Temptek Manual Veteran LS

I.O.M.
#092 12/06 updated 02/2013
INSTRUCTION MANUAL INSTALLATION OPERATION MAINTENANCE
Models with LS Series Instrument.
TEMPTEK, INC.
525 East Stop 18 Road Greenwood, IN 46142
317-887-6352 fax: 317-881-1277
Service Department fax: 317-885-8683
www.TempTek.com
e-mail: sales@TempTek.com
INSTRUCTION MANUAL
VETERAN TEMPERATURE CONTROL UNIT
with LS SERIES INSTRUMENT
COVERING
INSTALLATION
OPERATION
MAINTENANCE
TEMPTEK, INC. 525 East Stop 18 Road Greenwood, IN 46142

317-887-6352 fax: 317-881-1277 Service Department fax: 317-885-8683
www.TempTek.com e-mail: sales@TempTek.com
Temperature Control Units : With LS Series Instrument
TABLE OF CONTENTS
QUICK START-UP GUIDE 6

QUICK TROUBLESHOOTING GUIDE 7
1.0 GENERAL 9
1.1 Safety 10
1.2 Efficiency 10
1.3 Typical Label Placement 10
1.4 Component placement 11
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 16
3.0 START UP SEQUENCE 19

3.1 General 20
3.2 System fill/operations procedure 20
3.3 Instrument operation 25
3.4 Shut down/disconnect sequence 30
4.0 TROUBLESHOOTING 33
4.1 Unit will not start (Power light off) 34
4.2 Unit will not start (Power light on) 34
4.3 Unit stops 34
4.4 Unit overheats 35
4.5 Unit underheats 36
4.6 Pressure relief valve leaks 37
4.7 Cooling valve fault 38
5.0 MAINTENANCE 35
5.1 Pump seal replacement 36
5.2 Heater replacement 39
5.3 PVTTM cooling valve service 41
5.4 Probe calibration 43
5.5 Voltage changeover 45
5.6 Sensor probe service 48
5.7 Pressure switch service 50
5.8 Instrument service 51
5.9 Celsius temperature display 53
5.10 Electronic instrument repair policy 54
And procedure
TEMPTEK, INC. Page: 4

525 East Stop 18 Road Greenwood, Indiana 46142
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www.Temptek.com
6.0 COMPONENTS55
6.1 Mechanical system 56
6.2 Electrical system 58
7.0 RELATED DRAWINGS 61

7.1 Physical 62
7.2 Electrical 63
7.3 Circuit schematic 64
7.4 Regulator/bypass installation 65
7.5 Dual zone dolly 66
7.6 Stacking rack 67
8.0 APPENDIX 69
8.1 Specifications 70
8.2 Model # and suffix coding 71
8.3 Interpretation of process pressure gauges 72
8.4 Mold purge operation 73
8.5 Closed Circuit Operation 74
8.6 AS5 pump parts list - 1/2 HP to 1 HP 75
8.7 AS5 pump parts list - 1 1/2 HP to 3 HP 76
8.8 Parts list - LS instrument 77

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QUICK START-UP GUIDE

INSTALLED TO CORRECT ELECTRICAL SUPPLY BE CERTAIN UNIT IS INSTALLED
NO ...
ELECTRICAL SUPPLY? LISTED ON DATA TAG TO PROPER ELECTRICAL SUPPLY
YES
UNIT INSTALLED TO 'TO PROCESS' TO 'WATER IN' ON 'FROM PROCESS' TO 'WATER OUT'
NO ...
PROCESS CORRECTLY? PROCESS MANIFOLD ON PROCESS MANIFOLD
YES
WATER SUPPLY OPEN AND WATER SUPPLY PRESSURE MUST BE

NO
PRESSURE ADEQUATE? OVER 15 PSI FOR UNIT TO START
YES
DRAIN LINE CORRECTLY CONNECT DRAIN LINE TO PROPER

NO
INSTALLED? RETURN SYSTEM
YES
ENGAGE POWER SUPPLY... CHECK DISCONNECT FUSE OR

NO
'POWER' LIGHT ON? TRANSFORMER FUSE
YES
TURN UNIT 'ON' AND

SELECT SETPOINT

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QUICK TROUBLESHOOTING GUIDE

UNIT WILL NOT START
MAIN POWER SUPPLY REPLACE TRANSFORMER

"POWER" LIGHT ON? YES YES
"ON"? FUSE
NO
NO
WATER SUPPLY YES
PRESSURE SWITCH OPEN
ENGAGE POWER
PRESSURE LOW? SUPPLY UNIT WITH 15 PSI
NO
MOTOR OVERLOAD RESET OVERLOADS

YES
RELAY OPEN? ADJUST PROCESS FLOW
NO
HIGH TEMP LIMIT TEMPERATURE OVER 256

YES
SWITCH OPEN? ALLOW UNIT TO COOL
NO
INSTRUMENT DEFECTIVE
REPLACE
UNIT STOPS
MAIN POWER SUPPLY REPLACE TRANSFORMER

"POWER" LIGHT ON? YES YES
"ON"? FUSE
NO
NO
WATER SUPPLY YES
PRESSURE SWITCH OPEN
ENGAGE POWER
PRESSURE LOW? SUPPLY UNIT WITH 20 PSI
NO
MOTOR OVERLOAD RESET OVERLOADS

YES
RELAY OPEN? ADJUST PROCESS FLOW
NO
HIGH TEMP LIMIT TEMPERATURE OVER 256

YES
SWITCH OPEN? ALLOW UNIT TO COOL
NO
REPLACE
UNIT OVERHEATS
INADEQUATE WATER YES

WATER SUPPLY PRESSURE MUST BE
SUPPLY PRESSRE? SUFFICIENT FOR OPERATING TEMPERATURE
NO
AVT COOLING VALVE CHECK VALVE WIRE CLEAN/REPLACE REPLACE MOTOR/GEARBOX

YES OR OR
DEFECTIVE? HARNESS BALL VALVE ASSEMBLY ASSEMBLY
NO
DRAIN LINE OPEN23 CLOSED REDUCE HIGH DRAIN

YES OR
OBSTRUCTED? DRAIN LINE VALVE LINE PRESSURE
NO
LOW PROCESS CHECK FOR A CLOSED KINKED HOSE OR BLOCKED WATER CHANNEL
YES OR OR
FLOW RATE? PROCESS VALVE EXCESSIVE PIPE FITTINGS IN TOOLING OR MOLD
NO
CONTROL PROBE CHECK FOR WATER IN REPLACE PROBE

YES OR
DEFECTIVE? PROBE CONNECTION
NO
REPLACE
UNIT UNDERHEATS
PROCESS WATER CHECK FOR A DEFECTIVE LEAKING WATER PRESSURE

YES OR
LEAKAGE? AVT COOLING VALVE RELIEF VALVE
NO
HEATER ELEMENT REPLACE HEATER

YES
DEFECTIVE?
NO
HEAT LOSS? CHECK FOR EXCESSIVE DETERMINE IF UNIT

YES OR
UNIT RADIATION CAPACITY TOO LOW
NO
CONTROL PROBE CHECK FOR WATER IN REPLACE PROBE

YES OR
DEFECTIVE? PROBE CONNECTION
NO
REPLACE

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THIS PAGE INTENTIONALLY BLANK
Page: 8
1.0 GENERAL
1.1 SAFETY
1.2 EFFICIENCY
1.3 TYPICAL LABEL PLACEMENT
1.4 COMPONENT PLACEMENT

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1.1 SAFETY
A. It is important to become thoroughly familiar with this manual and

the operating characteristics of the equipment.
B. Several important references are made to safety considerations in

this manual. It is the owners responsibility to assure proper
operator training, installation, operation, and maintenance of the
water temperature controller with instrument.
1.2 EFFICIENCY
A. Long term efficiency of operation is largely determined by proper

maintenance of the mechanical parts of the unit and water quality.
We recommend filtering where required to prevent solids from
plugging critical parts such as pumps, heaters and seals. The
services of a competent water treatment specialist must be obtained
and his recommendations followed. Temptek accepts no
responsibility for inefficient operation, damage caused by foreign
materials, or failure to use adequate water treatment.
1.3 TYPICAL LABEL PLACEMENT
Warning Label
Summarizes the safety precautions
when unit is in use.
Process Connection Label

Details process connections hook-up.
Unit Data Tag

Details unit Serial Number, voltage and
other important unit information.

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1.4 COMPONENT PLACEMENT
A. The temperature controller is designed to circulate temperature

stabilized water through the process system to result in process
temperature control.
B. Please note that the ability of the equipment to achieve this

objective is significantly affected by the method of installation.
C. If the operator has any questions, contact the Sales or Service

Department at 317-887-0729.
Pressure Gauges
Heater
Instrument
Cooling Valve
Temperature Sensor
Heating Cylinder
Electrical Panel
(Inside stainless steel cabinet.)
Cooling Cylinder
Pump
Pump Motor
Thermoformed
Cover Panel
Vented Stainless
Steel Cabinet
Caster

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Manual & Quick

Start Guide
Electrical Panel
Lift-Off Cover
Panel

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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

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2.1 GENERAL
A. All process piping materials such as hose, rigid piping, valves or

filters, used in process water piping circuitry must be rated for
350F minimum temperature and 200 PSI minimum pressure.
B. Be certain all process piping materials have the equivalent or larger

diameter of the particular process connection.
To process connection:
Connect to water in on process manifold
Drain connection:
Connect to one of the following:
(Depending on water supply source)
plants open drain
tower water system return
chilled water system return
From process connection:

Connect to water out on process manifold
Water supply connection:

Connect to one of the following:
plants city water source
well water source
tower water supply
chilled water supply
2.2 TO AND FROM PROCESS CONNECTIONS
A. Connect the units To Process port to the Water In port on the

process manifold.
B. Connect the units From Process port to the Water Out port on the
process manifold.
C. Please note: Process water 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.
D. Valves and filters may be installed in the process water piping

circuitry to facilitate service and maintenance, provided that such
devices maintain the full inside diameter of the process connection.
If installed, all such devices must be open and clean during unit
operation.

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2.3 WATER SUPPLY CONNECTION
A. Connect the units Water Supply port to the plants city water, well
water, tower water or chilled water supply.
B. Water supply pressure requirements vary with operating

temperatures. Figure 2.2A shows the required operating water
supply pressures for various operating process temperatures. The
required water supply pressure retains process water in a liquid
state at temperatures over 180F. Failure to maintain the required
water supply pressure will cause premature failure of and increase
maintenance in susceptible areas such as the shaft seal and heater.
OPERATING TEMPERATURE
180F 190F 200F 210F 220F 230F 240F 250F
20 PSI 25 PSI 30 PSI 35 PSI 40 PSI 45 PSI 50 PSI 55 PSI
WATER SUPPLY PRESSURE
Figure 2.2A
C. The factory recommended

minimum operating water supply
pressure requirement is identified
on the units data tag (figure 2.2B).
D. Static water supply pressure can be

determined at the units location by
reading the units 0-160 PSI
pressure gauges when the units
pump motor is OFF.
Typical Data Plate Figure 2.2B
E. If water supply pressure as read on
the units pressure gauges exceeds
75 PSI, a pressure reducing
valve must be installed in the water
supply line (refer to section 7.4 of
this manual for installation
information). The factory
recommended regulated pressure
out is 55 PSI (figure 2.2C).
2.4 DRAIN CONNECTION:

Typical pressure reducing valve Figure 2.2C
A. Connect the units DRAIN port to installation (shown on S-925).
one of the following, determined by
the water supply source:
1. Open 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.

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B. The factory recommends a minimum of 10 psi pressure differential

between the water supply and drain line for proper cooling.
C. For most applications, the drain line

should not be valved. However, for
installations with a pressurized
drain system, it may be necessary
to install a valve in the drain line. In
such cases, the installed valve
must be fully opened after
installation and the valve handle
removed to prevent operating the
unit with a closed drain valve. The
valve handle can be reattached to Typical drain valve installation Figure 2.3A
the valve body when it is necessary (Shown on S-925)
to close the valve (figure 2.3A).
D. 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. NEMA 1 MODELS
1. Electrical power supply requirements for Nema 1 units are

identified on the equipment data tag. Verify that available
voltage supply is the same as the units voltage
requirements.
WARNING: DO NOT CONNECT THE UNIT TO A

VOLTAGE SUPPLY SOURCE NOT EQUAL TO THE
UNITS VOLTAGE REQUIREMENTS AS SPECIFIED ON
THE UNITS DATA PLATE.
Use of incorrect voltage will void the units warranty and

cause a significant hazard that may result in serious
personal injury and/or unit damage.
2. For units with 10 and 16 KW heaters, a four conductor

cable, 10 foot in length, has been provided for connection to
an operator supplied fused disconnect.
3. For units with 24 and 34 KW heaters, the operator 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 units power supply requirements
and local electrical codes.

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B. NEMA 12 MODELS
1. Nema 12 units are designated by the letter J in the model

number suffix. These units are constructed with a dust tight
electrical enclosure and branch circuit fusing. Electrical
power supply requirements are identified on the equipment
data tag. Verify that available voltage supply is the same as
the units voltage requirements.
WARNING: DO NOT CONNECT THE UNIT TO A

VOLTAGE SUPPLY SOURCE NOT EQUAL TO THE
UNITS VOLTAGE REQUIREMENTS AS SPECIFIED ON
THE UNITS DATA PLATE.
Use of incorrect voltage will void the units warranty and

cause a significant hazard that may result in damage to the
unit or serious personal injury.
2. Appropriate conduit and fittings should be selected which

will maintain the integrity of the cabinet.
3. Supply a power conductor sized according to the units

power supply requirements. Connect the power conductor
to the units power supply entry terminal block.
C. CONTROL CIRCUIT WIRING
1. The units 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 (figure 2.5C).
D. GENERAL
1. Make certain all ground Control circuit transformer fuse Figure 2.5C
connections to the unit are

properly affixed. 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 units power
supply requirements.
3. Make certain all electrical connections are tightly affixed.

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.

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Power Entry Terminal Strip Transformer Heater

Fuse Blocks Contactor
Covered Control Transformer Pump Motor

Low Water Controller
Pressure Switch

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3.0 OPERATIONS
3.1 GENERAL
3.2 MACHINE START UP/OPERATIONS PROCEDURE
3.3 INSTRUMENT OPERATION
3.4 SHUT DOWN/DISCONNECT PROCEDURE

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3.1 GENERAL
A. Failure to follow the factory required operation procedures may

adversely affect the units 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 fill,
electric motor phasing (pump rotation) and process flow
adjustments.
3.3 instrument Operation - follow this segment to start up and

operate the instrument. This section includes information on
automatic and manual venting, 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/OPERATIONS PROCEDURE
A. SYSTEM FILL
1. Engage the water supply source by opening the water

supply valve (customer installed) at the units location. If a
valve is not installed, engage the water supply source at the
plants water supply central control point.
2. Once the water supply source is open, the unit will fill
automatically. Allow a few moments for the unit to
completely fill. The operator can determine the unit is
properly filled when the To Process pressure gauge and the
From Process pressure gauge stabilize at equal or closely
similar pressure.
3. The operator must check for any water leakage in the units
mechanical system, the process, and throughout the plants
water supply system. If a water leak is observed, the
operator must disengage the water supply system, relieve
all pressure, and repair the leak. The operator must verify
the leak is repaired by refilling the system as outlined in this
procedure.

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4. During system fill, air is trapped at various places in the

water system. Air is purged automatically via the AVTTM
valve during initial pump start-up (outlined below). All air
must be purged before the unit is engaged for process
temperature control.
Entrained air in the system will adversely affect the units

ability to control process temperature. The operator can
determine all entrained air is purged when no pressure
spikes are evident via the units pressure gauges.
5. Adequate water fill and

pressure must be supplied
to the unit for efficient and
safe operation. To ensure
sufficient water fill, an
electrical panel mounted
pressure switch (figure
3.2A) is supplied with the
unit. A capillary line feeds
the pressure switch. If the
water supply pressure is Panel mounted pressure switch Figure 3.2A
not adequate the unit can
not be operated. This prevents operation with inadequate
water fill and pressure. If the unit is operated without
adequate water fill and pressure, the unit may be
susceptible to overheating and could result in unit damage
and/or serious injury to operating personnel.
B. ELECTRIC MOTOR PHASING (PUMP ROTATION)
1. The operator must determine the electric motor is phased

correctly. This is done by visually inspecting the rotation of
the motor shaft as outlined below. Incorrect phasing of the
unit results in poor operation and eventual damage.
a. Supply electrical power to the unit by engaging the

units disconnect switch. Once the correct voltage is
supplied to the unit, the Power light on the display
will illuminate.
b. Remove the thermoformed cover panel and open

the hinged electrical cabinet panel cover. Note that
the electrical power is engaged at this point and
caution must be observed while the electrical
supply is engaged and the cabinet panel is
open.
c. Locate the electric motor (figure 3.2B) and identify

the motor shaft inside the electric motor housing.
The motor shaft can be seen through the vent slots
in the motor housing or by removing the shaft
cover.

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d. Toggle the On / Off

switch. This will
cycle the motor
on and then off.
e. Observe the motor

shaft as it slows to
a stop to identify
the rotation.
Correct rotation is
clockwise, when Remove shaft cover to view Figure 3.2B
the motor shaft
viewed from the
rear of the motor. Incorrect rotation is counter-
clockwise when viewed from the rear of the motor.
If the shaft does not rotate when the unit is started,
the operator must identify the cause as outlined in
this manuals troubleshooting and repair section.
f. If the unit is phased correctly, continue with the start

up procedure at step C. If the unit is phased
incorrect, continue with step 2.
2. To correct unit phase:
a. Disengage the electrical power supply to the unit at

the units disconnect switch. Follow proper lockout
procedures before proceeding.
b. Once the electrical power supply is disengaged,

reverse any two power leads of the power cord at
the fused disconnect terminals.
c. Note: The operator

must reverse the
power leads at the
disconnect only and
not at the power
entry terminals on
the units electrical
panel (figure 3.2C).
The units internal
electrical system
wiring is phased DO NOT reverse power leads Figure 3.2C
at the units power entry
correctly at the
factory and must not be altered in the field.
3. To visually verify pump rotation, start the unit and observe

the pressure gauges. The To Process pressure will indicate
35-50 PSI more than the From Process pressure. In this
state, the pump rotation is correct (clockwise). If this is not
evident the unit is not correctly phased and should be
corrected as outlined in step 2.

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C. PROCESS FLOW ADJUSTMENTS
1. The operator must determine and set proper water flow rate
for the most efficient and trouble free operation.
a. Water flow rate through the process is determined

by the pressure losses in the process loop.
Generally, higher flow rates result in turbulent flow
achieving maximum temperature control and lower
maintenance.
b. If the flow rate exceeds the motor HP capacity, the

electric motor will draw excessive amps. This is a
result of the process loops ability to flow water at a
greater rate than can be provided by the pump.
This will eventually result in tripping the thermal
motor overload relay (overload relays open) and the
unit will shut down and illuminate the Safety and
Alarm lights on the display.
2. If an excessive flow situation

is encountered and the
motor overload circuit has
tripped, the operator must
manually reset the overload
relay before operations can
continue. This is done by
opening the electrical panel
cover, identifying the reset
lever on the overload relay
(figure 3.2D), and pushing Pump Motor Controller Figure 3.2D
the reset lever in until the

overloads are reset (evidenced by a clicking sound as the
overloads reset).
3. If a motor overload situation persists, the operator must

adjust the flow rate to match the system pressure loss
(reduce flow rate) to prevent continual tripping of the
overload relay. This procedure is outlined here:
a. Open electrical cabinet panel door. The panel cover

is hinged and held open by a support cable. Note
that the electrical power is engaged at this point
and caution must be observed while the cabinet
panel is open.
b. Identify the motor starter block. This block consists

of the motor starter contactor and the overload
relay.
c. Place an amp meter on a single power lead coming

from the overload relay.

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d. Locate the motor

name plate on the
pump motor housing
(figure 3.2D). The full
load amp rating for
the motor is listed on
the name plate.
e. Engage the electrical

power supply and
start the unit. Motor name plate Figure 3.2D
f. The amp meter will display the motor amps.

Compare the actual motor amps as displayed on
the amp meter to the full load amp rating as listed
on the motor name plate.
g. If the amp draw is excessive (higher than the listed

name plate amp rating), a throttling valve must be
installed in the from process water line. The
throttling valve can be a gate valve or a ball valve.
h. With the throttling valve installed, fully close the

valve and then engage the pump motor. Slowly
open the throttling valve and monitor the motor
amps as displayed on the amp meter until the
actual motor amps equal the listed full load amp
rating of the motor. The process flow is now
correctly adjusted. The valve should remain in this
position during operation.
6. LOW PROCESS FLOW: The minimum recommended

process flow rate is 10 GPM. Process restrictions may limit
the flow to less than 10 GPM. We recommend the addition
of bypass lines to raise the flow rate to 10 GPM. The best
place to add bypass lines are on the extra ports on the
molding machine manifold. If extra ports are not available,
add a tee in the To Process and From Process lines, install
a bypass line between the two tees with a throttling valve.
Adjust the valve for a minimum of 10 GPM.

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Setpoint
Adjustment Machine
Buttons Status Lights
Temperature
Display
Figure 3.3A
Unit On/Off
Switch
3.3 INSTRUMENT OPERATION
Note: Standard temperature range for VE Series mold

temperature control units is approximately 30F above the
cooling water supply temperature to 250F.
A. INSTRUMENT START-UP
1. When the correct electrical power and adequate water

supply pressure are supplied to the unit, it is possible to
start the unit for temperature control duty.
2. When the power is engaged to the unit, the instrument

(figure 3.3A) will momentarily illuminate all indicating lights
and digits on the display. After a short delay, the controller
software version number is displayed. At this time, the
operator can verify that all lights and digits are functioning
properly. If the operator determines an indicating light or
digit does not illuminate, the controller must be removed
and sent to the factory for repair.
3. Also, the instrument will immediately check the status of the

sensor probe, the high temperature safety switch, and the
water supply pressure switch for acceptable operating
conditions. If all systems are found to be ok, the unit will
begin operations. If a system is not found to be ok, the
instrument will not start and will illuminate no FLO in the
temperature display window.

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4. Conditions that will prevent the unit from starting process

temperature control operations are:
a. Water supply pressure inadequate (pressure

switch is open). The unit is prevented from
operating without adequate water supply pressure
by an electrical panel mounted pressure switch.
Sufficient water supply pressure must be present to
close the switch and consent the safety circuit.
b. Motor overload switch opened. The electric motor

is protected from excessive flow by a set of thermal
overload relays. These relays will open (trip) and
prevent operation. If open, the overload relay must
be reset before operations can continue. An
excessive flow condition must be corrected
immediately.
c. High temperature limit switch open. The unit is

prevented from operations with temperatures
exceeding 256F by a high temperature limit
switch. This switch is installed in the To Process
temperature sensor. If this switch is open (due to a
high temperature condition), the control circuit is not
consented and the unit cannot be started. If a high
temperature condition exists, the unit must first
cool down (reduce water temperature) before the
high temperature limit switch will automatically
reset to allow operation.
d. Temperature sensor. Failure of the To Process

temperature sensor will be indicated in the
Temperature window by a --- ---. Check the sensor
cable and connector for loose wires or moisture. If
no problems are found, replace the sensor.
B. INSTRUMENT OPERATION
1. Process temperature control operation is started by toggling

the units On / Off rocker switch to the on position.
2. When the On / Off rocker switch is toggled on, the

instrument will immediately display the process temperature
as indicated by the temperature sensor.
3. If the indicated temperature is less than 100F, the

instrument will automatically open the PVTTM cooling valve
for 45 seconds. This automatic system vent cycle will
purge entrained air from the process system (unit,
hoses/piping circuitry and tooling) to the drain. Automatic
venting is indicated by a Air Prg display in the Temperature
window. If the automatic vent cycle does not result in the

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venting of all entrained air to the drain (evidenced by a

rattling sound in the unit and fluctuating pressure gauges),
the operator must manually vent the system by depressing
and holding the Up Arrow and Down Arrow push buttons.
Release the buttons to conclude the manual vent sequence.
If the To Process temperature exceeds 100F, the
instrument will bypass the automatic system vent cycle and
step immediately to process temperature control operation.
4. To display the setpoint temperature, briefly touch the Up

Arrow or Down Arrow push buttons. To change the setpoint,
hold the Up Arrow or Down Arrow push buttons until the
preferred setpoint temperature is indicated in the
Temperature window. Setpoint temperatures can be
adjusted anytime during the process temperature control
cycle.
C. INSTRUMENT CONTROLS
1. UNIT ON/OFF SWITCH: This rocker switch

engages/disengages electrical supply to the pump, heater
and PVTTM cooling valve (figure 3.3A).
2. UP ARROW: Depress briefly to display the setpoint

temperature. Depress and hold to increase the setpoint
temperature. If pressed momentarily the setpoint value is
incremented by one degree. If held down for more than one
second, the setpoint will increase slowly at first and then
faster after about two seconds. The setpoint control range is
32 to 250F (0 - 121C).
3. DOWN ARROW: Depress briefly to display the setpoint

temperature. Depress and hold to decrease the setpoint
temperature. If pressed momentarily the setpoint value is
incremented by one degree. If held down for more than one
second, the setpoint will increase slowly at first and then
faster after about two seconds. The setpoint control range is
32 to 250F (0 - 121C).
D. STATUS INDICATING LIGHTS
1. POWER ON: Illuminates when power is applied to the unit.
2. PUMP: Illuminates when the units On / Off rocker switch is

turned on and the motor pump is operating. Even with the
On / Off rocker switch on, the Pump light will not illuminate
if a safety fault condition exists.
3. HEAT: Illuminates when the heater is on to increase

process water temperature.
4. COOL: Illuminates when the PVTTM valve is open. Opening

the valve will discharge process water to the drain. Opening

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the valve also allows cooling water flow from the water
supply source to enter the circulating system and mix with
the heated process water to reduce process temperature.
3.4 SHUT DOWN/DISCONNECT SEQUENCE
A. PRECAUTIONS/WARNINGS
1. The operator must precisely follow all shut down

procedures outlined in this manual. If the operator fails to
do so, an unsafe condition can develop resulting in damage
to the unit or injury and/or death to operating personnel.
2. When disconnecting the unit from the process system, the

operator must determine the units process temperature is
at ambient or below 85F and all system pressure is
relieved and the units pressure gauges read 0. Injury or
death to operating personnel and damage to the unit could
result if a hot and pressurized unit is disconnected from the
system.
B. UNIT SHUT DOWN (without system disconnect)
1. Adjust the setpoint temperature to 32F. The instrument will

disengage the heater contactor (if engaged) and open the
PVTTM valve. Operate the unit until process temperature as
indicated on the Temperature display is at the ambient
water supply temperature or below 85F.
2. Stop operations by switching off the On / Off rocker switch.
3. Disengage the water supply to the unit by closing the water

supply valve (if installed) or by turning off the water supply
source at the central control point. If any residual pressure
is evident open the pressure relief valve to dissipate.
4. Disengage the power at the fused disconnect. Determine

the Power light on the display is OFF.
5. Before disconnecting and removing the process circuitry, be

certain all system pressure is vented and the pressure
gauges read 0. When the process circuitry is disconnected
and removed from the unit, a small amount of water will be
discharged from the unit. Please note that this water should
not be warm or pressurized if all shut down and
disconnecting procedures were followed. Remaining
process water can be discharged by removing the pump
casing drain plug.

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4.0 TROUBLESHOOTING
4.1 UNIT WILL NOT START (POWER LIGHT IS NOT ILLUMINATED)
4.2 UNIT WILL NOT START (POWER LIGHT IS ILLUMINATED)
4.3 UNIT STOPS
4.4 UNIT OVERHEATS
4.5 UNIT UNDERHEATS
4.6 PRESSURE RELIEF VALVE LEAKS
4.7 COOLING VALVE FAULT ULU

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4.1 UNIT WILL NOT START (POWER LIGHT IS NOT ILLUMINATED)
A. One or more fuses at the main disconnect device are open (blown).
Determine continuity at each fuse. If continuity is not determined,
replace the fuse. Then determine cause of blown fuse.
B. Control circuit transformer fuse is open (blown). Determine

continuity at the control circuit transformer fuse. If continuity is not
determined, replace the fuse.
4.2 UNIT WILL NOT START (POWER LIGHT IS ILLUMINATED)
A. Power supply is ON. The operator can determine that electrical

power supply to the unit is on by an illuminated Power light on the
display. Even with the main power supply on, the unit is prevented
from operating by one of the following conditions:
1. Water supply pressure inadequate. (pressure switch is

open). The unit is prevented from operation without
adequate water supply pressure by the electrical panel
mounted pressure switch. Sufficient water supply pressure
must be present to close the switch.
2. Motor overload switch opened. The electric motor is

protected from overload conditions by a set of thermal
overload relays. These relays will open (trip). If the overload
relay is open, it must be reset before operation can
continue. An excessive flow condition must be isolated and
corrected immediately.
3. High temperature limit switch open. The unit is prevented

from operations at temperatures exceeding 256F by a
high temperature limit switch. This switch is installed in the
To Process temperature sensor. If this switch is open (due
to a high temperature condition), the unit cannot be started
and must cool down before the high temperature limit
switch will automatically reset.
4.3 UNIT STOPS
A. The operator should determine the main power supply to the unit is
ON by an illuminated Power light on the display. With the main
power supply on, the unit will be prevented from starting by the
following conditions:
1. Water supply pressure inadequate. (pressure switch is

open). The unit is prevented from operation without
adequate water supply pressure by the electrical panel
mounted pressure switch. Sufficient water supply pressure
must be present to close the switch.
2. Motor overload switch opened. The electric motor is

protected from overload conditions by a set of thermal

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overload relays. These relays will open (trip). If the overload

relay is open, it must be reset before operation can
continue. An excessive flow condition must be isolated and
corrected immediately.
3. High temperature limit switch open. The unit is prevented

from operations at temperatures exceeding 256F by a
high temperature limit switch. This switch is installed in the
To Process temperature sensor. If this switch is open (due
to a high temperature condition), the unit cannot be started
and must cool down before the high temperature limit
switch will automatically reset.
B. The operator should check the Power light on the display. The
operator should check the following conditions:
1. One or more fuses at the main disconnect device are open

(blown). Determine continuity at each fuse. If continuity is
not determined, replace the fuse. Then determine cause of
blown fuse.
2. Control circuit transformer fuse is open (blown). Determine

continuity at the control circuit transformer fuse. If continuity
is not determined, replace the fuse.
4.4 UNIT OVERHEATS
A. This is evidenced by To Process temperatures consistently above

the selected setpoint temperature. Overheating is also evidenced by
a To Process temperature that continues to escalate above the
setpoint temperature with no apparent cooling action, even though
the Cool light is on. Extreme overheating is evidenced by To
Process temperatures over 256F. The operator should check for
the following conditions:
1. Inadequate water supply pressure. The unit must be

supplied with adequate water flow to provide cooling when
required. The minimum pressure differential between the
water supply and drain to achieve full cooling capacity is 10
PSI. The minimum water supply pressure is 20 PSI. A drop
in water supply pressure operation will cause the pump to
stop and a safety fault to be displayed.
2. PVTTM valve defective. The instrument opens and closes

the PVTTM cooling valve as prescribed by the current
process load. If the valve becomes clogged with process
water debris or scaled with mineral deposits, its operation is
hindered or fully prevented and adequate process water
discharge to drain is prevented. The operator must service
the PVTTM valve and remove any loose debris. Massive
debris or scale deposits may necessitate replacement of the

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internal PVTTM valve components. The procedure for

servicing the valve is outlined in Section 5.3 of this manual.
3. Drain line obstruction. The operator must determine if the

drain line is obstructed by the following conditions. Section
2.4 outlines the parameters of correct drain line installation.
a. Closed drain line valve. An installed but partially

or fully closed valve in the drain line prevents full
discharge to drain and contributes to an
overheating condition. The operator should
determine the drain line is open.
b. High drain back pressure. Pressurized plant drain

lines will prevent flow to drain if the differential
between the water supply pressure and the drain
line pressure is inadequate. The factory
recommended minimum differential is 20 psi. If the
differential is less than the factory recommendation,
plant service personnel should take measures to
reduce drain line pressure.
4. Instrument defective. The instrument is designed and

manufactured exclusively by Temptek. The instrument is
life-tested and found to be field reliable. However, in the
case where the instrument is determined to be defective,
the operator must remove the assembly according to
instructions outlined in this manual and return the assembly
to the factory. The instrument is not a field serviceable
component.
4.5 UNIT UNDERHEATS
A. This is evidence by operations with To Process temperatures

consistently below the selected setpoint temperature.
1. Process water leakage. When the instrument engages the

heater to elevate process temperature, the input of heat into
the process can be offset by a defective PVTTM valve. If the
PVTTM valve is defective, it may pass a larger than required
stream to drain, thus providing unwanted cooling. A
defective PVTTM valve should be repaired immediately.
2. Heater element failure. A failed heater element will not

input adequate heat into the process to elevate the process
water temperature. The operator must check the amps at
the heater contactor with the contactor energized. Zero
amps at the contactor indicate a failed heater or burnt wire
connections. The operator should remove the failed heater
and replace with a new heater according to the procedure
outlined in section 5.2.

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3. Unit capacity too low. This occurs when the process

requires more heat than the unit is capable of producing.
The only option in such cases is to install a unit with an
adequate heater KW rating for the load.
4. Instrument defective. The instrument is designed and

manufactured exclusively by Temptek. The instrument is
life-tested and found to be field reliable. However, in the
case where the instrument is determined to be defective,
the operator must remove the assembly according to
instructions outlined in this manual and return the assembly
to the factory. The instrument is not a field serviceable
component.
4.6 PRESSURE RELIEF VALVE LEAKS
A. The unit has a 150 psi pressure relief valve mounted in the cooling
cylinder. If the valve is found to be leaking, the operator should
check the following:
1. Water supply pressure exceeds 75 psi. The unit is

designed to operate with water supply NOT exceeding 75
psi. See section 2.3 paragraph B for specific water supply
pressure requirements at corresponding setpoint
temperatures. If the plant water supply pressure exceeds 75
psi, the pressure relief valve may leak. Static water supply
pressure can be determined at the units location by reading
the units 0-160 PSI pressure gauges when the units motor
pump is off. If the water supply pressure at the units
location exceeds 75 PSI, a pressure reducing valve must
be installed in the water supply line. The factory
recommended regulated pressure out is 55 PSI. Refer to
section 7.4 for regulator installation drawing.
2. Back flow prevention device in water supply line. If a back flow

prevention device (check valve, pressure regulator, closed valve) is
installed in the water supply line, increased pressures from thermal
expansion are unable to move into the water supply line. This will
increase the units internal pressure causing the pressure relief
valve to leak. Refer to section 7.4 for regulator installation drawing.
3. Valve contamination. The pressure relief valve may become

contaminated with water debris causing the valve not to close
properly. If this is the case, flushing the valve for a moment will
cleanse the seat and allow it to work properly. If flushing the valve
does not remedy the leaking, the valve must be replaced.
4. Extreme internal system pressure. If the internal pressure in the

Sentra unit is elevated, the pressure relief valve will leak as a
safety measure to dissipate excessive pressure. If this is the case,
the operator must determine why the system internal pressure is
excessive and correct the condition.

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5.0 SERVICE/MAINTENANCE
5.1 PUMP SEAL REPLACEMENT
5.2 HEATER REPLACEMENT
5.3 PVTTM COOLING VALVE SERVICE
5.4 PROBE CALIBRATION
5.5 VOLTAGE CHANGEOVER
5.6 SENSOR PROBE SERVICE
5.7 PRESSURE SWITCH SERVICE
5.8 INSTRUMENT SERVICE
5.9 CELSIUS TEMPERATURE DISPLAY
5.10 ELECTRONIC INSTRUMENT REPAIR POLICY & PROCEDURE

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5.1 PUMP SEAL REPLACEMENT
A. The pump seal is a Rotating Member Tension Spring
carbon/ceramic shaft
seal assembly including
a stationary member,
rotating member and
tension spring (figure
5.1A).
B. The life cycle of the

pump seal is
Figure 5.1A
determined by hours of Stationary member
use, operating
temperature and water
quality. Poor water quality is the
primary reason for premature pump
seal failure.
D. The operator should follow this

procedure to replace the pump
seal:
1. Disengage process
operations and relieve all
system pressure.
Remove lift-off access panel Figure 5.1B
2. Disengage main power
supply. Verify the Power
light on the display is off.
3. Remove the lift-off access

panel and set aside (Figure
5.1B).
4. Remove the thermoformed

panel. It is attached to the
stainless steel cabinet by 4
small screws (figure 5.1C).
Thermoformed panel Figure 5.1C
removed and electrical
5. Drain machine by removing cabinet open.
the pump casing drain plug.
6. Remove the three motor

wire leads from the motor
wiring terminals. The
operator should map the
wire terminal locations to
ensure correct rewiring.
The power cord should be
removed from the motor
housing (figure 5.1D).
Motor leads Figure 5.1D

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7. Locate and remove the 4

pump casing bolts. These
bolts secure the motor and
motor adapter to the pump
casing (figure 5.1E).
8. Separate the motor and

adapter from the pump
casing to expose the pump
impeller (figure 5.1F).
Remove the motor and Pump casing bolts Figure 5.1E
adapter from the unit and
place on a workbench to
continue the procedure.
9. Locate and remove the

dust cap from the motor to
expose slotted motor shaft.
The motor shaft is free to
rotate, but must be secured
to remove the impeller. To
secure the motor shaft,
insert a flat bladed screw
Impeller Figure 5.1F
driver in slot to hold the
shaft stationary (figure
5.1G).
10. Locate and remove

impeller locking screw
(figure 5.1H). Using a
socket and ratchet, the
impeller retaining screw
can be removed. Once
removed, the impeller can
be unthreaded from the
motor shaft to expose the
Motor shaft Figure 5.1G
pump seal assembly.
11. Remove all seal parts

(figure 5.1I). Note seal
component arrangement to
facilitate reassembly.
12. Clean the motor shaft and

lubricate with a mild soap
solution. Note: Oil must
never be used as a
lubricant as it will
damage the rubber parts
of the seal assembly. Removing impeller locking Figure 5.1H
screw with ratchet

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13. Install new stationary seal

member in pump casing
cavity (figure 5.1J). Be
certain the stationary seal
member is fully squared
and seated in cavity.
14. Slide the rotating member

onto the lubricated pump
shaft (figure 5.1K). Be
certain not to damage or Seal components Figure 5.1I
tear the rubber bellows
assembly.
15. Place the spring onto the

rotating member.
16. Align the tension spring

and rotating member
before reinstalling the
impeller (figure 5.1L). Be
certain the spring and
rotating member are
Stationary member Figure 5.1J
aligned before the impeller
is fully tightened and the
impeller retaining screw is
reinstalled.
17. Clean the pump casing,

cavities, impeller and O-
ring before reassembly.
18. Mate the motor and

adapter to the pump
casing. Reinstall the 4
pump casing bolts. Rotating member Figure 5.1K
19. Reconnect the motor power

cord and leads.
20. Replace the thermoformed

front panel and the lift-off
cover.
E. When this procedure is complete,

the operator may restart the unit. In
many cases, a new pump seal will
experience a small amount of
leakage for a short time. This is
Aligning impeller and spring Figure 5.1L
normal. After a few moments, the
new seal will take seat and the leak
will stop.

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5.2 HEATER REPLACEMENT
A. The heater is a flange mounted

assembly and inserted into the cast
cylinder tank and secured by 4
bolts (figure 5.2A).
B. The operator can determine if the

heater requires replacement when
the heater draws 0 amps or when
a continuity check of each heater
element is negative.
Heater Figure 5.2A
C. Generally, heaters fail due to low
water flow, low water pressure, air
in the system, or defective heating elements.
D. The operator should follow this procedure to replace the heater:
1. Disengage operations and be certain all system pressure is

relieved and the units pressure gauges read 0.
2. Disengage main power supply. Verify the Power light on the

display is off.
3. Remove the lift-off access panel and set aside
4. Drain machine. The

machine can be drained by
removing the pump casing
drain plug.
5. Remove heaters junction

box cover to located wiring
connections. The operator
should map the wiring
connections to ensure
correct reinstallation (figure
Heater junction wires Figure 5.2B
5.2B).
6. Disconnect the three power

leads from the heater
terminals. Remove the
power cord from the
junction box.
7. Remove the 4 heater

mounting bolts (figure
5.2C).
8. Remove heater (figure

5.2D). Heater mounting bolt Figure 5.2C

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9. Before the new heater is

installed, the mating
surface of the cast tank
should be cleaned. Once
cleaned, place the new
heater gasket onto the tank
mating surface. Coat the
mating surface with a high
temperature gasket
sealant.
Remove heater Figure 5.2D
10. Set new heater into tank.
Aligning the bolt pattern of
the heater and tank flanges.
11. Replace the 4 heater mounting bolts. Alternate to the

opposite bolt while tightening.
12. Reconnect the power cable to the heater terminals. Be

certain to tighten the power cord junction box connector.
Replace the junction box cover and the lift-off cover panel.
D. When complete, restart the unit.

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5.3 PVTTM VALVE SERVICE
A. The unit uses the PVTTM; (Pulsed

Valved Technology) solenoid
valve (figure 5.3A) as the cooling
valve. The solenoid valve is
controlled by the instrument.
B. Generally, the PVTTM valve may

fail due to poor water quality, low
water flow, or defective valve
components.
Typical PVTTM valve Figure 5.3A
C. The operator should follow this

procedure to service the PVTTM; valve.
1. Disengage process operations according to the procedure

outlined in section 3.4. The operator must be certain
process fluid temperature is under 100F and pressure is
relieved (pressure gauge reads 0).
2. Disengage main power supply. The operator must verify the

Power light on the display is off.
3. Remove or open any access cover panel and set aside to

gain access to the solenoid valve.
4. Identify the retaining screw (figure 5.3B) on the solenoid

valve coil. Remove the screw. Keeping all electrical
connections intact, lift the coil off of the enclosure tube and
set aside.
5. Use a pair of channel lock pliers or a pipe wrench to

separate the bonnet assembly from the valve body. The
plunger is loose inside the enclosing tube. Be certain it is
retained in the enclosure tube as the bonnet is removed
(figure 5.3C).
6. Identify the diaphragm assembly. Gently remove the

assembly from the valve body (figure 5.3D).
7. Identify the mesh screen. Gently remove the mesh screen
and clean or replace as necessary.
8. Clean the valve body.
9. Reset the mesh screen into the valve body.
10. If a new diaphragm assembly was obtained, continue with

step 12. If not, disassemble the diaphragm assembly and
note component order (figure 5.3E). Clean the valve port,
plate, collar and O-ring. Once cleaned, reassemble the
diaphragm.

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11. Set the reassembled

diaphragm assembly or
the new assembly back
into the valve body.
The stem should be
facing out of the valve
body.
12. Insert the plunger with

spring first into the
enclosing tube of the
top bonnet (figure
5.3F). Holding the
plunger in the
enclosure tube, set the
top bonnet onto the
valve body and tighten.
13. Place the coil onto the

top bonnet and replace
the retaining screw.
14. Open the water supply

to circulate water to the
system. Check the
solenoid valve for
leakage. Restart the
unit as outlined in
section 3.
Coil and solenoid base sub assembly Valve body
Core Body Diaphragm Diaphragm assembly

assembly Gasket spring

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5.4 PROBE CALIBRATION
A. The temperature probe (figure

5.4A) is a temperature transducer.
The transducer is embedded into a
threaded bulb well. The transducer
converts the temperature of the
water into a proportional current
output, which the microprocessor
controller reads, displays, and
bases it controlling functions. The
gain is automatically calibrated
within the microprocessor Typical sensor probe Figure 5.4A
electronics. The zero adjustment
potentiometer is located on the CPU.
B. The temperature transducer and instrument circuitry is very stable.

A small drift may occur over time. To ensure correct temperature
reading, calibrate the probe annually or per your facility calibration
standards. Operation in high humidity and high vibration
environments may require more frequent calibration.
C. The operator should follow this procedure to calibrate the probe.
1. Disengage operations and verify all system pressure is

2. Disengage main power supply and verify the Power light on

the display is off.
3. Remove the To Process

temperature probe and
insert a 1/2 plug in its
place (figure 5.4B). To
complete the calibration
procedure, the unit will be
operated at full flow and
pressure. The plug is to
maintain the mechanical
integrity of the unit during
the calibration procedure.
Plug Figure 5.4B
4. Prepare an ice water bath. The operator should place an

accurate digital thermometer in the ice water bath to read
the temperature of the bath. The probe will be calibrated to
the temperature of the ice water bath.
5. Place the probe in the ice water bath.
6. Start the unit.
7. Reduce the units set point, via the Down Arrow push button
to 32F.

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8. With the unit in the operations mode, the to process

temperature on the display should equal the temperature of
the ice water bath as indicated by the digital thermometer. If
not, the operator must change the calibration of the probe.
a. To access the calibration potentiometer, open the

electrical cabinet panel door. The panel door is
secured by a support strap. Caution must be
employed when the electrical panel door is open
since power is applied to the unit.
b. Locate the instrument

CPU. The calibration
pot is located on the
mother board of the
instrument assembly
(figure 5.4C).
c. Use a non-conductive
device, to adjust the
potentiometer.
Adjust the Calibration port Figure 5.4C
potentiometer until
the to process temperature on the display equals
the temperature of the ice bath.
9. When the two temperatures (to process and ice water

bath) are equal, the calibration procedure is complete.
10. Shut down the unit. The operator must be certain to remove
the 1/2 plug and replace the sensor probe. Restart
operations.

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5.5 VOLTAGE CHANGEOVER
A. Some units can undergo a field voltage conversion by qualified

technicians. Consult with the Temptek Service Department to
determine if your unit can be converted. Have your Serial Number
ready and call 317-887-0729.
B. Typical Conversions for 1/2 to 7.5 horsepower motors and 10 to 16

kW heaters:
1. 240/3/60 to 480/3/60
2. 480/3/60 to 240/3/60
3. 480/3/60 to 208/3/60
Consult factory for other power conversions.
B. For a field voltage changeover, the Motor Starter and Overload Block
following items will require

replacement or rewiring:
1. Heater (rewiring)
2. Motor (rewiring)
3. Transformer (rewiring)
4. Motor starter and overload
block (replace)
5. Replace unit data tag with
tag stating new voltage and
amp rating. Figure 5.5A
Transformer
C. The qualified technician should follow

this procedure to complete a field voltage changeover:
1. Disengage operations and verify all system pressure is

2. Disengage main power supply. Follow proper lock-out

procedures. The operator
must verify the Power light
on the display is off.
3. Remove the lift-off access

panel and set aside. (figure
5.5A)
4. Rewire the heater to the

new voltage. Figure 5.5B
shows the wiring for 230
and 460 volt heaters.
Thermoformed panel Figure 5.5A
removed and electrical
cabinet open.
front panel and open the
electrical cabinet panel door. Unplug the instrument
connectors to fully extend the hinged panel.

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Wiring schematics for 240 and 480 volt heaters Revised 4/11 Figure 5.5B
208/240 460/480
4 4
6 7
5
1
L1
8
7
6
2
L2
9
8
3 1 L1
L3 2 L2
9 3 L3
Wiring schematics for 240 and 480 volt pump motors Figure 5.5C
6. Rewire the pump motor for the new voltage. Most Sentra
pump motors are dual voltage. Figure 5.5C shows the
wiring schematic for 240
and 480 voltages.
7. Rewire the transformer to

the proper voltages as
shown by the schematic on
the transformer (figure
5.5D).
8. Replace the motor starter

and overload block. Adjust
the overload block settings
Transformer Figure 5.5D

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Motor Starter and Overload Block

for the current draw at the
new voltage (figure 5.5E).
9. Once a voltage change is

complete, be certain the
unit is properly connected
to the new voltage supply,
as outlined in section 2.5
of this manual. Restart unit
operations according to
section 3 of this manual.
Figure 5.5E

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5.6 SENSOR PROBE SERVICE
A. Each temperature probe (figure Probe

5.6A) is a temperature transducer.
The transducer is embedded into a
bulb well, which is threaded into the
tank. The transducer converts the
temperature of the water into a
proportional current output, which
the microprocessor controller
reads, displays, and bases it
controlling functions. The gain is
automatically calibrated within the
controller electronics, the zero Service connection Figure 5.6A
adjustment potentiometer is located
on the CPU.
B. Sensor probe errors are indicated by the Probe light on the

instrument with a Flashing Red display. When a sensor probe error
is displayed, take the following steps to correct:
1. RECONNECTION. If the service connection of the sensor

probe becomes saturated with water. Simply unplug the
connection, shake out the water to clear the service
connection and replug. If this was the problem, the error
display should change to Solid Red which can be cleared
by pressing the Start push button. If not, continue with
replacement.
2. REPLACEMENT. Replacement of the sensor probe

involves ceasing process operations (as outlined in section
3.4 of this manual) and removing the defective sensor
probe. All factory supplied replacement probes are
complete with the service connection. Unit with HE Series
instruments use two sensor probes: A to process and a
from process. The high temperature limit safety switch is
a part of the to process sensor probe. To replace any
sensor probe, follow the procedure as outlined below:
a. Stop process operations as described in section

3.4 of this manual.
b. Determine that all process pressure is relieved and

the units pressure gauges read 0 pressure.
c. Drain the unit by removing the pump casing drain

plug. The unit can be drained only to below the
sensor probe mount if preferred.
d. Disconnect the sensor probe service plug.
e. Using a crescent wrench, remove the sensor probe

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from the cylinder. To install a new sensor probe

continue as follows:
f. The new sensor probe threads should be lined with

teflon tape and coated with leak preventative
sealant. Using a crescent wrench, thread the new
sensor into the machined boss of the cylinder.
g. Reconnect the service connection. Restart the unit

as outlined in section 3 of this manual.

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5.7 PRESSURE SWITCH SERVICE
A. The unit is protected from low

pressure operations by a pressure
switch (figure 5.7A). This switch is
mounted at the bottom of the
electrical cabinet.
B. The switch will close and consent

the control circuit when sufficient
water supply pressure is presented.
The switch is factory set to 20 psi.
Pressure switch Figure 5.7A
C. If insufficient water supply pressure
is present, the switch will open and
prevent operations.
D. In cases where sufficient water supply pressure is present as

indicated by the units pressure gauges and the pump is off, and if
the pressure switch fails to close, the pressure switch may be
defective. To replace the pressure switch, follow the steps outlined:
1. Shut down unit operations according to section 3.4 in this

manual. Be certain proper lock-out procedures are followed.
Also, be certain system pressure is eliminated and the units
pressure gauges read 0 pressure.
2. Drain unit by removing the pump casing drain plug.
3. A capillary runs from the cooling cylinder to the pressure

switch. Remove the capillary connection.
4. The brass elbow mounted on the pressure switch must be

removed.
5. Remove the electrical connections to the pressure switch.
6. The pressure switch is mounted onto the electrical cabinet

with two 1/2 nuts in series. Remove the nuts to remove the
pressure switch. A new pressure switch from the factory
should be installed by continuing with step 7.
7. Thread one 1/2 nut onto the pressure switch and then
place the pressure switch through the panel in the original
mounting hole. Thread the second 1/2 nut from the bottom
of the pressure switch. Tighten to lock the pressure switch
in place.
8. Install the brass elbow fitting. Teflon tape and leak

preventative paste should be used to prevent water
leakage. Install the capillary tube and resume operations.

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5.8 INSTRUMENT SERVICE
A. The instrument controller is a

microprocessor based
instrument designed to cycle the
heater and PVTTM solenoid
cooling valve to maintain
process temperature at setpoint
(figure 5.8A) .
B. The instrument is not a field

serviceable component. If the
instrument is determined to be in Sentra VE instrument Figure 5.8A
need of repair, the operator must
remove the assembly and return
it to the factory for repair.
C. To service the instrument, take the following steps:
1. Disengage process operations according to the procedure

outlined in section 3.4. The operator must be certain all
system pressure is relieved and the units pressure gauges
read 0.
2. Disengage main power supply and verify the Power light on

the display is off.
3. Remove the thermoformed front panel and set aside. The

panel is attached to the stainless steel cabinet by 4 small
screws.
4. Open the hinged electrical cabinet panel cover. The panel is

opened by removing four small screws.
5. The instrument is mounted

on the electrical cabinet
panel cover. The instrument
is secured by four mounting
bolts. A series of electrical
connections link the
instrument to the
mechanical components of
the unit (Figure 5.8B).
5. Remove the large molex Connections Figure 5.8B

connector.
6. Remove the ground terminals.
7. Remove the sensor plug.
8. Remove the four mounting nuts. The instrument is now

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loose and can be removed. To reinstall a factory issued

instrument, continue with step #9.
9. Place the instrument into the panel mount, aligning the four
mounting stems. Once the instrument is aligned, tighten the
nuts to secure the instrument.
10. Connect the sensor plug.
11. Connect the ground terminals.
12. Connect the large molex connector.
13. The operator can now start the unit as outlined in section 3
of this manual. The operator must reconfigure (if necessary)
the instrument to restore the preferred operating
parameters.

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5.9 CELSIUS TEMPERATURE DISPLAY
A. The following procedure changes the Temperature display units

from Fahrenheit to Celsius. Fahrenheit display is standard.
B. Note that there is no indication for Fahrenheit or Celsius

temperature display.
C. To change to Celsius temperature display, do the following:
1. Disengage process
operations and relieve all
system pressure.
2. Disengage main power

supply. Verify the Power
light on the display is off.
Follow standard lock out
procedures.

front panel and set aside.
The panel is attached to
the stainless steel cabinet
by 4 small screws.
4. Open the hinged electrical

cabinet panel cover. The
panel is opened by
removing four small
screws.
5. Locate the instrument. A

Changing jumper bar.
jumper bar controls the Figure 5.9B
Temperature display. The

jumper bar is located on
the larger circuit board
(figure 5.9A).
6. Using non conductive

pliers, remove the jumper
from the Fahrenheit
position (standard) (Figure
5.9B) to the Celsius
position (Figure 5.9C)
Jumper position for Celsius Figure 5.9C
temperature display.
7. After securing the electrical
panel cover and replacing
the thermoformed front panel, resume operations. The
change will take effect once power is resupplied to the unit.

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5.10 ELECTRONIC INSTRUMENT REPAIR POLICY AND PROCEDURE
A. All control instruments used in Temptek temperature control units

are covered by the machines warranty. Proprietary tailor made
instrument are manufactured specifically for Temptek by our
affiliated company Advantage Electronics.
B. IN WARRANTY SERVICE INCIDENT
1. Call the factory for diagnostic assistance.
2. If a control instrument is determined to be at fault, a new or

reconditioned instrument will be sent as a replacement.
3. Return the defective instrument freight pre-paid for full

credit. If the defective instrument is not returned you will
need to pay for it.
C. OUT OF WARRANTY SERVICE INCIDENT
1. Call the factory for diagnostic assistance.
2. If a control instrument is determined to be at fault, you will

be referred to the instrument manufacturer, Advantage
Electronics (an Temptek affiliated company. There are 3
options.
a. Purchase a new instrument as a replacement.

b. Send your instrument back for repair, freight
prepaid. For a nominal fee, your instrument will be
repaired and returned.
c. Purchase a new instrument and repair the old one
as a back up.
3. If you are sending your instrument back for repair, call the
Service Department for more information. Do not
disassemble the instrument.
D. Other Information:
1. Call the factory for current repair charges.
2. Repair warranty: 1 year.
3. Ship to Advantage Electronics, 525 East Stop 18 Road,

Greenwood, IN 46143. Attention: Repairs (317-887-1946).
Include in the shipping box: Part, purchase order, contact
name, phone number, and symptom (if available).
5. For Priority service, send the instrument to the factory via

overnight shipment. We usually repair these instruments the
same day we receive them.

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6.0 COMPONENTS
6.1 MECHANICAL SYSTEM
6.2 ELECTRICAL SYSTEM

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6.1 MECHANICAL SYSTEM
A. MOTOR/PUMP ASSEMBLY. The unit pump is a multi-component

assembly serving to circulate water through the process system.
The pump will increase the system pressure between 35 - 50 PSI
over the plant water supply pressure. The pump is
driven by an electrical motor. Pump Casing
1. Pump casing. The pump

casing is an exclusive
design. The casing is cast
of iron and flanged to
accept the heater/discharge
and cooling tanks. The
casing is the support
element in the pump/motor
assembly and is secured to
the unit base (figure 6.1A).
Electric Pump Figure 6.1A
2. Pump adapter. The pump Motor Adapter
adapter is the mating element

between the pump casing the electric motor. The adapter is
machined to accept the pump seal flush line. The stationary
pump seal member is set in the seal cavity of the pump
adapter (figure 6.1A).
3. Electrical motor. The

electric motor is a dual
voltage, 3 phase, ODP
motor. The motor serves to
turn the pump impeller
creating process flow
(figure 6.1A).
4. Impeller. The impeller is

custom designed for the
unit and creates the higher
flow (gpm) from standard Impeller Figure 6.1B
HP ratings (figure 6.1B).
5. Pump Seal. The pump seal

prevents water leakage
from the pump adapter.
The seal is made up of
three items: The stationary
member (seated in the seal
cavity), the rotating
member (placed on the
motor shaft) and the
tension spring (figure 6.1C
shows the stationary
member only). Stationary member Figure 6.1C

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6. Pump seal flush. The

pump seal flush is a flow
diverter which serves to
cleanse the pump seal
assembly of debris which
may lodge on the seal and
create a leak (figure 6.1D).
B. HEATER. The heater is a dual

voltage, flange mounted immersion
heater set in the pump discharge Seal flush tube Figure 6.1D
cylinder. The heater elements have
a stainless steel sheath. Electrical
supply to the heater is provided via
a mercury contactor (figure 6.1E).
C. HEATER/PUMP DISCHARGE
CYLINDER. The heater/pump
discharge cylinder is a custom cast
tank. The tank is flanged mounted
to the pump casing. Reinforced
machined bosses accept the to
process/high temperature limit
sensor probe and the to process Heater Figure 6.1E
Discharge tank
connection (figure 6.1E).
PVT valve
D. COOLING CYLINDER. The cooling

cylinder is a custom cast tank. The
tank is flanged mounted to pump
casing. Reinforced machined
bosses accept the pressure relief
valve, the from process pressure
gauge and pressure switch
capillary connector, PVTTM solenoid
cooling valve, the water supply
connection and the from process
connection (figure 6.1F). Figure 6.1F
E. PRESSURE RELIEF VALVE. The pressure relief valve

is a 150 psi relief valve serving to discharge excessive unit pressure
to atmosphere. The valve can be manually activated by lifting the
actuating lever (figure 6.1F).
F. PVTTM VALVE. The PVTTM valve is a microprocessor control

solenoid valve use to discharge heated process water to drain as
needed to control process temperature.
G. PRESSURE GAUGES. To and from process pressure gauges

display the system pressure. To process pressure originates at the
heat/pump discharge cylinder. From process pressure originates
at the cooling cylinder. The gauges accurately display system
pressures from 0 to 160 PSI (figure 6.1G).

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H. CASTERS. The unit is mounted on 4 swivel ball bearing casters.

The casters allow the unit to be portable and easily move from
location to location.
I. STAINLESS STEEL CABINETRY.

The stainless steel cabinetry
prevents unsightly rust and metal
decay. The electrical cabinet cover
is hinged. The unit base is made of
pressed steel with galvanized zinc
coating. The lift off access panel is
secured to the unit base by 5
screws (figure 6.1G).
Figure 6.1G
6.2 ELECTRICAL SYSTEM
A. INSTRUMENT. The instrument is a

custom designed and assembled
microprocessor controller. The
instrument is mounted to the
electrical panel cover. The
instrument controls the cycling of
the heater, motor pump and AVTTM
valve. System and setpoint
temperatures are displayed
continually. System parameters are
programmable (figure 6.2A).
Typical instrument with Figure 6.2A
service connections
B. TRANSFORMER. The transformer removed
supplies 110 volts to the controlling
instrument (figure 6.2B).
C. MOTOR STARTER/OVERLOAD RELAY. The electrical motor is

engaged when the motor starter contacts close, on command by the
instrument. The electric motor is protected from excessive
amperage by a set of thermal overload relays, which open when
excessive amperage heats the overloads and the relay opens
(figure 6.2B).
C. PUMP MOTOR CONTROLLER. The electrical motor is engaged

when the motor starter contacts close, on command by the
instrument. The electric motor is protected from excessive
amperage by a set of thermal overload relays, which open when
excessive amperage heats the overloads and the relay opens
(figure 6.2B).
D. HEATER CONTACTOR. The heater contactor is a solid state

contactor. On command from the instrument, the contactor will close
and voltage will be supplied to the heater (figure 6.2B).
F. SENSOR PROBES. The unit uses two sensor probes. The to

process temperature sensor and the high temperature limit safety

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switch are housed in the same Transformer Heater Pump Motor

Contactor Controller
assembly and mounted in the
heater/pump discharge tank (figure
6.2C). The from process probe is
mounted in the suction tank.
G. POWER CORD. The supplied

power cord is factory installed to
the unit. The power cord is a 3
conductor with 1 ground wire sized
for the unit and 10 in length.
Pressure switch Figure 6.2B
Sensor probe and high Figure 6.2C

temperature limit

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Page: 60
7.0 RELATED DRAWINGS

7.1 PHYSICAL
7.2 ELECTRICAL
7.3 CIRCUIT SCHEMATIC
7.4 REGULATOR/BYPASS INSTALLATION
7.5 DUAL ZONE DOLLY
7.6 STACKING RACK

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7.1 PHYSICAL
Left Side View Left Side View

19 1/2
To Process
Instrument
Drain
Pressure Gauges
From Process
26 5/8
Water Supply
Rear View Right Side View

12 1/2

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L1
POWER ENTRY
L2
L3
7.2
L4
GROUND
1
1 1
2 2
3
3 3
supplied with unit for details.

Provided for display purposes
H1
only. Refer to electrical drawing

M1
1 MOL
5 8 8
6
ELECTRICAL
4
M1 H1 NOTE
7 9 7 9
2nd HEATER EXISTS
PROCESS PUMP HEATER HEATER 2 ON SOME UNITS

1 3 TRANSFORMER
110VAC SEC.
BLK
GROUND
21
FU 1
HIGH TEMP MOLD PURGE
LIMIT SWITCH PRESSURE INACTIVE/ACTIVE
WHT 12 12 13 SWITCH 10 11 50 MOLD PURGE SOLENOID (OPTIONAL)
50
MOLD PURGE SOLENOID (OPTIONAL)
MOTOR COIL
1 MOL
TAN 15 50
M1 PUMP MOTOR COIL
PINK Q
GRN 50 50
GROUND (INSTRUMENT)
ORE
M1 HEATER COIL
BRN 50
H1 HEATER COIL
UNIT
ON/OFF
Q
OPTIONAL COOLING SOLENOID

BLU 18 18 50
COOLING SOLENOID (OPTIONAL)
TEMPTEK, INC.
www.Temptek.com
Q
RED 19 WHT
ALARM
INACTIVE/ACTIVE M1
21 22 23 50
GRY 20 BLK ALARM BUZZER (OPTIONAL)
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TO PROCESS PROBE/HIGH TEMP. LIMIT

Page: 63
7.3 CIRCUIT SCHEMATIC
HEATER
TO PROCESS
PRESSURE GAUGE
TO PROCESS
CONNECTION
DRAIN CONNECTION
TO PROCESS SENSOR
HI TEMP SAFETY
PVT COOLING VALVE
DISCHARGE TANK
FROM PROCESS
CONNECTION
PRESSURE RELIEF
VALVE
FROM PROCESS
PRESSURE GAUGE
WATER SUPPLY
CONNECTION
SUCTION TANK
PUMP
PUMP SEAL FLUSH
DRAIN

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7.4 REGULATOR/BYPASS INSTALLATION
TO PROCESS
FROM PROCESS
DRAIN
WATER PRESSURE REGULATOR VALVE

TYPE: WATTS U5B 1/2" BYPASS VALVE
SUPPLY
TYPE: WATTS BP-30 1/2"
25-75psi RANGE.
45-100psi RANGE.

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7.5 DUAL ZONE DOLLY
SENTRA '1"
DRAIN CONNECTION
SENTRA '2"
FROM PROCESS
CONNECTION
DRAIN CONNECTION
TO PROCESS
CONNECTION
TO PROCESS CONNECTION
FROM PROCESS CONNECTION

WATER SUPPLY
CONNECTION
WATER SUPPLY CONNECTION
WATER SUPPLY MANIFOLD
WATER SUPPLY CONNECTION

TO SENTRA '1'
WATER SUPPLY MANIFOLD CONNECTION ELECTRICAL CABINET
WATER SUPPLY CONNECTION STRUCTURAL STEEL BASE

TO SENTRA '2'
DRAIN CONNECTION TO SENTRA '1' CASTER
DRAIN MANIFOLD CONNECTION WATER SUPPLY MANIFOLD
DRAIN CONNECTION TO SENTRA '2'

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7.6 STACKING RACK
FRONT VIEW SIDE VIEW BACK VIEW TO PROCESS

DRAIN CONNECTION
TO FROM
TEMPERATURE
C F POWER SELECT
CONNECTION
SETUP
TEMP FLOW NETWORK MACHINE
FLOW
START STOP
PUMP ON LPM GPM
CAPACITY %
HEAT COOL DEAD BAND
PROCESS MACHINE STATUS COMM ALARM
TEMP FLOW PROBE WATER HI PUMP VALVE PHASE TX

DEV PRESS TEMP OL
RS-485
FROM PROCESS
CONNECTION
WATER SUPPLY
CONNECTION
WATER SUPPLY
MANIFOLD
CONNECTIONS
TO PROCESS
CONNECTION
TEMPERATURE
POWER SELECT
TO FROM C F
64" TEMP FLOW
PUMP ON
SETUP
NETWORK MACHINE
FLOW
LPM GPM
START STOP
CAPACITY %
HEAT COOL DEAD BAND
PROCESS MACHINE STATUS COMM ALARM
TEMP FLOW PROBE WATER HI PUMP VALVE PHASE

DEV PRESS TX
TEMP OL
DRAIN
RS-485
CONNECTION
FROM PROCESS
CONNECTION
WATER SUPPLY
CONNECTION
CONNECTION TO CONNECTION TO
21.5" 29" PLANT WATER SUPPLY PLANT DRAIN

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Page: 68
8.0 APPENDIX
8.1 SPECIFICATIONS
8.2 MODEL # AND SUFFIX CODING
8.3 INTERPRETATION OF PROCESS PRESSURE GAUGES
8.4 OPERATION OF MOLD PURGE
8.5 CLOSED CIRCUIT OPERATION
8.6 AS5 PUMP PARTS LIST - 1/2 HP TO 1 HP
8.7 AS5 PUMP PARTS LIST - 1.5 HP TO 3 HP
8.8 PARTS LIST - LS INSTRUMENT

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8.1 SPECIFICATIONS
620 635 645 665 675 680 1020 1035 1045 1065 1075 1080 1090 10100 1620 1635 1645 1665
1
Heater kW 6 6 6 6 6 6 10 10 10 10 10 10 10 10 16 16 16 16
Process Pump HP /2
1 3
/4 1 11/2 2 3 1
/2 3
/4 1 11/2 2 3 5 71/2 1
/2 3
/4 1 11/2
GPM 20 35 45 62 75 80 20 35 45 62 75 80 90 100 20 35 45 62
PSI 30 30 30 30 30 30 30 30 30 30 30 30 34 54 30 30 30 30
Full Load Amperage 230 volt 17.0 17.8 18.6 20.2 21.8 24.6 27.0 27.8 28.6 30.2 31.8 34.6 40.3 47.1 42.0 42.8 43.6 45.2
2
@3/60hz 460 volt 8.5 8.9 9.3 10.1 10.9 12.3 13.5 13.9 14.3 15.1 15.9 17.3 20.2 23.5 21.0 21.4 21.8 22.6
Dimensions (inches) Height 281/4 281/4 281/4 281/4 281/4 281/4 281/4 281/4 281/4 281/4 281/4 281/4 44 44 281/4 281/4 281/4 281/4
Width 121/2 121/2 121/2 121/2 121/2 121/2 121/2 121/2 121/2 121/2 121/2 121/2 16 16 121/2 121/2 121/2 121/2
Depth 19 /2 1
19 /2 1
19 /2 1
19 /2 1
19 /2 1
19 /2 1
19 /2 1
19 /2 1 19 /2 1
19 /2 1
19 /2 1
19 /2 1
24 24 19 /2 1
19 /2 1
19 /2 1 191/2
3
Connections (inches) T/F 1 /41
1 /41
1 /41
1 /41
1 /41
1 /41
1 /41
11/4 1 /41
1 /41
1 /41
1 /41
2 2 1 /41
1 /41
1 /41 11/4
4
S/D /2
1 1
/2 1
/2 /2
1 1
/2 /2
1 1
/2 1
/2 1
/2 1
/2 1
/2 /2
1 1
/2 1
/2 1
/2 1
/2 /2
1 1
/2
5
Weight (pounds) Shipping 195 200 205 205 210 220 198 200 208 208 213 223 275 290 200 205 210 210
1675 1680 1690 16100 2435 2445 2465 2475 2480 2490 24100 3435 3445 3465 3475 3480 3490 34100
1
Heater kW 16 16 16 16 24 24 24 24 24 24 24 34 34 34 34 34 34 34
Process Pump HP 2 3 5 7 /21 3

/4 1 1 /21
2 3 5 7 /21
/4
3
1 1 /21 2 3 5 71/2
GPM 75 80 90 100 35 45 65 75 80 90 100 35 45 65 75 80 90 100
PSI 30 30 34 54 30 30 30 30 30 34 54 30 30 30 30 30 34 54
Full Load Amperage 230 volt 46.8 49.6 55.4 62.2 63.1 63.9 65.5 67.1 69.9 75.5 82.3 88.2 89.0 90.6 92.2 95.0 100.6 107.4
2
@3/60hz 460 volt 23.4 24.8 27.7 31.1 31.6 32.0 32.8 33.6 35.0 37.8 41.2 44.1 44.5 45.3 46.1 47.5 50.3 53.7
Dimensions (inches) Height 281/4 281/4 44 44 44 44 44 44 44 44 44 44 44 44 44 44 44 44
Width 121/2 121/2 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16
Depth 19 /2 1
19 /2 1
24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24
3
Connections (inches) T/F 11/4 11/4 2 2 11/4 11/4 11/4 11/4 11/4 2 2 11/4 11/4 11/4 11/4 11/4 2 2
4
S/D /2
1 1
/2 1
/2 /2
1 1
/2 /2
1 1
/2 1
/2 1
/2 1
/2 1
/2 /2
1 1
/2 1
/2 1
/2 1
/2 /2
1 1
/2
5
Weight (pounds) Shipping 220 225 285 300 270 275 280 285 290 295 310 280 285 290 295 300 305 320
Notes: 1. Derate heater output by 25% for 208/3/60 operation. 2. Consult factory for 50hz operations. 3. T - to process; F - from process. 4. S - water supply; D - drain. 5. Approximate unit shipping weight.

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8.2 SENTRA MODEL # AND SUFFIX CODING
MODEL # SUFFIX
VT-1045-LX-41CX
HEATER KILOWATTS
6 = 6 KW
10 = 10 KW
16 = 16 KW
24 = 24 KW
36 = 36 KW
GPM BY HP
35 = 35 GPM @ 3/4 HP
45 = 45 GPM @ 1 HP
65 = 65 GPM @ 1 1/2 HP
75 = 75 GPM @ 2 HP
90 = 90 GPM @ 5 HP
100 = 100 GPM @ 7 1/2 HP
INSTRUMENTATION
LS = LS instrument
LX = LX instrument
300 = 300F instrument
VOLTAGE
2 = 208-230/3/60
3 = 380/3/50
4 = 460/3/60
5 = 575/3/60
6 = 415/3/60
ELECTRICS
1 = NEMA 1
2 = NEMA 12
J = JIC
VALVE SIZE
A = None
B = 1/4"
C = 3/8"
D = 1/2"
E = 3/4"
F = 1"
SPECIAL OPTIONS
Consult factory for more information

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8.3 INTERPRETATION OF PROCESS PRESSURE GAUGES
A. READ AVAILABLE WATER

PRESSURE AT UNITS
LOCATION. When a temperature
control unit is attached to the
process with the water supply on
and the pump off, both gauges will
read the water supply pressure at
the units location (figure 7.3A).
B. READ PRESSURE DROP

ACROSS PROCESS ( P). With
Pressure gauges Figure 7.3A
the pump on, the to process
pressure gauge will rise to read the
sum of the water supply pressure and pump generated pressure.
The from process pressure gauge reads the effect of water supply
pressure and pump suction pressure. The difference between the to
and from process gauges is the pump generated circulating
pressure... which is also equal to the pressure drop across the
process.
C. PUMP ROTATION INDICATION. If the pump is running, and both

gauges are close to same value, it is likely that the pump is
rotating backward, or the pump is generating such a high flow that
an overload condition will result.
D. PUMP MOTOR OVERLOAD CONDITION. If the P is low with the

pump rotating correctly, then the flow rate is high, which probably
will result in a motor overload. Refer to the representative pump
curve below.
E. WATER HAMMER (COMPETITIVE SOLENOID VALVE UNITS). On

competitive mold temperature controllers, when P gauges are
supplied, the water hammer effect of on/off solenoid valves can be
seen. When the solenoid valve is open, both to and from process
pressure gauges will fall as the system depressurizes. When the
valve closes, there will be a momentary spike that will be seen on
both pressure gauges, then they will settle back to normal P
values. This spike is called water hammer.

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8.4 OPERATION OF MOLD PURGE
A. Temptek supplies an optional MOLD PURGE kit for temperature control

units. The mold purge kit contains several solenoid valves and check
valves. When activated and supplied with compressed air, the mold purge
kit will expel process water from the mold to the central water supply or
drain. Temptek mold purge kits are supplied as a factory installed option or
a field retrofitted kit.
B. The operation of the mold purge is as follows (see illustration)
1. Stop the pump, maintain electrical

power to unit.
2. Close the water supply ball valve.
3. Connect a regulated air supply to

mold purge compressed air
connection.
Note: Air supply should be

regulated approximately 10 PSI
above drain line pressure.
4. Activate mold purge with button

located on electrical cabinet.
5. When water is purged disconnect air

supply.
6. Depress and hold vent button

(approximately 30 seconds to release
air pressure.
7. Disconnect power to unit.
LINE TO DRAIN
CHECK VALVE
DRAIN CONNECTION Prevents compressed air from purging
unit
AVT VALVE
TO PROCESS CONNECTION
Closed to prevent purge of unit
MOLD PURGE SWITCH CHECK VALVE

Turns on/off mold purge feature. Located on Prevents water bleed to air line during
electrical cabinet normal run cycle
WATER SUPPLY COMPRESSED AIR

CONNECTION CONNECTION
Valve must be closed during mold purge
operation
SOLENOID VALVE
Opens to allow compressed air to enter
FROM PROCESS CONNECTION during mold purge operation
SOLENOID VALVE
Opens to purge water to drain

317-887-6352 Fax: 317-881-1277
www.Temptek.com
8.5 CLOSED CIRCUIT OPERATION
A. Standard mold temperature controllers are supplied as open-circuit

units. VT units can be used on closed-circuit applications with the
installation of the SE kit.
B. Factory installed SE kits place a heat exchanger into system to

separate the cooling water loop from the process circulation loop.
Cooling water from plant water supplies circulate only through the
tube side of the heat exchanger. Process water circulates through
the shell side of the heat exchanger.
C. To control process water

temperature, a
microprocessor controlled
AVTTM modulating valve is
installed on the heat
exchanger drain line. TO PROCESS
D. The closed circuit kit will

add 10 to the overall height
of the unit. The width and
depth do not change,
although the length of
connection hose extending
from the back of the unit
must be accounted for.
BYPASS VALVE
FROM PROCESS
TO PROCESS WATER
SUPPLY
HEAT
DRAIN EXCHANGER
AVT VALVE
BYPASS VALVE
HEAT
EXCHANGER
FROM PROCESS
WATER SUPPLY
DRAIN

317-887-6352 Fax: 317-881-1277
www.Temptek.com
8.6 AS5 PUMP PARTS LIST - 1/2 HP TO 1 HP
PART # DESCRIPTION
6206995 MOTOR/PUMP ASSEMBLY 1/2HP AS5 2/4/3/60

414 Adapter - iron C2-4551 AS5
771599 Pump case - iron D2-1839 AS5
3444400 Tank gasket 2-3/8 A-9159 AS5
3444401 Tank gasket 4-1/2 A2-8748 AS5
4310601 Impeller B2-5264 4.37 AS5
4757861 Motor AE5/AS5/A5W 1HP #S-2771R
5486522 Nut S-4989 AS5
5622271 O-ring Case S-5091 AS5
6490000 Shaft seal 101-173 5/8 EPT
6491000 Shaft seal EPT/Ceramic 4949 AE5/AS5
6207000 MOTOR/PUMP ASSEMBLY AS5 3/4HP ODP 230/460

3444400 Tank gasket 2-3/8 A-9159 AS5
3444401 Tank gasket 4-1/2 A2-8748 AS5
4310602 Impeller B2-5264 4.5 AS5
4757862 Motor AE5/AS5/A5W 3/4HP #S-2772R
5486522 Nut S-4989 AS5
6490000 Shaft seal 101-173 5/8 EPT
6207010 MOTOR/PUMP ASSEMBLY AS5 1HP AS5 2/4/3/60

3444400 Tank gasket 2-3/8 A-9159 AS5
3444401 Tank gasket 4-1/2 A2-8748 AS5
4310603 Impeller B2-5264 4.75 AS5
4757863 Motor AE5/AS5/A5W 1 HP #S-2773R
5486522 Nut S-4989 AS5
6490000 Shaft seal 101-173 5/8 EPT

317-887-6352 Fax: 317-881-1277
www.Temptek.com
8.7 AS5 PUMP PARTS LIST - 1.5 HP TO 3 HP
PART # DESCRIPTION
6207020 MOTOR/PUMP ASSEMBLY AS5 1.5HP 2/4/3/60

3444400 Tank gasket 2-3/8 A-9159 AS5
3444401 Tank gasket 4-1/2 A2-8748 AS5
4310604 Impeller B2-5264 5.06 AS5
4757864 Motor AE5/AS5/A5W 1-1/2HP #S-2774R
5486522 Nut S-4989 AS5
6490000 Shaft seal 101-173 5/8 EPT
6207030 MOTOR/PUMP ASSEMBLY AS5 2HP 2/4/3/60

3444400 Tank gasket 2-3/8 A-9159 AS5
3444401 Tank gasket 4-1/2 A2-8748 AS5
4310605 Impeller B2-5264 5.25 AS5
4757865 Motor AE5/AS5/A5W 2HP #S-2775R
5486522 Nut S-4989 AS5
6490000 Shaft seal 101-173 5/8 EPT
6207040 MOTOR/PUMP ASSEMBLY 3HP AS5 2/4/3/60

3444400 Tank gasket 2-3/8 A-9159 AS5
3444401 Tank gasket 4-1/2 A2-8748 AS5
4310605 Impeller B2-5264 5.25 AS5
4757866 Motor AE5/AS5/A5W 3HP #4551R
5486522 Nut S-4989 AS5
6490000 Shaft seal 101-173 5/8 EPT

317-887-6352 Fax: 317-881-1277
www.Temptek.com
8.8 PARTS LIST - LS INSTRUMENT
Note: Typical parts list shown. Please supply model and serial numbers when order-
ing parts
PART # DESCRIPTION
299082 Bracket, home switch SI MD-1642
781000 Caster 2 swivel #EY459R
1835050 Contactor #3030APS 30 AMP
1843601 Adapter coupling SI MD-1642
2735358 Sentra top SS - DWG #EP-103
2746237 Electrical enclosure door SS - DWG #EP-103
2761201 Electrical sub panel - DWG #EP-103
2851112 Gauge panel - DWG #EP-103
2877542 Base - DWG #EP-103
3581000 Pressure gauge 0-160 PSI 2 face
3708505 Plastic handle P2-41
3775510 Heater 10KW 2/4/3/60 square flange
3520005 Heater flange gasket 4.50 OD
4439900 Instrument kit SK-SI
4713377 Drip Cover SI MD-1642
6207000 Motor/pump assembly AS5 3/4HP ODP 230/460
414 Adapter iron C2-4551 AS5
771599 Pump case iron 137-001-166 AS5
3444400 Tank gasket 2-3/8 A-9159 AS5
3444401 Gasket, tank flange 4-1/2 AS5
4310602 Impeller B2-5264 4.5 AS5
4310611 Impeller AS5 #100345 4.5 mfg. After 2-97
4714466 Motor 3/4HP 113-000-354T 2/4/3/60
4757862 Motor AE5/AS5/A5W 3/4HP #S-2772R
5486522 Nut S-4989 AS5
5622271 O-ring case 116.000.252
6490000 Shaft seal niresist 5/8
6491000 Shaft seal ceramic 5/8
6748201 Cap screw #102RO3A2
9118502 Impeller washer #100301
7370000 Motor starter CR354AB3AA1B
1733456 Auxiliary contact kit #353XAAA
7541000 Panel mount pressure switch #82681
7732250 Heater cylinder AS5 #D2-1841
8240000 Transformer 9T58B42
8764940 AVT valve SI 1/2
8764939 AVT SI repair kit #EH-124
8764949 AVT drive kit for 3/8 and 1/2 valves #977700
9060000 Pressure relief valve #150 PSI

317-887-6352 Fax: 317-881-1277
www.Temptek.com
Page: 78
END
2013 Temptek, INC.
RE 1 02/13

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I.O.M.

#092 12/06 updated 02/2013

INSTRUCTION MANUAL INSTALLATION OPERATION MAINTENANCE

Models with LS Series Instrument.

TEMPTEK, INC. 525 East Stop 18 Road Greenwood, IN 46142

QUICK START-UP GUIDE 6

3.0 START UP SEQUENCE 19

TEMPTEK, INC. Page: 4

7.0 RELATED DRAWINGS 61

TEMPTEK, INC. Page: 5

QUICK START-UP GUIDE

WATER SUPPLY OPEN AND WATER SUPPLY PRESSURE MUST BE

DRAIN LINE CORRECTLY CONNECT DRAIN LINE TO PROPER

ENGAGE POWER SUPPLY... CHECK DISCONNECT FUSE OR

TURN UNIT 'ON' AND

TEMPTEK, INC. Page: 6

QUICK TROUBLESHOOTING GUIDE

MAIN POWER SUPPLY REPLACE TRANSFORMER

MOTOR OVERLOAD RESET OVERLOADS

HIGH TEMP LIMIT TEMPERATURE OVER 256

MAIN POWER SUPPLY REPLACE TRANSFORMER

MOTOR OVERLOAD RESET OVERLOADS

HIGH TEMP LIMIT TEMPERATURE OVER 256

INADEQUATE WATER YES

AVT COOLING VALVE CHECK VALVE WIRE CLEAN/REPLACE REPLACE MOTOR/GEARBOX

DRAIN LINE OPEN23 CLOSED REDUCE HIGH DRAIN

CONTROL PROBE CHECK FOR WATER IN REPLACE PROBE

PROCESS WATER CHECK FOR A DEFECTIVE LEAKING WATER PRESSURE

HEATER ELEMENT REPLACE HEATER

HEAT LOSS? CHECK FOR EXCESSIVE DETERMINE IF UNIT

CONTROL PROBE CHECK FOR WATER IN REPLACE PROBE

TEMPTEK, INC. Page: 7

TEMPTEK, INC. Page: 9

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

B. Several important references are made to safety considerations in

A. Long term efficiency of operation is largely determined by proper

1.3 TYPICAL LABEL PLACEMENT

Process Connection Label

Unit Data Tag

TEMPTEK, INC. Page: 10

1.4 COMPONENT PLACEMENT

A. The temperature controller is designed to circulate temperature

B. Please note that the ability of the equipment to achieve this

C. If the operator has any questions, contact the Sales or Service

TEMPTEK, INC. Page: 11

Manual & Quick

TEMPTEK, INC. Page: 12

TEMPTEK, INC. Page: 13

A. All process piping materials such as hose, rigid piping, valves or

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

From process connection:

Water supply connection:

2.2 TO AND FROM PROCESS CONNECTIONS

A. Connect the units To Process port to the Water In port on the

C. Please note: Process water piping circuitry should be designed to

D. Valves and filters may be installed in the process water piping

TEMPTEK, INC. Page: 14

2.3 WATER SUPPLY CONNECTION

B. Water supply pressure requirements vary with operating

C. The factory recommended