Factory set to 515°F.

B High temperature limit instrument relay.

C Power entry terminal block.

D Motor starter and overload block.

E Transformer fuses.

F Control transformer

G Heater contactors

H Water supply pressure switch

I Power Cord. Note : typically included on most 12 kW models with up to 3 HP pumps. Units with 16 kW to 48 kW

heaters and pumps do not include a power cord.

Temperature Control Unit : Regal with G500 Series Instrument

Page: 19

Advantage Engineering, Inc.

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-0729 Fax: 317-881-1277

Service Department Fax: 317-885-8683 www.AdvantageEngineering.com

3.0 OPERATIONS

3.1 General

3.2 Machine Start Up and Operation

3.3 Instrument Operation : Quick Start

3.4 Instrument : Basic Navigation

3.5 Instrument : Operating Screens

3.6 Instrument : Fault Screens

3.7 Instrument : Main Menu

3.8 Instrument : Setpoints Menu

3.9 Instrument : Utilities Menu

3.10 Instrument : Network Menu

3.11 Instrument : Features Menu

3.12 Instrument : Options Menu

3.13 Instrument : Machine Menu

3.14 Shut Down / Disconnect

Temperature Control Unit : Regal with G500 Series Instrument

Page: 20

Advantage Engineering, Inc.

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-0729 Fax: 317-881-1277

Service Department Fax: 317-885-8683www.AdvantageEngineering.com

3.1 GENERAL

A. Failure to follow the factory required operation procedures may adversely affect the unit’s

ability to adequately control process temperature and may create a hazardous operating

condition which may result in unit damage or serious operator injury.

B. The Operations segment of this manual is outlined below:

3.2 Machine start-up/operations procedure - follow this segment to start the unit

after the initial installation or to restart the unit after reinstallation to the same or

different process. This section includes information on system ll, electric motor

phasing (pump rotation) and process ow adjustments.

3.3 Instrument Operation - follow this segment to start up and operate the

instrument. This section includes information on setpoint selection and

adjustment and feature explanations.

3.4 Shut down procedure - follow this segment to shut down the unit. This segment

includes information on system cool down, shut down, electrical power supply

precautions, and disconnection from the system.

3.2 MACHINE START UP AND OPERATION

A. System Fill

1. Use only approve high temperature heat transfer uids in this unit such as

Paratherm NF or an equivalent uid (www.paratherm.com). Never use water in

this unit.

List of Approved Heat Transfer Fluids

• Paratherm OR (https://www.paratherm.com/heat-transfer-uids/paratherm-or-heat-transfer-uid/)

• Paratherm NF (https://www.paratherm.com/heat-transfer-uids/paratherm-nf-heat-transfer-uid/)

• Multitherm PG-1 (http://www.multitherm.com/multitherm-pg-1.html)

• Calo FG (https://lubricants.petro-canada.com/productoverview/brand/calo)

2. The primary method of system ll is through the ll port located on the top of the

unit. Simply remove the cap plug and add uid. Replace the cap plug and tighten

when the ll is complete.

3. The alternate method of system ll is through the ll/drain valve. If a pressurized

source is available, simply connect to the ll/drain valve, open the valve and

engage the supply source. Close the valve when the ll is complete.

4. Proper unit ll is essential for efcient and safe operation. An oil level sight

glass is provided to determine unit ll. For initial ll: units up to 12 KW - ll until

WARNING: Follow all Factory operations procedures. Failure to do so may create a

hazardous operating condition which may result in serious operator injury and/or unit damage.

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Regal G500 Series Temperature Control Unit User manual

Regal G500 Series Temperature Control Unit User manual

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