For ABB Employee Use Only

Any other use is in violation of International Copyright Laws. For an end user copy of this manual, send a fax to: U.S.A. 614-261-2172 Attn: Documentation.

AccuRay 1190 Liquid Cooling Unit Reference Manual

For ABB Employee Use Only

Any other use is in violation of International Copyright Laws. For an end user copy of this manual, send a fax to: U.S.A. 614-261-2172 Attn: Documentation.

PROPRIETARY DATA This document contains proprietary data of ABB Industrial Systems Inc. No disclosure, reproduction, or use of any part thereof may be made except by written permission.

Produced by the Technical Publications Department of the Pulp and Paper Division. Writer: Bill Houston, Robert Macchia Illustrator: Melinda Hoyle Technical Contributors: Larry Reece, Bernard McLoughlin

1992, 1995 by ABB Industrial Systems Inc. All rights reserved. 1190 is a trademark of ABB Industrial Systems Inc. AccuRay is a registered trademark and service mark of ABB Industrial Systems Inc.

January 1995 101333-003 Version B

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Document Version History

AccuRay 1190 Liquid Cooling Unit Reference Manual
Version Level A B Effective Date August 1992 January 1995 Sections Changed by Revision Original Release Figure 5-2 Sections Added by Revision Sections Deleted by Revision

101333-003

Document Version History

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Preface
The Liquid Cooling Unit Reference Manual, 101333-003, is written for customer and ABB engineering and service personnel. This manual supports the operation, maintenance, troubleshooting, and replacement of the components that make up the Liquid Cooling Unit (LCU). The manual will enable the users to operate and maintain the LCU. This manual will also enable the user to locate and replace any faulty components within the LCU.

101333-003

Preface

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CAUTION

If using this cooling unit with a metal x-ray gauge, make the coolant mixture 50%/50% ethylene glycol and distilled water.

101333-003

Note

iii

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Table of Contents
Preface ........................................................................................... i Table of Contents ........................................................................ v List of Figures ............................................................................ vii 1 Theory of Operation................................................................. 1 2 Operation .................................................................................. 3 3 How to Adjust the Temperature of the LCU........................... 5 4 Maintenance ............................................................................. 7 5 Troubleshooting....................................................................... 9
Troubleshooting the Flow Switch..............................................................12 Troubleshooting the Digital Thermometer................................................13 Operating Parameters for the LCU ............................................................14 Wiring Diagram............................................................................................14

6 Replacement Procedures ...................................................... 17

Preparing the LCU for Servicing................................................................18 Connecting the LCU After Servicing .........................................................19 Drain and Refill the LCU .............................................................................20 Full Light or Fill Light Replacement ..........................................................22 Power Switch Replacement .......................................................................23 Regulated Power Supply Replacement.....................................................24 Digital Thermometer Replacement ............................................................25 Reservoir Assembly Replacement ............................................................26 Flow Control Valve Replacement...............................................................28 Water Pressure Regulator Replacement...................................................29 Flow Switch Replacement ..........................................................................30 Pump Assembly Replacement ...................................................................31 Top Panel Replacement..............................................................................32 Back Panel Replacement............................................................................33 Front Panel Replacement ...........................................................................34

7 Replacement Parts List ......................................................... 35 Index ........................................................................................... 37

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Table of Contents

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List of Figures
Figure..................................................................................................Page Figure 1-1 Figure 1-2 Figure 3-1 Figure 3-2 Figure 5-1 Figure 5-2 Figure 6-1 Figure 6-2 Figure 6-3 Figure 6-4 Figure 6-5 Figure 6-6 Figure 6-7 Simplified Diagram of the LCU .............................................. LCU, Side View with the Service Panel Removed ................. Liquid Cooling Unit, Top View ............................................... Penn Control Thermostat ......................................................... Test Points for the Flow Switch ............................................... Wiring Diagram for the LCU ................................................... LCU, Top View ....................................................................... Liquid Cooling Unit, Front View ............................................ Full Light Wiring ..................................................................... Wiring for the Regulated Power Supply .................................. Wiring for the Reservoir Float ................................................. Liquid Cooling Unit, Rear View .............................................. Flow Switch ............................................................................. 2 2 6 6 12 15 18 21 22 24 27 29 30

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List of Figures

vii

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1
Theory of Operation
The Liquid Cooling Unit (LCU), Part Number 101536-002, is a heat exchanger. Warm coolant from the sensor is cooled by customer-provided water. A simplied ow diagram of the LCU is shown in Figure 1-1. Refer to Figure 1-2 for a cutaway view. The LCU is a closed distribution system. The LCU consists of a plastic reservoir with a copper coil inside. A coolant mixture is pumped through a closed loop to the device to be cooled. The warm coolant is returned to the reservoir where it is cooled by passing it over and through the coils in the reservoir. The cooling coil in the reservoir carries customer-supplied water that must be less than 29C (85F). This coil transfers heat from the coolant mixture which is circulating through the reservoir and the sensor. The tank holds about 10.4 liters (2 3/4 U.S. gallons) of the coolant mixture. A thermostatic ow control valve is mounted in the customer water line and controls the amount of water circulating through the coils. The valve is controlled by the thermostat in the coolant line going back to the sensor. The valve is activated by the temperature of the liquid. Power for the unit is 208 to 240 Volts at 50 or 60 Hertz. There is a power switch provided to control the overall operation of the unit.

101333-003

Theory of Operation

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Filter and Filter Housing

Flow Valve

Customer Water Supply

Coolant

From Sensor Sensor Flow Switch

To Sensor Customer Water Out Pressure Pump

Figure 1-1 Simplied Diagram of the LCU

Penn Flow Control Valve Thermostat

SERVICE PANEL

Tank and Coil Assembly

AIR PURGE

Flow Switch
DANGER
HIGH VOLTAGE

Terminal Block

Pump Assembly

Figure 1-2 LCU, Side View with the Service Panel Removed

Theory of Operation

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2
Operation
Use the following procedure to operate the Liquid Cooling Unit (LCU). Step 1. Procedure After the installation is complete, prepare the coolant mixture. The mixture is 25 percent ethylene glycol and 75 percent potable water. Comments The reservoir tank holds 10.4 liters (2 3/4 U.S. gallons). Do not substitute automotive 2.6 liters of ethylene glycol to 7.8 liters of water antifreeze for ethylene glycol. or 0.69 gallons of ethylene glycol to 2.06 gallons of water. See caution on page iii. NOTE: If Ethylene glycol connot be obtained locally, it can be ordered from stock. The part number is 101447-001 (5 gallons). 2. Fill the tank to approximately two inches over the coils. This should take 7.6 liters (2 gallons, U.S.) of the coolant mixture. Turn On power to the unit. The Fill light will come on when you turn On power to the unit and begin to ll it. The Fill light will go out when the unit has been lled past the minimum acceptable limit. The Full light will go on when the LCU has been lled to the maximum acceptable level. The Full light will stay on until the coolant level drops below the maximum acceptable level. The Fill light will not come on again until the coolant level falls below the minimum acceptable level. continued on next page

3.

101333-003

Operation

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continued Step 4. Procedure Add the coolant mixture until the sensor and feed lines are purged of air. Comments Do not overll. The Full Light will come on when at maximum capacity. 5. Operate the LCU for 3 to 5 minutes to make Add more coolant mixture, if certain all the air has been purged from the lines. necessary. The LCU will stabilize temperature in about 30 minutes. 6. When the system is up and running, adjust the See the procedure on page 5. Penn Flow Control Valve Thermostat (controlled with a screwdriver slot) located inside the service panel. Maintain proper water level and temperature setting. The Fill and Full Lights will be your guide to maintaining proper coolant. Adjust the operating temperature according to the procedure on page 5.

7.

Operation

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3
How to Adjust the Temperature of the LCU
After the LCU is installed and operating, the operating temperature will have to be adjusted. Use the following procedure to adjust the operating temperature of the LCU. Step 1. Procedure Read the temperature at the thermometer on the top panel of the LCU. Comments See Figure 3-1. The temperature should be 33C 2C (90F 2F) 2. If the temperature is outside the specied operating range, adjust the Penn Flow Control Valve Thermostat. See Figure 3-2. The adjustment mechanism is a screwdriver slot inside the service panel. Allow approximately 30 minutes for the unit temperature to stabilize.

3.

Turn the Penn Flow Control Valve Thermostat clockwise to lower the temperature. Turn the Penn Flow Control Valve Thermostat counterclockwise to raise the temperature.

101333-003

How to Adjust the Temperature of the LCU

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SENSOR WATER TEMPERATURE

ON

OFF

FULL

FILL

ABB
Figure 3-1 Liquid Cooling Unit, Top View

COW

Thermometer Adjustment Slot

Figure 3-2 Penn Control Thermostat

How to Adjust the Temperature of the LCU

CW

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4
Maintenance
Preventive Maintenance for the LCU consists of the following checks: Preventive Maintenance Visually inspect all connections to and from the LCU for leaks. Visually check the coolant uid for signs of contamination. Corrective Action Repair any leaks by tightening or replacing ttings. The coolant uid should be colorless. If the uid is not colorless, drain the unit and replace the coolant uid. See page 20 for the procedure to drain and rell the LCU (see Figure 6-2 on page 21). If the lter appears clogged, replace it. Part number 101544-001. If it is necessary to replace the ow switch, refer to the procedure on page 30. Visually inspect the external 50 micron lter to make certain it is clean. Verify that the coolant uid is circulating through the sensor heads. This can be done by opening the reservoir tank and looking for signs of circulation. OR This can also be accomplished by verifying the operation of the ow switch. Put an ohmmeter across terminal pins 9 and 10 on terminal blocks. The ohmmeter will read 0 (a short) if there is no ow. The ohmmeter will read innity (an open) if there is ow.

FLOW SWITCH

RED RED 1234567891 1 1 012

101333-003

Maintenance

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Preventive Maintenance Make certain the uid level is between Fill and Full.

Visually Inspect The Fill and Full Lights The Fill Light will come on when the LCU is below minimum acceptable level. The Full Light will come on when the LCU has reached the maximum ll capacity.

Make Certain the LCU is operating at the correct temperature. Make certain the area around the LCU is free of debris.

The LCU digital thermometer The area around the LCU, the vents on the underside of the unit

If the LCU requires cleaning of the external surface, use a damp cloth and a mild detergent for the wash. Do not wash the inside of the LCU. The LCU contains a 240 Volt AC power supply. You could severely injure yourself if you attempted to wash the inside of the unit while it is connected to the power.

Maintenance

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5
Troubleshooting
Symptom There is no uid ow through the LCU to the sensor. Possible Cause Corrective Action The power breaker to the LCU Turn On power to the LCU. is off. The power switch is off. Turn On the power switch. The power switch is defective. Replace the power switch. See page 23. The pump is defective. Replace the pump. See page 31. Repair the leaky connection. Remove restrictions from the tubing. Fill the tank. See Operation on page 3.

There is a leaky connection.

The tubing is clogged or pinched. The tank is empty.

101333-003

Troubleshooting

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Symptom There is no water ow from the drain on the LCU.

Possible Cause There is no water pressure to the LCU.

Corrective Action Customer to supply water at minimum pressure of 40 psi and ow rate of at least 10 gph. See page 14. Open the valve.

The valve from the customer water supply to the LCU is closed.

The external 50 micron lter is Replace the lter. clogged (P/N 101544-001). The Penn Flow Control Valve Replace the ow contol valve. is defective. See page 28. Pressure regulator defective Replace pressure regulator. See page 29. Water in reservoir is below 33C (90F).

Penn Flow Control Valve closed

The Fill Light is On.

The uid level is below the Fill the reservoir. minimum acceptable level or the reservoir is empty.

The level switch is defective. Replace the level switch. See page 30. The Full Light is Off and The level switch is defective. Replace the level switch. See the uid level is above the page 30. Light is defective coils. Replace light. See page 22.

The Full Light is On and Level switch is defective the uid level is below the coils The LCU leaks. Loose or cracked ttings

Replace level switch. See page 30. Check the ttings at the reservoir and pump.

10

Troubleshooting

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Symptom The thermometer does not display a proper temperature.

Possible Cause

Corrective Action

The thermometer probe is out Place the thermometer probe of the sensing tube. back in the tube. See page 25. The thermometer is defective. Replace the thermometer. See page 25. The power supply is not delivering the 6 Volts direct current to the thermometer. The thermometer power supply is defective. Use a voltmeter to verify the voltage going to the thermometer. See page 7. Replace the thermometer power supply. See page 24.

The LCU leaks. The sensor goes to the off-sheet position. This will only occur if the Flow Switch is connected to the system.

Adjust the Penn Control The thermometer is out of the Thermostat. See page 5. operating range. Loose or cracked ttings. Check the ttings at the reservoir and pump. The LCU is not sending the Check for ow to the proper ow to the sensor(s). sensor(s). Make certain the ow switch is operating correctly. Normally the ow switch contacts are open when there is a low ow (or no ow) to the sensor head. The ow switch contacts close when there is acceptable ow to the sensor heads. Refer to page 12 for the troubleshooting procedures for the Flow Switch. Check for loose wiring connections. Tighten as necessary.

101333-003

Troubleshooting

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Troubleshooting the Flow Switch

Normally the Flow Switch contacts are open when there is low ow (or no ow) to the sensor. The Flow Switch contacts are closed when there is sufcient ow to the sensor. Use the following procedure to troubleshoot the Flow Switch. Step 1. 2. 3. Procedure Disconnect the wires from TS 9 and TS 10 to the system computer. Comments See Figure 5-1.

Use a digital volt meter across TS 9 and TS 10 to verify See Figure 5-1. continuity in the Flow Switch. Turn Off the LCU and check for continuity. When the LCU is Off and the coolant is not circulating, there will not be continuity in the circuit. If the circuit indicates continuity, refer to Step 5. When the LCU is On and the coolant is circulating, there will be continuity in the circuit. If the circuit indicates no continuity, refer to Step 5.

4.

Turn On the LCU.

5. 6. 7. 8. 9.

Turn Off the LCU. Unscrew the top of the Flow Switch. Determine if the magnetically equipped piston is stuck. If the piston is stuck, loosen it. Close the Flow Switch and repeat Steps 2 through 4. If the Flow Switch still does not respond, replace it. This piston is spring loaded.

FLOW SWITCH

RED RED 123456789 11 1 01 2

To the system computer

Figure 5-1 Test Points for the Flow Switch

12

Troubleshooting

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Troubleshooting the Digital Thermometer

When you order a replacement thermometer, you will receive: the digital thermometer, the wiring and sensing probe assembly, and the thermometer power supply. Use the following procedure to determine if the thermometer failure was due to a failed thermometer, wiring, or the power supply. This will save you time, instead of replacing all three parts you may only have to replace the failed item. Step 1. Procedure Plug in the new thermometer to the existing wiring. Comments If the thermometer works then neither the wiring and probe assembly nor the power supply need to be replaced. Replace the power supply, if it is not working.

2.

Use a voltmeter to check the thermometers power supply. The power supply should be sending 6 volts to the thermometer. If the power supply is working and it is connected to the new thermometer, yet the thermometer is not working, replace the wiring and probe assembly.

3.

101333-003

Troubleshooting

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Operating Parameters for the LCU

The following list of requirements are to be met by the customer to ensure proper operation of the LCU. Parameter Water Pressure Specication

The minimum water pressure is 45 pounds per square inch gauge (PSIG). Flow Rate The minimum ow rate is 37.9 liters per hour (10 gallons/hour). Water Temperature The maximum acceptable temperature for customer supplied water is 29C (85F). Water Quality Clean: Drinking water purity pH: 6.0 to 8.0 Hardness: Less than 85 ppm Ambient Temperature The maximum ambient temperature is 43C (110F). Humidity: 5% to 90%

Wiring Diagram
See Figure 5-2 on page 15 for a schematic of the LCU wiring.

14

Troubleshooting

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208 240 V

ON/OFF SWITCH
1 2 4 3 BLU BRN BLU BRN

POWER

BRN BLU BRN BLU

2 1 3 4

To Switch

GRN

YEL-GRN

BLU

1 2 3 4

BLU BRN

FLOAT

BRN

BRN

BRN BLU

BLU

PUMP
BRN

BLU

5 6 7 8 9
RED

BLK

RED RED YELLOW RED BLK BLK RED BLK RED

RED

FLOW SW

WHITE

10 11

PROBE

RED

G FULL

R FILL

GRAY

RED

12
.5 5 x2 .5 4 WHITE

RED

Indicator Lights

RED

240 V TO 6 V.D.C.

BRN BLU

POWER SUPPLY

DIGITAL THERMOMETER

Note: If the mill cannot meet the minimum water temperature, a pre-chiller must be used. Figure 5-2 Wiring Diagram for the LCU

101333-003

Troubleshooting

15

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6
Replacement Procedures
All service to the LCU must begin with the procedure, Preparing the LCU for Servicing and end with the procedure, Connecting the LCU After Servicing Failure to follow these procedures could result in injury to yourself or damage to the equipment.

101333-003

Replacement Procedures

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Preparing the LCU for Servicing

Step 1. 2. 3. 4. 5. Procedure Turn Off power from the sensor. Turn Off power to the LCU. Turn Off the power switch on the LCU (top panel). Turn Off uid and cold water valves. Drain the reservoir, if necessary, for repair. See page 20. See Figure 6-1. Comments

SENSOR WATER TEMPERATURE

ON

OFF

FULL

FILL

ABB

Figure 6-1 LCU, Top View

18

Replacement Procedures

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Connecting the LCU After Servicing

Step 1. 2. 3. 4. 5. Procedure Make certain all electrical and plumbing connections are secure. Turn On valves. Fill reservoir, if empty. Turn On power to the LCU. Turn On the power switch on the LCU (top panel). See Figure 6-1. See page 20. Comments

SENSOR WATER TEMPERATURE

ON

OFF

FULL

FILL

ABB

101333-003

Replacement Procedures

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Drain and Rell the LCU

Metal edges on the LCU may be sharp and can cause injury if not properly handled.

Step 1. 2.

Procedure Before servicing the LCU, complete the Preparation for Service Procedures. Drain coolant mixture from reservoir by removing the plug on bottom lower right side of unit. (Use socket wrench size 1 1/8 in.)

Comments See page 18. Ethylene glycol is toxic. Dispose of properly according to local regulations. See Figure 6-2.

3. 4. 5.

Apply a pipe sealant to the threads of the plug. Replace the plug. Rell the reservoir. (See Chapter 2, Operation) The coolant mixture should be 25 percent ethylene glycol and 75 percent potable water. 2.6 liters of ethylene glycol to 7.8 liters of water or 0.69 gallons of ethylene glycol to 2.06 gallons of water. CAUTION: Do not substitute automotive antifreeze for ethylene glycol Tank capacity is 10.4 liters (2 3/4 U.S. gallons).

20

Replacement Procedures

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Fill Coolant Mixture

FROM SENSOR

208-240 V. 50/60 HZ

TO SENSOR

DRAIN

COLD WATER INLET

Drain

Figure 6-2 Liquid Cooling Unit, Front View Note: If Ethylene glycol cannot be obtained locally, it can be ordered from stock. The part number is 101447-001 (5 gallons).

101333-003

Replacement Procedures

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Full Light or Fill Light Replacement

Step 1. 2. 3. 4. 5. 6. 7. 8. Procedure Comments Before servicing the LCU, complete the Preparation for See page 18. Service Procedures. Remove the service panel. Remove the Full Light (Fill Light) wires from terminal See Figure 6-3. block. Snap the Full Light (Fill Light) out of top panel by pushing upward out of panel. Install the new Full Light (Fill Light). Connect the Full Light (Fill Light) wires to the terminal block. Replace the wire ties. Connect the LCU after service See page 19.

Indicator Lights
Fill Full

RED

BLACK

BLACK

RED

1 2 3 4 5 6 7 8 9 10 11 12

Figure 6-3 Full Light Wiring

22

Replacement Procedures

101333-003

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Power Switch Replacement

Step 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Procedure Before servicing the LCU, complete the Preparation for Service Procedures. Remove the service panel. Loosen the protective boot from the switch. Remove the power switch. Slide protective sleeve off terminals. Remove the wires from power switch. Assemble wires to new switch. Replace protective sleeve. Install the new power switch. Put the switch in the Off position. Replace protective boot and tighten nut. Hold switch straight. Prepare the LCU for service. Replace the service panel. See page 19. Mark the wire. Use a 5/8-inch nut driver or wrench. Check the switch position. Comments See page 18.

101333-003

Replacement Procedures

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Regulated Power Supply Replacement

Step 1. 2. 3. Procedure Before servicing the LCU, complete the Preparation for Service Procedures. Remove the service panel. Remove brown and blue power wires from the terminal blocks going to the regulated power supply next to the terminal block. Remove red and white wire from regulated power supply. Remove the two #6-32 screws holding regulated power supply to tank support bracket (Do not discard). Install the new regulated power supply. Use the two #6-32 screws holding the regulated power supply to the tank support bracket. See Figure 6-4. New power wire will have to be cut. Use defective part as template. Comments See page 18.

4. 5.

6.

7. 8.

Connect red (+) and white (-) wire to the new See gure required for LCU. regulated power supply from the terminal strip. Connect the brown and blue power wires from the regulated power supply to the terminal block. Tighten screws. Prepare LCU for service. Replace the service panel. See gure required for LCU.

9. 10.

See page 19.

DIGITAL THERMOMETER

PROBE

Gray Red 240 V TO 6V.D.C. -+

REGULATED POWER SUPPLY

1 2

4 5

7 8

9 10 11 12

Brn

Blu Red

Figure 6-4 Wiring for the Regulated Power Supply

24

Replacement Procedures

101333-003

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Digital Thermometer Replacement

Note: New thermometer power wires will have to be cut and stripped to length. Use the defective thermometer power wires as a template. Step 1. 2. 3. 4. Procedure Before servicing the LCU, complete the Preparation for Service Procedures. Remove the service panel. Remove the two screws holding the digital thermometer (Do not discard). Phillips screwdriver Comments See page 18.

Unplug the wires to the thermometer. Remove Check wires for cuts or the thermometer from underneath the top breaks. panel. Install the new digital thermometer. Install the two screws that will hold the new thermometer. Tighten screws securely. Plug in the wires to the thermometer. Prepare the LCU for service. Replace the service panel. Make sure looking tab is in place. See page 19.

5. 6. 7. 8. 9.

101333-003

Replacement Procedures

25

Proprietary Data: This document contains proprietary data of ABB Industrial Systems Inc. No disclosure, reproduction, or use may be made except by written permission.

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Reservoir Assembly Replacement

Step 1. 2. 3. 4. 5. 6. 7. 8. 9. Procedure Before servicing the LCU, complete the Preparation for Service Procedures. Drain the reservoir. Remove the service panel. Remove the ll cap. Remove the six 10-32 screws holding top panel in place. Lift the top panel up and swing it to the side. Loosen the hose clamp from the hoses to the reservoir. Remove all hoses, suction-tube assembly nut and the ow valve from reservoir. Remove the 10-32 screw and the spacer from the reservoir located at the tank support bracket. Remove the level switch wires (black-yellowred) from the terminal block. Remove the tank from the LCU. Slide the reservoir back to clear suction tube assembly and lift up. Be sure all screws, spacers, wires, and nuts are securely fastened. Comments See page 18. See page 20.

10. 11.

12.

Install the new reservoir in reverse order.

13. 14. 15.

Replace the level switch wires (black-yellow- See Figure 6-5. red) from the terminal block. Replace all hoses, the suction-tube assembly and the ow valve to reservoir tubes. Replace the 10-32 screw and the spacer from the reservoir located at the tank support bracket. Tighten the hose clamps to reservoir tubes. Replace the top panel and six screws. Rell the Reservoir. Turn On power. Replace the ll cap. Replace the service panel Check wire connections on top panel. See page 20.

16. 17. 18. 19. 20. 21.

26

Replacement Procedures

101333-003

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For ABB Employee Use Only

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Blk Red L-1 Yellow L-2

L-2

1 2

3 4

6 7

8 9 10 11 12
L-1

Figure 6-5 Wiring for the Reservoir Float

101333-003

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For ABB Employee Use Only

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Flow Control Valve Replacement

Step 1. 2. 3. 4. 5. 6. Procedure Before servicing the LCU, complete the Preparation for Service Procedures. Drain the LCU unit. Remove the service panel. Remove the compression tting nut holding ow valve to reservoir. Remove the hose clamp and remove the hose from the plastic tting. Remove the thermostat from suction tube assembly. 15/16 in. open end wrench 1/4 in. nut driver Loosen the small nut (1/2 in. wrench) rst, then, loosen the larger nut (7/8 in. wrench). Comments See page 18. See page 20.

7.

Remove the ow valve and the thermostat from NOTE: This valve is fragile. Do not apply pressure to areas the LCU. other than the casting. Replace the thermostat. NOTE: After large nut (7/8 in.) is tightened into suction tube assembly, slide capillary tube into position and measure from top of large nut to top of 2 1/2 exible solder tting (2 1/2 in.). Hold tube and tighten small (1/2 in.) nut securely. See assembly view. Make certain to apply pipe sealant to threads on thermostat tting nut (7/8 in.) before assembling back into suction tube assembly. Tighten securely The capillary tube that is connected to the thermostat will have to be coiled prior to assembly. Wrap the capillary tubing around a two-inch diameter object to avoid kinking it. Tighten securely. Reset the control valve according to the procedure on page 35.

8.

9.

Replace the ow control valve to reservoir.

10. 11.

Rell the unit. Prepare the LCU for service.

See page 20. See page 19.

28

Replacement Procedures

101333-003

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Water Pressure Regulator Replacement

Step 1. 2. 3. Procedure Before servicing the LCU, complete the Preparation for Service Procedures. Shut off the water supply. Remove the service panel. Comments See page 18. The pressure regulator is located inside the unit on the cold water inlet bulkhead tting inside the LCU. See Figure 6-6. 1/4 in. nut driver

4. 5. 6. 7. 8. 9. 10. 11.

Remove the hose clamp and hose. Unscrew the pressure regulator from the GHT plastic tting (turn counterclockwise). Remove the 1/2-inch NPT to hose barb 90 15/16 in. box wrench elbow from regulator. Replace the 1/2-inch NPT to the hose barb 90 Use pipe sealant on the threads. elbow on the new regulator. Replace regulator on plastic tting (GHT). Replace the hose and hose clamp. Rell LCU. Prepare the LCU for service. See page 20. See page 19.

Fill Coolant Mixture

FROM SENSOR

208-240 V. 50/60 HZ

TO SENSOR

DRAIN

COLD WATER INLET

Drain

Figure 6-6 Liquid Cooling Unit, Rear View

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Replacement Procedures

29

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For ABB Employee Use Only

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Flow Switch Replacement

Step 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Procedure Before servicing the LCU, complete the Preparation for Service Procedures. Drain the LCU unit. Remove the service panel. Remove the hose clamp and hose from the discharge tting. Unscrew the ow switch from the sensor tube assembly. Remove the two red wires from the terminal block. Screw the new ow switch to the sensor tube assembly. Replace the two red wires from the terminal block. Replace the hose clamp and hose to the discharge tting. Rell the LCU. Prepare LCU for service. See page 20. See page 19. Check the O-ring for cuts. See Figure 6-7. 1/4 in. nut driver See Figure 6-7. Comments See page 18. See page 20.

Flow Switch

DANGER
HIGH VOLTAGE

Figure 6-7 Flow Switch

30

Replacement Procedures

101333-003

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For ABB Employee Use Only

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Pump Assembly Replacement

Step 1. 2. 3. 4. Procedure Before servicing the LCU, complete the Preparation for Service Procedures. Drain the LCU unit. Remove both service panels. Remove the wires from the terminal block. Terminal numbers 3 (brown) and 4 (blue) and ground. Only hand tighten. 5/16 in. nut driver 7/16 in. wrenches top and bottom Comments See page 18. See page 20.

5. 6. 7. 8. 9. 10.

Remove union from the suction side of the pump. Remove hose, sensor tube, and ow switch assembly from discharge side of the pump. Remove the four 1/4-20 bolts and nuts from the base assembly. Remove the pump assembly. Remove tting from the suction side of the pump.

Reassemble the tting to the suction side of the Do not over tighten. replacement pump. Pipe sealant on threads. Replace the new pump assembly. Replace the four 1/4-20 bolts and nuts from the 7/16 in. wrenches top and base assembly. bottom. Replace the union to the suction side of the pump and hand tighten.. Replace hose, sensor tube and ow switch assembly to discharge side of pump. Replace the wires from the terminal block and remove ground wire from the tank support bracket. Upon replacement of the new pump, purging of the pump will be necessary. Turn pump off, wait 10 seconds and turn pump back on. Rell the LCU. Replace both service panels. Prepare the LCU for service. See page 19. Tighten hose clamp with 5/16 in. nut driver Terminal numbers 3 (brown) and 4 (blue) and ground. This will release any air still trapped in pump. Repeat if necessary. See page 20.

11. 12. 13. 14. 15.

16.

17. 18. 19.

101333-003

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31

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For ABB Employee Use Only

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Top Panel Replacement

Step 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Procedure Prepare the LCU for service. Remove both service panels. Remove ll cap. Remove switch boot from switch. Remove switch from underneath top panel. Unscrew two screws holding thermometer to top panel. Remove the thermometer from underneath top panel. Remove the ll and full light wires from Note wire locations for terminal block. Remove lights from top panel. reassembly. Remove the six screws (do not discard). Remove the top panel. Assemble the new top panel and secure with six screws. Reassemble the lights, switch, and thermometer in reverse order. Prepare the LCU for service. Replace the service panel. See page 19. Phillips screwdriver Phillips head driver 5/8 in. nut driver Comments See page 18.

32

Replacement Procedures

101333-003

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For ABB Employee Use Only

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Back Panel Replacement

Step 1. 2. 3. 4. 5. 6. 7. 8. Procedure Prepare the LCU for service. Remove the service panels. Remove the six screws (three in base and 3 in top panel). Slide the back panel off the base. Pull the back panel down to remove from the top panel. Panel is now free. Replace new back panel in reverse order. Prepare the LCU for service. Replace the service panels. See page 19. Do not discard these screws. Comments See page 18.

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33

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For ABB Employee Use Only

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Front Panel Replacement

Step 1. 2. 3. 4. 5. 6. 7. 8. Procedure Prepare the LCU for service. Drain the LCU. Remove the service panels. Remove six screws in front panel (three in the base and three in the top panel). Loosen the hose clamps at copper tubes (reservoir) in two places Loosen the hose clamp at ows switch tting. CAUTION: Do not pry hard on tting. Unscrew the water regulator from the front panel. Remove front panel assembly from reservoir tubes and ow switch tting. Pull the front panel down from under the top panel. Replace the new front panel assembly in reverse order. Rell the LCU for service. Prepare the LCU for service. See page 20. See page 19. Phillips screwdriver 1/4 in. nut driver 1/4 in. nut driver Comments See page 18. See page 20.

9. 10. 11.

34

Replacement Procedures

101333-003

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For ABB Employee Use Only

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7
Replacement Parts List
Part Number 101536-101 101536-202 101536-103 101536-104 101536-105 101536-206 101536-107 101536-108 101536-109 101536-110 101536-211 101536-112 101536-113 101536-114 101536-115 101536-002 086519-001 101544-001 101543-001 101610-001 SWITCH PUMP ASSEMBLY REGULATOR 45 PSI TANK CAP FLOW CONTROL VALVE THERMOMETER/POWER SUPLY FILL LIGHT - Red FULL LIGHT - Green FLOW SWITCH SWITCH BOOT SIDE PANEL TOP PANEL ASSEMBLY BACK PANEL ASSEMBLY FRONT PANEL ASSEMBLY RESERVOIR ASSEMBLY LCU, COMPLETE ASSEMBLY EXPLODED VIEW OF THE LCU 50 MICRON FILTER 50 MICRON FILTER HOUSING PRE-CHILLER (OPTIONAL) Description

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Index
B
Back Panel Replacement Procedure, 33

R
Regulated Power Supply Replacement Procedure, 24 Replacement Parts List, 35 Replacement Procedures, 17 back panel, 33 connecting LCU after servicing, 19 digital thermometer, 25 drain and refill, 20 flow control valve, 28 flow switch, 30 front panel, 34 full light and fill light, 22 power switch, 23 preparing LCU for servicing, 18 pump assembly, 31 regulated power supply, 24 reservoir assembly, 26 top panel, 32 water pressure regulator, 29 Reservoir Assembly Replacement Procedure, 26

C
Connecting LCU after Servicing, 19

D
Digital Thermometer Replacement Procedure, 25 Digital Thermometer, Troubleshooting, 13 Drain and Refill, 20

F
Flow Control Valve Replacement Procedure, 28 Flow Switch Replacement Procedure, 30 Flow Switch, Troubleshooting, 12 Front Panel Replacement Procedure, 34 Full Light and Fill Light Replacement Procedure, 22

M
Maintenance, 7

T
Temperature Adjustment, 5 Theory of Operation, 1 Top Panel Replacement Procedure, 32 Troubleshooting, 9 digital thermometer, 13 flow switch, 12 operating parameters, 14 wiring diagram, 14

O
Operating Parameters, 14 Operation, 3

P
Power Switch Replacement Procedure, 23 Preparing LCU for Servicing, 18 Pump Assembly Replacement Procedure, 31

W
Water Pressure Regulator Replacement, 29 Wiring Diagram, 14

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User Comments Request Form

We appreciate your comments on this manual. Please call or send comments to: ABB Industrial Systems Inc. Pulp and Paper BU Technical Publications Department 650 Ackerman Road Columbus, Ohio 43202-9972 Attention: Technical Documentation Supervisor (614) 261-2000

Comments can also be sent via FAX to: Technical Documentation Supervisor (614) 261-2113

101333-003

Liquid Cooling Unit Reference Manual