Conair Water System UGE014 0999 User Manual

WARNING - Reliance on this Manual Could Result in Severe Bodily Injury or Death!  
This manual is out-of-date and is provided only for its technical information, data and capacities. Portions of this manual  
detailing procedures or precautions in the operation, inspection, maintenance and repair of the product forming the subject  
matter of this manual may be inadequate, inaccurate, and/or incomplete and cannot be used, followed, or relied upon.  
Contact Conair at [email protected] or 1-800-654-6661 for more current information, warnings, and materials about  
more recent product manuals containing warnings, information, precautions, and procedures that may be more adequate  
than those contained in this out-of-date manual.  
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It’s a good idea to record the model and serial number(s) of  
your equipment and the date you received it in the User  
Guide. Our service department uses this information, along  
with the manual number, to provide help for the specific  
equipment you installed.  
Please record your  
equipment’s model and  
serial number(s) and  
the date you received it  
in the spaces provided.  
Please keep this User Guide and all manuals, engineering  
prints and parts lists together for documentation of your  
equipment.  
Date:  
Manual Number: UGE014/0999  
Serial number(s):  
Model number(s):  
DISCLAIMER: The Conair Group, Inc., shall not be liable for errors  
contained in this User Guide or for incidental, consequential dam-  
ages in connection with the furnishing, performance or use of this  
information. Conair makes no warranty of any kind with regard to  
this information, including, but not limited to the implied warranties  
of merchantability and fitness for a particular purpose.  
Copyright 1999  
All rights reserved  
THE CONAIR GROUP, INC.  
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INTRODUCTION . . . . . . . . . . . . . . . . . . .1-1  
TABLE OF  
CONTENTS  
Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . .1-2  
How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . .1-2  
Your responsibilities as a user . . . . . . . . . . . . . . . . . . . . . .1-2  
ATTENTION: Read this so no one gets hurt . . . . . . . . . . .1-3  
DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1  
What is the WT and ST tank? . . . . . . . . . . . . . . . . . . . . . .2-2  
How it works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3  
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4  
Features and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5  
INSTALLATION . . . . . . . . . . . . . . . . . . . .3-1  
Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2  
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-3  
Aligning the tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4  
Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . .3-5  
Connecting the water and air supplies . . . . . . . . . . . . . . . .3-6  
Connecting a chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7  
Testing the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8  
OPERATION . . . . . . . . . . . . . . . . . . . . . .4-1  
Preparing for operation . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2  
Starting the WT/ST tank . . . . . . . . . . . . . . . . . . . . . . . . . .4-4  
Stopping the WT/ST tank . . . . . . . . . . . . . . . . . . . . . . . . .4-4  
MAINTENANCE . . . . . . . . . . . . . . . . . . . .5-1  
Preventative maintenance schedule . . . . . . . . . . . . . . . . . . .5-2  
Replacing gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3  
Lubricating the tank compartments . . . . . . . . . . . . . . . . . .5-3  
Cleaning the tank and spray bars . . . . . . . . . . . . . . . . . . . .5-3  
Checking electrical connections . . . . . . . . . . . . . . . . . . . . .5-4  
TROUBLESHOOTING . . . . . . . . . . . . . . . .6-1  
Before beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2  
A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2  
Product quality problems . . . . . . . . . . . . . . . . . . . . . . . . . .6-3  
Water system problems . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3  
APPENDIX  
Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1  
Warranty information . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2  
UGE014/0999  
Water/Spray Tanks  
i
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INTRODUCTION  
Purpose of the User Guide . . . .1-2  
How the guide is organized . . . .1-2  
Your responsibilities as a user .1-2  
ATTENTION: Read this so  
no one gets hurt . . . . . . . . . . .1-3  
UGE014/0999  
Water/Spray Tanks  
1-1  
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This User Guide describes the Conair WT and ST series  
water/spray tanks. It explains step-by-step how to install,  
operate, maintain and repair this equipment.  
PURPOSE OF  
THE USER  
GUIDE  
Before installing this product, please take a few moments  
to read the User Guide and review the diagrams and safety  
information in the instruction packet. You also should review  
manuals covering associated equipment in your system. This  
review won’t take long, and it could save you valuable instal-  
lation and operating time later.  
Symbols have been used to help organize the User Guide and  
call your attention to important information regarding safe  
installation and operation.  
HOW THE  
GUIDE IS  
ORGANIZED  
Symbols within triangles warn of conditions that could  
!
be hazardous to users or could damage equipment.  
Read and take precautions before proceeding.  
Numbers within shaded squares indicate tasks or steps  
to be performed by the user.  
1
A diamond indicates the equipment’s response to an  
action performed by the user.  
An open box marks items in a checklist.  
A shaded circle marks items in a list.  
You must be familiar with all safety procedures concerning  
installation, operation and maintenance of this equipment.  
Responsible safety procedures include:  
YOUR  
RESPONSIBILITY  
AS A USER  
Thorough review of this User Guide, paying particular  
attention to hazard warnings, appendices and related  
diagrams.  
Thorough review of the equipment itself, with careful  
attention to voltage sources, intended use and warning  
labels.  
Thorough review of instruction manuals for associated  
equipment.  
Step-by-step adherence to instructions outlined in this  
User Guide.  
Water/Spray Tanks  
UGE014/0999  
1-2  
INTRODUCTION  
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We design equipment with the users safety in mind. You can  
avoid the potential hazards identified on this machine by  
following the procedures outlined below and elsewhere in  
the User Guide.  
!
ATTENTION:  
READ THIS SO NO  
ONE GETS HURT  
WARNING: Improper installation,  
operation or servicing may result in  
equipment damage or personal injury.  
This equipment should be installed, adjusted,  
and serviced by qualified technical personnel  
who are familiar with the construction, opera-  
tion and potential hazards of this type of  
machine.  
All wiring, disconnects and fuses should be  
installed by qualified electrical technicians in  
accordance with electrical codes in your region.  
Always maintain a safe ground. Do not operate  
the equipment at power levels other than what  
is specified on the the machine serial tag and  
data plate.  
You should keep the area around the tank  
clean and free from pooling water. We recom-  
mend installing a grate or drain system beneath  
this equipment to prevent water from pooling  
around the tank.  
WARNING: Voltage hazard  
This equipment is powered by three-phase  
alternating current, as specified on the machine  
serial tag and data plate.  
A properly sized conductive ground wire from  
the incoming power supply must be connected  
to the chassis ground terminal inside the elec-  
trical enclosure. Improper grounding can result  
in severe personal injury and erratic machine  
operation.  
Always disconnect and lock out the incoming  
main power source before opening the electri-  
cal enclosure or performing non-standard oper-  
ating procedures, such as routine maintenance.  
Only qualified personnel should perform trou-  
bleshooting procedures that require access to  
the electrical enclosure while power is on.  
UGE014/0999  
Water/Spray Tanks  
INTRODUCTION 1-3  
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DESCRIPTION  
What is a WT or ST tank? . . . . .2-2  
How it works . . . . . . . . . . . . . . .2-3  
Specifications . . . . . . . . . . . . . .2-4  
Features and options . . . . . . . . .2-5  
UGE014/0999  
Water/Spray Tanks  
2-1  
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Conair Water and Spray Tanks are designed to provide addi-  
tional spray or flood cooling of extruded profiles, tubing and  
pipe, or as a primary spray or cooling tank. Leveling floor  
jacks and adjustment handwheels at both ends of the tank  
ensure proper alignment with the extrusion line.  
WHAT IS THE  
WT OR ST  
TANK?  
After an extrusion has been sized and solidified, it may  
require additional controlled cooling to obtain the desired  
characteristics.  
The WT water tank provides flood cooling. You can sub-  
merge the extrusion in heated water to slow the cooling rate,  
or in cool water to cool it more quickly. The internal plumbing  
configuration for flood cooling is designed to provide maxi-  
mum turbulence to break up the temperature strata that forms  
around the extrusion for optimum heat transfer. Support and  
hold-down rollers keep the buoyant extrusion in place as it  
passes through the tank.  
The ST spray tank reduces the buoyancy of the extrusion in  
the water and provides maximum heat transfer through evapo-  
ration by spraying water onto the hot extrusion surface. The  
extrusion can be held above the water level or submerged in  
the water in the spray compartment.  
Both WT and ST tanks have two compartments: a long water  
or spray compartment for controlled cooling of the extrusion,  
and a short air-wipe compartment for removing water from the  
pipe surface as it leaves the water or spray compartment.  
The water and spray compartments are sealed by gaskets on  
each end. Black wiping gaskets backed up by red support  
gaskets retain the flood and spray water.  
An optional closed water recirculation reservoir, pump and  
heat exchanger can interface with your portable chiller or cen-  
tral chiller for reduced water consumption.  
Water Spray Tanks  
UGE014/0999  
2-2  
DESCRIPTION  
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The extrusion enters the water or spray compartment after  
leaving the calibration tooling or a sizing tank. Simple support  
and hold-down rollers ar used to hold small diameter hollow  
forms in position as the extrusion passes through the tank.  
Contoured support and hold-down rollers usually are required  
for large hollow forms.  
HOW IT WORKS  
In a WT water tank, the extrusion is submerged in a flooded  
water compartment. Water enters the compartment through a  
quick fill valve or through one center-supply, drilled water  
header that is mounted along the top and back side of the  
compartment. The water level is controlled by a telescoping  
overflow standpipe.  
In the ST spray tank, the extrusion may be submerged or  
held above the water.  
All water enters the compartment  
through four center-supply water  
headers mounted at the four  
corners along the full length of the  
compartment. These water headers  
are drilled or equipped with spray  
heads. Each pair of spray headers  
has its own water supply valve.  
Water levels are controlled by the  
setting of the standpipe. When set  
low, the standpipe keeps the water  
level below the extrusion. When set  
high, the standpipe allows com-  
plete submersion of the extrusion  
in a flooded compartment.  
The extrusion passes from the water or spray compartment  
into an air-wipe compartment equipped with two, tubular air  
wiper rings connected to compressed air. Angled holes drilled  
in the wiper ring blasts air on the extrusion in the direction of  
the extruder to blow off surface water. A gasket seal at the  
exit of the air wipe compartment ensures the extrusion will be  
dry as it reaches the puller.  
UGE014/0999  
Water/Spray Tanks  
DESCRIPTION 2-3  
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SPECIFICATIONS  
A
B
V caster width  
22 in. {56 cm}  
E
D
C
MODEL  
TANK STYLE  
WT104  
104-16-2  
WT/ST105*  
105-16-2  
WT/ST107  
104-12--2  
104-21-2 WT105-12-2  
105-21-2  
107-16-2  
107-21-2  
Performance characteristics  
Tube/profile diameter in. {cm}  
Tank cross section in. {cm}  
Water flow gpm {liters/sec}  
Dimensions inches {cm}  
A - Overall height  
up to 2 {5.1}  
8 x 8 {20.3 x 20.3}  
35 {2.7}  
up to 4.5 {11.4}  
12 x 12 {30.5 x 30.5}  
35 {2.7}  
up to 6.625 {16.8}  
14 x 14 {35.6 x 35.6}  
50 {3.8}  
52 {132}  
42 {107}  
156 {396}  
144 {366}  
26.5 {67}  
52 {132}  
42 {1067}  
204 {518}  
192 {468}  
26.5 {67}  
52 {132}  
42 {1067}  
264 {671}  
252 {640}  
26.5 {67}  
53 {135}  
42 {1067}  
156 {396}  
144 {366}  
26.5 {67}  
53 {135}  
42 {1067}  
204 {518}  
192 {468}  
26.5 {67}  
53 {135}  
54 {137}  
42 {1067}  
204 {518}  
192 {468}  
26.5 {67}  
54 {137}  
42 {1067}  
264 {671}  
252 {640}  
26.5 {67}  
B - Height to centerline‡  
C - Overall length  
42 {1067}  
264 {671}  
252 {640}  
26.5 {67}  
D - Tank length  
E - Overall width  
Weight lbs {kg}  
Shipping  
950 {430}  
1050 {476}  
1150 {522} 1200 {544}  
1300 {590} 1400 {635} 1600 {726} 1700 {816}  
Water requirements  
Compressed air requirements  
80 gpm @ 60-70 psi {6.1 liters/sec @ 4.8-5.5 bars}; main supply line 1.5 in. NPT fitting  
maximum consumption 5 SCFM @ 80 psi {0.38 liters/sec @ 6.1 bars}  
SPECIFICATION NOTES:  
MODEL  
TANK STYLE  
WT/ST109  
109-16-2 109-21-2  
ST114  
114-16-2 114-21-2  
ST118  
118-16-2 118-21-2  
These tables define stan-  
dard configurations only.  
Specifications can  
Performance characteristics  
Tube/profile diameter in. {cm}  
Tank cross section in. {cm}  
Water supply flow gpm {liters/sec}  
Dimensions inches {cm}  
A - Overall height  
up to 8.5 {21.6}  
16 x 16 {40.6 x 40.6}  
60 {4.5}  
up to 13 {33.0}  
22 x 22 {55.9 x 55.9}  
60 {4.5}  
up to 18 {16.8}  
26 x 26 {66 x 66}  
60 {4.5}  
change without notice.  
ST models come with  
spray bars.  
* 12-foot tank available  
as WT water tank only.  
55 {138}  
42 {107}  
204 {518}  
192 {468}  
33 {83.8}  
55 {138}  
42 {1067}  
264 {671}  
252 {640}  
33 {83.8}  
58 {147}  
42 {1067}  
204 {518}  
192 {468}  
33 {83.8}  
58 {147}  
42 {1067}  
264 {671}  
252 {640}  
33 {83.8}  
60 {152}  
60 {152}  
42 {1067}  
264 {671}  
252 {640}  
33 {83.8}  
B - Height to centerline‡  
C - Overall length  
D - Tank length  
E - Overall width  
42 {1067}  
204 {518}  
192 {468}  
33 {83.8}  
† Centerline height is  
adjustable 2 inches.  
Weight lbs {kg}  
Shipping  
1800 {816} 1900 {862}  
2100 {953} 2200 {998} 2600 {1179} 2755 {1247}  
Water requirements  
Compressed air requirements  
80 gpm @ 60-70 psi {6.1 liters/sec @ 4.8-5.5 bars}; 1.5 in. NPT fitting  
maximum consumption 5 SCFM @ 80 psi {0.38 liters/sec @ 6.1 bars}  
ELECTRICAL REQUIREMENTS: Electrical connections are required only if the optional water recirculation package  
and heat exchanger is used. See wiring diagrams supplied with the equipment for voltage and amp draws.  
Water/Spray Tanks  
UGE014/0999  
2-4  
DESCRIPTION  
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FEATURES AND  
OPTIONS  
Hinged fiberglass cover  
(optional)  
Stainless steel tank  
Overflow  
collector  
Three-plane adjustment  
(optional)  
Air wipe  
compartment  
Recirculation pump  
(optional)  
Heat exchanger  
(optional)  
Welded steel frame with  
casters and leveling jacks  
Recirculation reservoir  
(optional)  
Tank: The stainless steel, all-welded tank has two com-  
partments: a long water or spray compartment and a short  
air-wipe compartment. Spray header water connections are  
stainless steel fittings welded through the tank bottom. The  
air wipe compartment has two drilled copper blow-off rings  
mounted concentric to the extruded product. The rings are  
drilled at an angle to generate water blow-off forces oppo-  
site to the direction of extrusion flow. Air supply is  
through the front sidewall of the compartment. A throttling  
valve is supplied.  
Bulkheads are equipped with studs for applying gaskets.  
Black gaskets wipe the extruded product. Red gaskets pro-  
vide dynamic sealing.  
Tank Support: The tank support system provides for  
(1) accurate vertical positioning of each end of the tank to  
meet centerline height requirements,  
(2) for accurate horizontal positioning of each end of the  
tank to meet tank centerline alignment requirements, and  
(3) accurate axial positioning of the tank.  
The system is comprised of two basic elements: a micro-  
height adjusting system to move the tank up and down and  
a tank cradle system that cages the tank and carries means  
for horizontal and axial positioning.  
Water Supply System: Water is supplied from a short  
water supply header carried on the tank. A ball valve con-  
trols water to each spray header. This valve is used to mod-  
ulate water to the tank. On small water tanks with one  
spray header, the second valve is used for "quick fill". On  
long tanks a third ball valve directs water to an end port to  
assist in "quick fill".  
UGE014/0999  
Water/Spray Tanks  
DESCRIPTION 2-5  
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Tank Drain System: All tanks have overflow stand pipes  
that continuously carry modulating water to the drain with-  
out drain valving. To drain the tank quickly, one to three  
drains are supplied, depending on the tank length and tank  
size. Additional tank drains, controlled by gate valves,  
empty into the tank drain header pipe. The header pipe,  
made of rigid PVC with demented fittings, is attached to  
the base frame and slopes toward the extruder.  
FEATURES AND  
OPTIONS (CON.)  
The large drain size provides unrestricted water flow to the  
plant drains or plant water recovery system.  
Casters and Wheels: The tank base is supported at all four  
corners by vee grooved casters. Plain wheels are available.  
Leveling Jacks: After positioning the tank, it is necessary  
to anchor the tank against line forces. Two leveling jacks  
(floor locks) are provided on one side of the base, effective-  
ly anchoring the tank in place.  
Vertical Adjustment System: The tank support system is  
moved vertically up and down on each end to position the  
centerline and to level the horizontal plane. The cradle car-  
rying the tank rests on micro-height adjusting plate at each  
end. The cradle is caged axially by angles welded to the  
micro-height plates. The small handwheel horizontally  
mounted to each micro-height plate engages a worm gear to  
drive a vertically mounted threaded rod. When the hand-  
wheel is rotated, that end of the tank is moved up or down.  
The adjustment is self locking.  
Horizontal Adjustment Option: To allow side-to-side  
positioning, the sides of the cradle are moved away from  
the tank. Rotation of knobs, which drive threaded blocks  
beneath the tank, moves the tank side to side.  
Axial Adjustment Option: This option allows you to  
move the tank backward and forward (longitudinally) in a  
precise manner, with positive locking at any position. The  
tank is supported on caged solid rollers running in short  
tracks to allow easy movement. Rotation of the large hand-  
wheel produces axial motion of the tank, depending on the  
status of the detent arm. When the detent is disengaged, the  
shaft is free to turn and the tank will move toward the  
puller. When the detent is pushed in and engaged, the one  
way locking action of the bearing on the shaft prohibits  
shaft rotation and the tank is locked in position. The detent  
must be removed if tank movement toward the puller is  
desired.  
Water/Spray Tanks  
UGE014/0999  
2-6  
DESCRIPTION  
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Closed Water Recirculation System Option  
FEATURES AND  
OPTIONS (CON.)  
The system includes a reservoir (sump tank), pump and  
heat exchanger. .On a closed water pump system, spray  
water introduced into the tank through the spray headers is  
drained to a sump tank. The water is then pumped back to  
the spray water supply header for control by the header  
valves. The sump tank, filled from customer's water supply,  
has automatic water level control. The pump has a suction  
filter inside the sump tank at the pump port. The pump is  
mounted on the bottom tank frame members. Two pump  
choices are available: centrifugal and gear.  
The 5 Hp centrifugal pump has a capacity up to 60 GPM  
at 70 PSI, and is self protecting. It can be operated without  
damage with the spray header valves fully closed.  
The 2 Hp gear motor has a capacity of about 16 GPM. A  
relief valve on the output of the pump directs water to the  
tank to protect the pump if the spray header valves are fully  
closed.  
Sump Tank Option: On recirculating systems, a sump  
tank holds water for the open loop systems. Bottom tank  
frame members support the sump, which is caged but not  
anchored. The overflow PVC drain fitting is dual purpose,  
reversible. As installed, the NPTF is outboard for screwed  
piping. When the fitting is reversed, external piping may be  
cemented into the sweat end.  
Circulation Pump Option: A Crane circulating pump is  
normally used to move tank water across the optional  
immersion heating elements or optional cooling coils. The  
pump is hard piped to the tank and moves with it. Water  
flow is parallel to extrudate flow. The pump is operated at  
120 volts through a step down transformer with the primary  
at 230 or 460 volts, single phase, 60 HZ. Power require-  
ments are about 0.5 KVA.  
Immersion Heater Option: The 230 volt, 3 kW, single-  
phase tubular electric heater is a self contained unit with  
off-on control and a temperature setting control dial. The  
unit is mounted through the sidewall of the tank and  
extends into the space below the extrusion. A pump is  
applied to move the tank water over the heater tubes to  
modulate end-to-end water temperature. The immersion  
heater is supplied direct at 230 volts but requires a 3 KVA  
transformer at 460 volts. The transformer is mounted in the  
lower part of the tank frame. Care must taken to ensure that  
the heater tubes are always immersed during operation, and  
that the heater is turned off before draining tank water.  
UGE014/0999  
Water/Spray Tanks  
DESCRIPTION 2-7  
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Cooling Coils Option: Cooling coils remove heat buildup  
in water. Connections are made with bulkhead fittings  
through the rear wall of the tank, slightly above the high  
water level. Inlet and outlet connections are close together  
for easy connection to chilled water. When cooling coils are  
supplied, the cooling coils placed in the sump tank and the  
water tank are shaped to cover the bottom of the tank.  
Connections are NPTF.  
FEATURES AND  
OPTIONS (CON.)  
Tank Covers Option: Water tanks seldom require covers  
as there is little or no splashing. However, spray tanks with  
their cross spray patterns, may require covers.  
Thermometers Option: On water tanks, thermometers  
may be mounted through the tank sidewall to monitor water  
temperature in the tank. On a tank with a gear pump sys-  
tem, the thermometers are mounted through the sump tank  
sidewall to monitor temperatures in the sump that indicates  
the temperature of water to the tank.  
Water/Spray Tanks  
UGE014/0999  
2-8  
DESCRIPTION  
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INSTALLATION  
Unpacking the boxes . . . . . . . . .3-2  
Preparing for installation . . . . . .3-3  
Aligning the tank . . . . . . . . . . . .3-4  
Connecting the main  
power supply . . . . . . . . . . . . . .3-5  
Connecting the water and  
air supplies . . . . . . . . . . . . . . . .3-6  
Connecting a chiller . . . . . . . . . .3-6  
Testing the installation . . . . . . . .3-7  
UGE014/0999  
Water/Spray Tanks  
3-1  
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CAUTION: Exercise caution when moving the  
WT/ST tank. The tank may be lifted with a fork-  
lift or hoist and straps that have been positioned  
at the tank’s center of gravity.  
UNPACKING  
THE BOXES  
!
The WT/ST tank comes fully assembled in a single crate.  
Carefully uncrate the tank and its components.  
1
Remove all packing material, protective paper, tape,  
and plastic. Compare contents to the shipping papers to  
ensure that you have all the parts.  
2
Carefully inspect all components to make sure no  
damage occurred during shipping. Check all wire terminal  
connections, bolts, and any other electrical connections,  
which may have come loose during shipping. Immediately  
report any damage or missing components to the freight  
company that delivered the tank.  
3
Take a moment to record serial numbers and  
specifications in the blanks provided on the back of the  
User Guides title page. The information will be helpful  
if you ever need service or parts. The User Guide is in  
a folder inside the tank.  
4
5
You are now ready to begin installation.  
Complete the preparation steps on the next page.  
Installation Hardware Needed:  
wire strain relief (for recirculation package only)  
one plumb bob or laser bore sight  
one hex key wrench  
one flathead screwdriver  
flexible hose with 1.5 inch NPT coupling  
Water/Spray Tanks  
UGE014/0999  
3-2  
INSTALLATION  
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You will install the WT/ST tank on the extrusion line, down-  
stream of the extruder and any calibration/sizing equipment.  
PREPARING FOR  
INSTALLATION  
Make sure the installation area provides:  
1
A source of water. City, tower or chilled water may  
be used. Water supply flow should be about 80 gpm @  
60-70 psi {6.1 liters/sec @ 4.8-5.5 bars}.  
A grounded 3-phase power source supplying the  
correct current and voltage for the recirculation sys-  
tem on your tank. Check the serial tag for the correct  
amps and voltage. Electrical power is required only if  
you have the recirculation system option.  
Minimum clearance for safe operation and mainte-  
nance. The distance, or air gap, between the face of  
the die or sizing tank and the upstream end of the  
WT/ST tank may be up to 12 inches (305 mm). Allow  
at least 12 to 24 inches (305 to 610 mm) between the  
downstream end of the tank and the upstream end of  
the puller to roll the tank away from the extruder for  
maintenance.  
Determine the correct position for the tank on  
the extrusion line.  
2
There may be an additional cooling tank or an optional  
laser gauge/diameter gauge between the downstream end  
of the WT/ST tank and the puller. Allow 1 to 2 feet (305 to  
610 mm) between the WT/ST tank and an additional cool-  
ing tank. Allow 1 to 3 feet (305 to 914 mm) between the  
WT/ST tank and a laser gauge and between a laser gauge  
and the puller.  
Install v-rails. If your tank comes with v-groove cast-  
3
ers, you may choose to use v-rails to insure repeatable  
tank alignment. The overall length of the rails will be  
determined by equipment sharing the rails. The v-rails  
should be long enough to move all downstream equipment  
away from the extruder for removal of the screw.  
Typically, the rails should be 2 to 4 feet (610 to 1219 mm)  
longer than the WT/ST tank. The distance between the  
centers of the v-groove casters on standard WT/ST tanks is  
22 inches (558.8 mm). Optional widths may have been  
ordered.  
UGE014/0999  
Water/Spray Tanks  
INSTALLATION 3-3  
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CAUTION: To avoid personal injury or damage  
to the tank, you should lift and move the tank  
with a forklift or hoist and straps positioned at the  
tank’s center of gravity.  
ALIGNING THE  
TANK  
!
WARNING: Improper installation could  
result in equipment damage and severe  
personal injury from electrical shock .  
Electrical connections should be made only by  
qualified personnel. This machine requires a  
well-grounded circuit and three-phase alternat-  
ing current as specified on the data plate. If the  
correct power supply is not available, you must  
install a transformer between the building sup-  
ply and the machine. A properly sized conduc-  
tive ground wire from the power supply must be  
connected to the ground terminal on the tank.  
1
2
3
Position the tank downstream of the extruder.  
Place the tank inline with the extruder. Set the tanks  
v-groove casters on the v-rails, if present.  
Adjust the height of the tank to match the extrud-  
ers centerline height. Use a level and turn the hand wheels  
to adjust height at both ends of the tank.  
Adjust the horizontal (side-to-side) position of  
the tank. If you have the horizontal adjustment option,  
turn the handwheel to align the unit with other compo-  
nents in the extrusion line. Use a plumb bob or laser to  
guide the alignment.  
Water/Spray Tanks  
UGE014/0999  
3-4  
INSTALLATION  
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WARNING: Improper installation could  
result in equipment damage and severe  
personal injury from electrical shock .  
CONNECTING  
THE MAIN  
POWER  
Electrical connections should be made only by  
qualified personnel. This machine requires a  
well-grounded circuit and three-phase alternat-  
ing current as specified on the data plate. If the  
correct power supply is not available, you must  
install a transformer between the building sup-  
ply and the machine. A properly sized conduc-  
tive ground wire from the power supply must be  
connected to the ground terminal on the tank.  
Electrical connections are required only on WT/ST tanks with  
the optional water recirculation system and/or heat exchanger.  
Always refer to the wiring diagrams that came with your tank  
before making electrical connections. The diagrams show the  
minimum size main power cable required for you tank, and  
the most accurate electrical component information. The pro-  
cedure for making electrical connections willy vary according  
to the options ordered with the tank.  
Generally, you should:  
Disconnect and lock out the incoming main  
power source.  
1
Open the electrical enclosure.  
2
Connect the power and ground wires to the  
terminals indicated on the wiring diagram that came with  
your machine.  
3
4 Check every terminal screw to make sure wires are  
secure. Gently tug each wire. If a wire is loose, use a  
screwdriver to tighten the terminal.  
UGE014/0999  
Water/Spray Tanks  
INSTALLATION 3-5  
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The standard WT.ST tanks are designed for use with city,  
tower or chilled water supplies. You may choose to treat the  
water to prevent algae build-up.  
CONNECTING  
THE WATER AND  
AIR SUPPLIES  
WARNING: Do not use deionized water, brine  
or other corrosive water mixtures for the main water  
supply unless your tank has been specially designed  
for such mixtures. Consult a water treatment special-  
ist for the best way to prevent algae build-up without  
damaging the equipment.  
Connect the main water supply to the 11/2-inch  
NPT fitting on the tank.  
1
Connect the compressed air supply to the fitting  
on the tank air wipe compartment.  
2
You can connect a chiller to the tanks optional heat exchang-  
er to remove heat from the extrudate more efficiently.  
Typically, the tank comes with the 3/4 inch lines of the stan-  
dard tube and shell heater plumbed to the tanks water mani-  
fold. The 11/2 inch inlet and outlet of the heat exchanger can  
be used for the chiller.  
CONNECTING A  
CHILLER  
For maximum water flow:  
Connect the chiller To Processand From Processlines to  
the largest NPT fittings in the shell of the heat exchanger.  
To chiller  
From chiller  
To water manifold  
From water  
pump  
For maximum cooling efficiency:  
TIP: If you have a water  
supply with high mineral  
content, connect the chiller  
to the tube ends of the  
heat exchanger.  
Connect the chiller To Processand From Processlines to  
the smallest NPT tube ends of the heat exchanger.  
From water pump  
To chiller  
To water manifold  
From chiller  
Water/Spray Tanks  
UGE014/0999  
3-6  
INSTALLATION  
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Adjust the standpipe for the water level you  
want to maintain.  
TESTING THE  
INSTALLATION  
1
2
Turn water supply on and fill the tank.  
Water fills the tank to the water level you set.  
If you have a spray tank, water should enter the tank  
through the spray bars.  
Excess water flows through the drain lines.  
If you have the optional recirculation system:  
Turn water pump on.  
Press the REC START button.  
1
The pump draws water through the heat exchanger and  
into the upper tank.  
Check the pump for proper rotation. The pump  
rotation must match the direction indicated on the rotation  
sticker on top of the pump.  
2
WARNING: If a pump rotates in the wrong  
direction for more than a very short time, dam-  
age will occur.  
!
If the pump rotation is incorrect, turn off the pump and  
disconnect power. Swap any two of the three power source  
wires on the terminal block in the electrical enclosure.  
WARNING: Voltage Hazard  
Always disconnect and lock out the main power  
sources before making electrical adjustments.  
Electrical adjustments should be made only by  
qualified personnel.  
UGE014/0999  
Water/Spray Tanks  
INSTALLATION 3-7  
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OPERATION  
Preparing for Operation . . . . . . .4-2  
Starting the WT/ST tank . . . . . . .4-3  
Stopping the WT/ST tank . . . . . .4-3  
UGE014/0999  
Water/Spray Tanks  
4-1  
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The WT tank provides cooling through tank water flow, while  
the ST spray tank cools with water flow and water sprayed  
onto the extrusion Immersion rollers inside each tank cham-  
ber keep the extrusion positioned for even cooling.  
PREPARING FOR  
OPERATION  
Determine the cooling mode you will use.  
The best cooling mode and roller position for your profile  
depends upon your material and process.  
1
Immersion cooling: The extrusion should be fully  
immersed in the tank water. The immersion rollers are  
usually positioned above the extrusion to keep it sub-  
merged.  
Spray cooling: The extrusion is cooled by water  
sprayed over its surface. An inch or two of runoff  
water flows below the extrusion. The immersion  
rollers are usually positioned below the profile.  
Make sure the extruder and puller are ready.  
The extruder should be discharging melt or extrudate that  
is up to the correct temperature. Set the extruder and  
puller at minimum speed.  
2
3
Center the tank with the extrudate. During  
installation, you aligned the tank with the extrusion line.  
Before each operation of the tank, you should fine tune  
the height and side-to-side position of the tank to align it  
with the center of the extrudate.  
Height Adjustment:  
Looking down from above the tank, turn the small hand-  
wheel to move the tank toward or away from the operator  
side until it aligns with the center of the extrudate as it  
exits the die.  
Side to Side adjustment:  
Kneeling at the upstream end of the tank at eye level with  
the die, turn the large, spoked wheel to adjust the tank  
height until it aligns with the center of the extrudate.  
Turn on the water supply to fill the tank.  
Adjust the standpipe for the water level you want to main-  
tain. If you have the optional recirculation system, make  
sure the water level in the reservoir is above the pump  
input before proceeding.  
4
5
Move the tank downstream from the die. Use  
the large linear actuator handwheel to slide the tank about  
4-8 inches downstream from the die or additional sizing  
equipment.  
Water/Spray Tanks  
UGE014/0999  
4-2  
OPERATION  
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CAUTION:  
Hot surfaces.  
PREPARING FOR  
OPERATION  
Wear gloves to protect yourself from the hot  
extrudate and hot surfaces on the extruder.  
Thread the extrudate through the tank.  
Cut the extrudate off close to the die face and ball up the  
end using a soft-metal spatula or scraper. Walk the extru-  
date through the system, threading the extrudate through  
any calibration or sizing equipment, the water/spray tank  
and into the puller.  
6
7
Move the tank back upstream for normal  
operation. Turn the linear actuator handwheel to move  
the tank upstream to within 1 inch of the extruder die face,  
or to within 1 to 12 inches of the end of a sizing tank.  
Recheck the tank alignment. With the extrudate  
threaded, verify that the tank is precisely aligned with the  
center of the extrudate.  
8
9
Position the immersion rollers to prevent the  
extrusion from sinking or floating. Slide each  
roller a up or down to the desired position. The best posi-  
tion for the rollers depends upon your material, process  
and cooling mode.  
UGE014/0999  
Water/Spray Tanks  
OPERATION 4-3  
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Turn water pump on, if you have the optional  
recirculation system.  
STARTING THE  
WT/ST TANK  
1
After the tank has been filled, press REC START button.  
Start the other equipment in the extrusion line.  
2
3
Gradually increase line speed. Raise extruder rpms  
slowly until extrudate is close to the product desired.  
Wet tank rim lightly and close lid. Dip fingers  
4
5
into tank water and wet the tank rim to improve the seal.  
Adjust water flow and water levels. The best  
water flow rates and levels depend upon your material,  
process and cooling mode.  
NOTE: You should check profile size and surface  
finish at start up and periodically throughout pro-  
cessing. Check the size of the profile using an  
optional in-line laser gauge, ID or OD gauge. Check  
the surface finish for imperfections. See the  
TROUBLESHOOTING section for product quality prob-  
lems that could be related to the WT/ST tank.  
Tank operation is stopped by turning off the water pump.  
Extrudate will continue to move through the tank unless the  
entire extrusion line is shut down. A typical shutdown proce-  
dure is given below.  
STOPPING THE  
WT/ST TANK  
1
Move the tank downstream. While the material  
is still running, turn the large handwheel to move the tank  
away from the die.  
Lower extruder rpms.  
2
3
Cut the plastic off at the die with a soft metal  
spatula or scraper.  
Cover the tank entrance hole. Place one hand  
over the hole to limit water spillage when you stop the  
pump.  
4
Turn the water pump off. Press REC STOP.  
5
6
Drain the tank and reservoirs if the tank will  
not be used ore requires water system mainte-  
nance.  
Water/Spray Tanks  
UGE014/0999  
4-4  
OPERATION  
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MAINTENANCE  
Maintenance schedule . . . . . . . .5-2  
Replacing gaskets . . . . . . . . . . .5-3  
Lubricating tank components . .5-3  
Cleaning the tank and  
spray bars . . . . . . . . . . . . . . . .5-3  
Checking electrical  
connections . . . . . . . . . . . . . . .5-4  
UGE014/0999  
Water/Spray Tanks  
5-1  
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Normal operation of the WT/ST tank involves extended expo-  
sure of many components to minerals and other water system  
contaminants. These minerals and contaminants can produce  
deposits, scales, slime or algae that will reduce tank perfor-  
mance.  
PREVENTATIVE  
MAINTENANCE  
SCHEDULE  
To maintain the best performance, you should follow this  
maintenance schedule and develop an effective water treat-  
ment program.  
Weekly, or as often as needed.  
Inspect gaskets.  
Gaskets at the ends of the tank should be kept in good  
condition. Replace any gaskets that are excessively  
worn, cracked or torn.  
Drain and clean the tank.  
Remove any particles and wipe all surfaces thoroughly.  
Monthly  
Lubricate all threads, shafts, sliding components,  
linear actuator and bearings.  
Lubricate not only the grease fittings but coat shafts  
and other sliding surfaces with a seize-resistant bearing  
compound to prevent corrosion. You may need to  
lubricate more often than monthly.  
Drain and clean the reservoir.  
If you have the optional recirculation system, remove  
any particles and wipe all surfaces thoroughly.  
Clean the spray bars.  
Check for clogged holes. Rinse or use compressed air to  
remove blockage.  
Quarterly (every 3 months)  
Lubricate water pump bearing frame, motor and  
coupling.  
Refer to manufacturers instructions. Recheck pump  
alignment after performing any maintenance that  
requires moving the unit.  
Every 6 months  
Inspect power cords, wires and electrical  
connections.  
Check for loose wires, burned contacts, and signs of  
overheated wires. Check exterior power cords to the  
main power source and from the electrical box to the  
pumps. Check the ground wire. Replace any wire that  
appears damaged or has worn or cracked insulation.  
Water/Spray Tanks  
UGE014/0999  
5-2  
MAINTENANCE  
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To replace an end gasket:  
REPLACING  
GASKETS  
Remove the retaining rings. Loosen the wing nuts  
1
and lift off the ring that holds the gasket in place.  
Remove the damaged gasket and slide a new  
gasket over the studs. No sealant is required.  
2
Reassemble. Slip the retaining ring over the studs to  
3
cover the gasket. Tighten the wing nuts.  
Normal operation of the WT/ST tank creates many wet sur-  
faces. We recommend generous monthly lubrication of any  
threaded or sliding components involved in positioning the  
tank. Those components include the positioning mechanisms  
such as the up/down vertical support shafts, side-to-side cross  
thread, and the linear actuator. You may need to lubricate  
more often than monthly.  
LUBRICATING  
THE TANK  
COMPONENTS  
Tools required:  
grease gun  
seize-resistant  
bearing  
Lubricate the vertical support shaft and  
grease fittings. Apply bearing compound to the fit-  
tings until it overflows. Apply a coating of the compound  
to the shafts as well.  
1
compound  
Lubricate the side-to-side cross thread grease  
fittings. Apply bearing compound to the fittings until it  
overflows. Apply a coating of the compound to the  
thread as well.  
2
Lubricate the linear actuator according to  
manufacturer’s instructions.  
3
The tank, spray bars and optional recirculation reservoir  
should be thoroughly to remove particles that can accumulate.  
CLEANING THE  
TANK AND  
SPRAY BARS  
Drain the tank and reservoir.  
1
Wipe surfaces thoroughly to remove particles.  
2
Remove the spray bars. Twist each spray bar coun-  
3
terclockwise and pull it out.  
Clean the spray bars. Flush each bar with a  
4
compressed air line or water hose. Use a soft brush  
to remove any particles clogging the small holes.  
Reassemble by repeating the steps in reverse  
order.  
5
UGE014/0999  
Water/Spray Tanks  
MAINTENANCE 5-3  
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WARNING: High voltage  
CHECKING  
ELECTRICAL  
CONNECTIONS  
This equipment is powered by three-  
phase main voltage. Always disconnect  
and lock out the main power source  
before opening the unit or servicing.  
Normal operation of the WT/ST Tank produces many wet sur-  
faces. If you have the optional recirculation system, we rec-  
ommend that you carefully check all electrical wires for signs  
of damage that could result in a serious shock.  
1
2
Stop the WT/ST tank. Press the REC STOP button  
and lockout the main power source.  
Open the electrical enclosure. A safety device  
prevents you from opening the door unless the power  
is shut down.  
Inspect the wires and connections. Look for  
loose wires, burned contacts, and signs of over-heated  
wires. Have a qualified electrician make any repairs  
or replacements necessary.  
3
4
Inspect the exterior power cords. Carefully  
check the power cords from the electrical enclosure  
to the pumps. Cords should not be crimped, exposed  
or rubbing against the frame. Also check the power cord  
to the machine. If the main power cord runs along the  
floor, make sure it is not positioned where it could be run  
over and cut by wheels or casters.  
Water/Spray Tanks  
UGE014/0999  
5-4  
MAINTENANCE  
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TROUBLESHOOTING  
Before beginning . . . . . . . . . . . .6-2  
Product quality problems . . . . .6-3  
Water system problems . . . . . . .6-3  
UGE014/0999  
Water/Spray Tanks  
6-1  
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You can avoid most problems by following the recommended  
installation, operation and maintenance procedures outlined in  
this User Guide. If you do have a problem, this section will  
help you determine what caused it and tell you how to fix it.  
BEFORE  
BEGINNING  
Before you begin troubleshooting:  
Find the wiring, plumbing and assembly  
diagrams that were shipped with your equipment.  
These diagrams are the best reference for correcting a prob-  
lem. The diagrams also will note any custom features, such as  
special wiring, control or plumbing options, not covered in  
this User Guide.  
Verify that you have all instructional materials  
related to the WT/ST tank. Additional details about  
troubleshooting and repairing specific components of the tank,  
including pumps and heat exchanger can be found in the man-  
ufacturers manuals included in this instruction packet.  
Verify that you have manuals for equipment  
located upstream of the tank on the extrusion line.  
Solving problems related to extrudate quality may require  
troubleshooting malfunctions or incorrect operating proce-  
dures on other pieces of equipment in the extrusion line.  
WARNING: This machines should be  
A FEW WORDS  
OF CAUTION  
!
adjusted and serviced only by qualified  
technical personnel who are familiar with  
construction and operation of this type of  
equipment.  
DANGER: Voltage hazard.  
Troubleshooting the electrical system of  
this equipment requires use of precision  
electronic measuring equipment, as well  
as access to the electrical enclosure  
while power is on. Exposure to potentially  
fatal voltage levels is unavoidable. These  
troubleshooting procedures should be  
performed only by qualified electrical  
technicians who know how to use this  
precision electronic equipment and who  
understand the hazards involved.  
Water/Spray Tanks  
UGE014/0999  
6-2  
TROUBLESHOOTING  
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This section contains product quality problems that may be be  
related to WT/ST tank operation. Of course, other sections of  
the extrusion line also influence the quality of the extruded  
product. This section does not provide solutions to problems  
that originate with other equipment on the extrusion line.  
PRODUCT  
QUALITY  
PROBLEMS  
Problem  
Solution  
Possible cause  
Poor surface quality:  
Swirls on the surface.  
Is the extrusion dragging  
against the calibration  
tooling or tank edges?  
Check alignment.  
Poor surface quality:  
Dimples on the  
surface  
Are air bubbles adhering  
to the extrusion surface,  
causing uneven cooling?  
Increase spray bar flow.  
Increase agitation in the  
water tank.  
Add an anti-static agent  
to the water.  
This section contains problems that may be be related to  
optional water recirculation system on the WT/ST tank.  
WATER SYSTEM  
PROBLEMS  
Possible cause Solution  
Problem  
Is power and the correct  
voltage reaching the  
pump?  
Verify that the emergency  
No water flow.  
stop button has not been  
activated, and check all  
power connections.  
Verify that the supply power  
matches the rating on the  
motor data plate  
Has the pump overload  
tripped?  
If necessary, manually reset  
the pump overload by pressing  
the reset button. Verify the  
overload is set to the FLA  
specified on the motor data  
plate. If the correct voltage is  
reaching the pump and the  
overload continues to trip, you  
may need to replace the pump.  
The pump is run-  
ning, but water flow  
is very low.  
Is there a blockage in the  
flow path?  
Check the heat exchanger  
for blockages.  
Check for a restriction in  
the spray bars.  
UGE014/0999  
Water/Spray Tanks  
TROUBLESHOOTING 6-3  
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Conair has made the largest investment in customer support in  
the plastics industry. Our service experts are available to help  
with any problem you might have installing and operating  
your equipment. Your Conair sales representative also can help  
analyze the nature of your problem, assuring that it did not  
result from misapplication or improper use.  
WERE HERE  
TO HELP  
To contact Customer Service personnel, call:  
HOW TO CONTACT  
CUSTOMER  
SERVICE  
From outside the United States, call: 814-437-6861  
You can commission Conair service personnel to provide on-  
site service by contacting the Customer Service Department.  
Standard rates include an on-site hourly rate, with a one-day  
minimum plus expenses.  
If you do have a problem, please complete the  
following checklist before calling Conair:  
BEFORE YOU  
CALL ...  
Make sure you have all model, serial and parts list  
numbers for your particular equipment. Service  
personnel will need this information to assist you.  
Make sure power is supplied to the equipment.  
Make sure that all connectors and wires within  
and between control systems and related  
components have been installed correctly.  
Check the troubleshooting guide of this manual  
for a solution.  
Thoroughly examine the instruction manual(s)  
for associated equipment, especially controls.  
Each manual may have its own troubleshooting  
guide to help you.  
Additional manuals and  
prints for your Conair  
equipment may be  
ordered through the  
Customer Service or  
Parts Departments for a  
nominal fee.  
Check that the equipment has been operated as  
described in this manual.  
Check accompanying schematic drawings for  
information on special considerations.  
IMS0002/0296  
SERVICE INFORMATION  
APPENDIX A-1  
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Conair guarantees the machinery and equipment on this order,  
for a period as defined in the quotation from date of shipment,  
against defects in material and workmanship under the normal  
use and service for which it was recommended (except for  
parts that are typically replaced after normal usage, such as  
filters, liner plates, etc.). Conairs guarantee is limited to  
replacing, at our option, the part or parts determined by us to  
be defective after examination. The customer assumes the cost  
of transportation of the part or parts to and from the factory.  
EQUIPMENT  
GUARANTEE  
Conair warrants that this equipment will perform at or above  
the ratings stated in specific quotations covering the equip-  
ment or as detailed in engineering specifications, provided the  
equipment is applied, installed, operated and maintained in the  
recommended manner as outlined in our quotation or specifi-  
cations.  
PERFORMANCE  
WARRANTY  
Should performance not meet warranted levels, Conair at its  
discretion will exercise one of the following options:  
Inspect the equipment and perform alterations or adjust-  
ments to satisfy performance claims. (Charges for such  
inspections and corrections will be waived unless failure  
to meet warranty is due to misapplication, improper  
installation, poor maintenance practices or improper oper-  
ation.)  
Replace the original equipment with other Conair equip-  
ment that will meet original performance claims at no  
extra cost to the customer.  
Refund the invoiced cost to the customer. Credit is sub-  
ject to prior notice by the customer at which time a  
Return Goods Authorization Number (RGA) will be  
issued by Conairs Service Department. Returned equip-  
ment must be well crated and in proper operating condi-  
tion, including all parts. Returns must be prepaid.  
Purchaser must notify Conair in writing of any claim and pro-  
vide a customer receipt and other evidence that a claim is  
being made.  
Except for the Equipment Guarantee and Performance  
Warranty stated above, Conair disclaims all other warranties  
with respect to the equipment, express or implied, arising  
by operation of law, course of dealing, usage of trade or oth-  
erwise, including but not limited to the implied warranties of  
merchantability and fitness for a particular purpose.  
WARRANTY  
LIMITATIONS  
APPENDIX A-2  
WARRANTY INFORMATION  
IMS0003/0796  
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