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

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.

Document Version History

AccuRay® 1190™
Liquid Cooling Unit Reference Manual

Version Effective Sections Changed Sections Added Sections Deleted

Level Date by Revision by Revision by Revision
A August 1992 Original Release
B January 1995 Figure 5-2

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 i
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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

101333-003 Table of Contents v

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List of Figures

Figure..................................................................................................Page

Figure 1-1 Simplified Diagram of the LCU .............................................. 2

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

101333-003 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 simplified
flow 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 29°C (85°F). 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 flow 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 1

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Filter and Flow Valve

Filter Housing

Coolant
Customer From Sensor
Water Supply
Sensor

Flow Switch

To Sensor
Customer Pressure Pump
Water Out

Figure 1-1 Simplified 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

2 Theory of Operation 101333-003

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2
Operation
Use the following procedure to operate the Liquid Cooling Unit (LCU).
Step Procedure Comments
1. After the installation is complete, prepare the The reservoir tank holds 10.4
coolant mixture. The mixture is 25 percent liters (2 3/4 U.S. gallons).
ethylene glycol and 75 percent potable water.
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.
3. Turn On power to the unit. The Fill light will come on
when you turn On power to the
unit and begin to fill it. The Fill
light will go out when the unit
has been filled past the
minimum acceptable limit.

The Full light will go on when

the LCU has been filled 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

101333-003 Operation 3
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continued
Step Procedure Comments
4. Add the coolant mixture until the sensor and feed Do not overfill.
lines are purged of air.
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.
7. Maintain proper water level and temperature The Fill and Full Lights will be
setting. your guide to maintaining
proper coolant.

Adjust the operating

temperature according to the
procedure on page 5.

4 Operation 101333-003
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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 Procedure Comments
1. Read the temperature at the thermometer on See Figure 3-1.
the top panel of the LCU.
The temperature should
be 33°C ± 2°C
(90°F ± 2°F)
2. If the temperature is outside the specified See Figure 3-2.
operating range, adjust the Penn Flow Control
Valve Thermostat. The adjustment
mechanism is a
screwdriver slot inside
the service panel.
3. Turn the Penn Flow Control Valve Thermostat Allow approximately 30
clockwise to lower the temperature. minutes for the unit
temperature to stabilize.
Turn the Penn Flow Control Valve Thermostat
counterclockwise to raise the temperature.

101333-003 How to Adjust the Temperature of the LCU 5

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SENSOR WATER
TEMPERATURE

ON OFF

FULL

FILL

ABB

Figure 3-1 Liquid Cooling Unit, Top View

COW

CW

Thermometer
Adjustment Slot

Figure 3-2 Penn Control Thermostat

6 How to Adjust the Temperature of the LCU 101333-003

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4
Maintenance
Preventive Maintenance for the LCU consists of the following checks:
Preventive Maintenance Corrective Action
Visually inspect all connections to and Repair any leaks by tightening or replacing
from the LCU for leaks. fittings.
Visually check the coolant fluid for The coolant fluid should be colorless. If the
signs of contamination. fluid is not colorless, drain the unit and replace
the coolant fluid. See page 20 for the procedure
to drain and refill the LCU (see Figure 6-2 on
page 21).
Visually inspect the external If the filter appears clogged, replace it. Part
50 micron filter to make certain it is number 101544-001.
clean.
Verify that the coolant fluid is If it is necessary to
circulating through the sensor heads. replace the flow switch, FLOW
refer to the procedure SWITCH
This can be done by opening the on page 30.
reservoir tank and looking for signs of
circulation.

OR

This can also be accomplished by

verifying the operation of the flow
switch. Put an ohmmeter across
terminal pins 9 and 10 on terminal RED
blocks. The ohmmeter will read 0 (a RED
short) if there is no flow. The ohmmeter
will read infinity (an open) if there is 1234567891 1 1
012
flow.

101333-003 Maintenance 7
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Preventive Maintenance Visually Inspect

Make certain the fluid level is between The Fill and Full Lights
Fill and Full.
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 fill
capacity.
Make Certain the LCU is operating at The LCU digital thermometer
the correct temperature.
Make certain the area around the LCU The area around the LCU, the vents on
is free of debris. 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.

8 Maintenance 101333-003
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5
Troubleshooting
Symptom Possible Cause Corrective Action
There is no fluid flow The power breaker to the LCU Turn On power to the LCU.
through the LCU to the is off.
sensor.
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.

There is a leaky connection. Repair the leaky

connection.

The tubing is clogged or Remove restrictions from the

pinched. tubing.

The tank is empty. Fill the tank. See “Operation”

on page 3.

101333-003 Troubleshooting 9
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Symptom Possible Cause Corrective Action

There is no water flow There is no water pressure to Customer to supply water at
from the drain on the the LCU. minimum pressure of 40 psi
LCU. and flow rate of at least 10
gph. See page 14.

The valve from the customer Open the valve.

water supply to the LCU is
closed.

The external 50 micron filter is Replace the filter.

clogged (P/N 101544-001).

The Penn Flow Control Valve Replace the flow contol valve.
is defective. See page 28.

Pressure regulator defective Replace pressure regulator.

See page 29.

Penn Flow Control Valve Water in reservoir is below

closed 33°C (90°F).

The Fill Light is On. The fluid 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 fluid level is above the page 30.
coils. Light is defective Replace light. See page 22.

The Full Light is On and Level switch is defective Replace level switch.
the fluid level is below the See page 30.
coils
The LCU leaks. Loose or cracked fittings Check the fittings at the
reservoir and pump.

10 Troubleshooting 101333-003
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Symptom Possible Cause Corrective Action

The thermometer does The thermometer probe is out Place the thermometer probe
not display a proper of the sensing tube. back in the tube. See page 25.
temperature.
The thermometer is defective. Replace the thermometer. See
page 25.

The power supply is not Use a voltmeter to

delivering the 6 Volts direct verify the voltage going to the
current to the thermometer. thermometer. See page 7.

The thermometer power Replace the thermometer power

supply is defective. supply. See page 24.

Adjust the Penn Control

The thermometer is out of the Thermostat. See page 5.
operating range.
The LCU leaks. Loose or cracked fittings. Check the fittings at the reservoir
and pump.
The sensor goes to the The LCU is not sending the Check for flow to the
off-sheet position. proper flow to the sensor(s). sensor(s).

This will only occur if Make certain the flow switch is

the Flow Switch is operating correctly.
connected to the system.
Normally the flow switch
contacts are open when there is a
low flow (or no flow) to the
sensor head.

The flow switch contacts close

when there is acceptable flow 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 11
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Troubleshooting the Flow Switch

Normally the Flow Switch contacts are open when there is low flow (or no flow) to
the sensor. The Flow Switch contacts are closed when there is sufficient flow to the
sensor. Use the following procedure to troubleshoot the Flow Switch.
Step Procedure Comments
1. Disconnect the wires from TS 9 and TS 10 to the See Figure 5-1.
system computer.
2. Use a digital volt meter across TS 9 and TS 10 to verify See Figure 5-1.
continuity in the Flow Switch.
3. 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.
4. Turn On the LCU. 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.
5. Turn Off the LCU.
6. Unscrew the top of the Flow Switch. Determine if the This piston is spring
magnetically equipped piston is stuck. loaded.
7. If the piston is stuck, loosen it.
8. Close the Flow Switch and repeat Steps 2 through 4.
9. If the Flow Switch still does not respond, replace it.

FLOW
SWITCH

RED
RED

123456789 11 1
01 2 To the system
computer
Figure 5-1 Test Points for the Flow Switch

12 Troubleshooting 101333-003
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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 Procedure Comments
1. Plug in the new thermometer to the existing If the thermometer works
wiring. then neither the wiring and
probe assembly nor the power
supply need to be replaced.
2. Use a voltmeter to check the thermometer’s Replace the power supply, if
power supply. The power supply should be it is not working.
sending 6 volts to the thermometer.
3. 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.

101333-003 Troubleshooting 13
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For ABB Employee Use Only

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

Humidity: 5% to 90%

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

14 Troubleshooting 101333-003
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208 ON/OFF SWITCH

240 V
1 4
2 3

POWER BLU
BRN
BLU BRN

BRN
2
BLU
1 To Switch
BRN
3
BLU 4

GRN

BLU BLU
YEL-GRN 1 FLOAT

BRN BRN
2
BRN
BRN 3
BLU
BLU
4
PUMP BLU BLK
5
BRN
RED
6
RED

YELLOW
7 RED
RED

BLK
8
BLK
BLK RED

9 RED FLOW
RED

SW
PROBE
10 RED G R
WHITE
FULL FILL
11 GRAY

RED Indicator
12 RED Lights
.5
5
x2 WHITE

.5
4
240 V
TO
RED 6 V.D.C.
-
+

BRN
POWER
BLU 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 17

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For ABB Employee Use Only

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Preparing the LCU for Servicing

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

SENSOR WATER
TEMPERATURE

ON OFF

FULL

FILL

ABB

Figure 6-1 LCU, Top View

18 Replacement Procedures 101333-003

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For ABB Employee Use Only

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Connecting the LCU After Servicing

Step Procedure Comments

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

SENSOR WATER
TEMPERATURE

ON OFF

FULL

FILL

ABB

101333-003 Replacement Procedures 19

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For ABB Employee Use Only

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Drain and Refill the LCU

Metal edges on the LCU may be sharp and can cause

injury if not properly handled.

Step Procedure Comments

1. Before servicing the LCU, complete the See page 18.
Preparation for Service Procedures.
2. Drain coolant mixture from reservoir by Ethylene glycol is toxic.
removing the plug on bottom lower right side Dispose of properly
of unit. according to local
(Use socket wrench size 1 1/8 in.) regulations.

See Figure 6-2.

3. Apply a pipe sealant to the threads of the plug.
4. Replace the plug.
5. Refill 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 101333-003

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Fill Coolant
Mixture

208-240 V.
FROM SENSOR 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 21

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For ABB Employee Use Only

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Full Light or Fill Light Replacement

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

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

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.

Power Switch Replacement

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

101333-003 Replacement Procedures 23

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

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.

Regulated Power Supply Replacement

Step Procedure Comments
1. Before servicing the LCU, complete the See page 18.
Preparation for Service Procedures.
2. Remove the service panel.
3. Remove brown and blue power wires from the See Figure 6-4. New power
terminal blocks going to the regulated power wire will have to be cut. Use
supply next to the terminal block. defective part as template.
4. Remove red and white wire from regulated
power supply.
5. Remove the two #6-32 screws holding
regulated power supply to tank support bracket
(Do not discard).
6. Install the new regulated power supply. Use the two #6-32 screws
holding the regulated power
supply to the tank support
bracket.
7. Connect red (+) and white (-) wire to the new See figure required for LCU.
regulated power supply from the terminal strip.
8. Connect the brown and blue power wires from See figure required for LCU.
the regulated power supply to the terminal
block. Tighten screws.
9. Prepare LCU for service. See page 19.
10. Replace the service panel.

DIGITAL
THERMOMETER

PROBE Gray

Red
240 V
TO REGULATED
6V.D.C. POWER
-+ SUPPLY

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

Brn Blu
Red

Figure 6-4 Wiring for the Regulated Power Supply

24 Replacement Procedures 101333-003

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

For ABB Employee Use Only

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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 Procedure Comments

1. Before servicing the LCU, complete the See page 18.
Preparation for Service Procedures.
2. Remove the service panel.
3. Remove the two screws holding the digital Phillips screwdriver
thermometer (Do not discard).
4. Unplug the wires to the thermometer. Remove Check wires for cuts or
the thermometer from underneath the top breaks.
panel.
5. Install the new digital thermometer.
6. Install the two screws that will hold the new
thermometer. Tighten screws securely.
7. Plug in the wires to the thermometer. Make sure looking tab is
in place.
8. Prepare the LCU for service. See page 19.
9. Replace the service panel.

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.

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.

Reservoir Assembly Replacement

Step Procedure Comments
1. Before servicing the LCU, complete the See page 18.
Preparation for Service Procedures.
2. Drain the reservoir. See page 20.
3. Remove the service panel.
4. Remove the fill cap.
5. Remove the six 10-32 screws holding top panel
in place.
6. Lift the top panel up and swing it to the side.
7. Loosen the hose clamp from the hoses to the
reservoir.
8. Remove all hoses, suction-tube assembly nut
and the flow valve from reservoir.
9. Remove the 10-32 screw and the spacer from
the reservoir located at the tank support
bracket.
10. Remove the level switch wires (black-yellow-
red) from the terminal block.
11. Remove the tank from the LCU. Slide the reservoir back to
clear suction tube
assembly and lift up.
12. Install the new reservoir in reverse order. Be sure all screws,
spacers, wires, and nuts
are securely fastened.
13. Replace the level switch wires (black-yellow- See Figure 6-5.
red) from the terminal block.
14. Replace all hoses, the suction-tube assembly
and the flow valve to reservoir tubes.
15. Replace the 10-32 screw and the spacer from
the reservoir located at the tank support
bracket.
16. Tighten the hose clamps to reservoir tubes.
17. Replace the top panel and six screws. Check wire connections
on top panel.
18. Refill the Reservoir. See page 20.
19. Turn On power.
20. Replace the fill cap.
21. Replace the service panel

26 Replacement Procedures 101333-003

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

For ABB Employee Use Only

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Blk
Red L-1

Yellow L-2

L-2

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

Figure 6-5 Wiring for the Reservoir Float

101333-003 Replacement Procedures 27

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

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.

Flow Control Valve Replacement

Step Procedure Comments
1. Before servicing the LCU, complete the See page 18.
Preparation for Service Procedures.
2. Drain the LCU unit. See page 20.
3. Remove the service panel.
4. Remove the compression fitting nut holding 15/16 in. open end wrench
flow valve to reservoir.
5. Remove the hose clamp and remove the hose 1/4 in. nut driver
from the plastic fitting.
6. Remove the thermostat from suction tube Loosen the small nut (1/2 in.
assembly. wrench) first, then, loosen the
larger nut (7/8 in. wrench).
7. Remove the flow valve and the thermostat from NOTE: This valve is fragile.
the LCU. Do not apply pressure to areas
other than the casting.
8. Make certain to apply pipe
Replace the thermostat. sealant to threads on
NOTE: After large nut (7/8 in.) thermostat fitting nut (7/8 in.)
is tightened into suction tube before assembling back into
assembly, slide capillary tube suction tube assembly.
into position and Tighten securely
measure from top of
large nut to top of
flexible solder fitting 2 1/2” The capillary tube that is
(2 1/2 in.). Hold tube connected to the thermostat
and tighten small will have to be coiled prior to
(1/2 in.) nut securely. See assembly. Wrap the capillary
assembly view. tubing around a two-inch
diameter object to avoid
kinking it.
9. Replace the flow control valve to reservoir. Tighten securely.

Reset the control valve

according to the procedure on
page 35.
10. Refill the unit. See page 20.
11. Prepare the LCU for service. See page 19.

28 Replacement Procedures 101333-003

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

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.

Water Pressure Regulator Replacement

Step Procedure Comments
1. Before servicing the LCU, complete the
See page 18.
Preparation for Service Procedures.
2. Shut off the water supply.
3. Remove the service panel. The pressure regulator is located
inside the unit on the cold water
inlet bulkhead fitting inside the
LCU. See Figure 6-6.
4. Remove the hose clamp and hose. 1/4 in. nut driver
5. Unscrew the pressure regulator from the GHT
plastic fitting (turn counterclockwise).
6. Remove the 1/2-inch NPT to hose barb 90°
15/16 in. box wrench
elbow from regulator.
7. Replace the 1/2-inch NPT to the hose barb 90°
Use pipe sealant on the threads.
elbow on the new regulator.
8. Replace regulator on plastic fitting (GHT).
9. Replace the hose and hose clamp.
10. Refill LCU. See page 20.
11. Prepare the LCU for service. See page 19.

Fill Coolant
Mixture

208-240 V.
FROM SENSOR 50/60 HZ

TO SENSOR

DRAIN COLD WATER

INLET

Drain

Figure 6-6 Liquid Cooling Unit, Rear View

101333-003 Replacement Procedures 29

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

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.

Flow Switch Replacement

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

Flow Switch DANGER

HIGH
VOLTAGE

Figure 6-7 Flow Switch

30 Replacement Procedures 101333-003

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

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.

Pump Assembly Replacement

Step Procedure Comments
1. Before servicing the LCU, complete the See page 18.
Preparation for Service Procedures.
2. Drain the LCU unit. See page 20.
3. Remove both service panels.
4. Remove the wires from the terminal block. Terminal numbers 3
(brown) and 4 (blue) and
ground.
5. Remove union from the suction side of the Only hand tighten.
pump.
6. Remove hose, sensor tube, and flow switch 5/16 in. nut driver
assembly from discharge side of the pump.
7. Remove the four 1/4-20 bolts and nuts from 7/16 in. wrenches top and
the base assembly. bottom
8. Remove the pump assembly.
9. Remove fitting from the suction side of the
pump.
10. Reassemble the fitting to the suction side of the Do not over tighten.
replacement pump.
Pipe sealant on threads.
11. Replace the new pump assembly.
12. Replace the four 1/4-20 bolts and nuts from the 7/16 in. wrenches top and
base assembly. bottom.
13. Replace the union to the suction side of the
pump and hand tighten..
14. Replace hose, sensor tube and flow switch Tighten hose clamp with
assembly to discharge side of pump. 5/16 in. nut driver
15. Replace the wires from the terminal block and Terminal numbers 3
remove ground wire from the tank support (brown) and 4 (blue) and
bracket. ground.
16. Upon replacement of the new pump, purging This will release any air
of the pump will be necessary. Turn pump off, still trapped in pump.
wait 10 seconds and turn pump back on. Repeat if necessary.
17. Refill the LCU. See page 20.
18. Replace both service panels.
19. Prepare the LCU for service. See page 19.

101333-003 Replacement Procedures 31

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

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.

Top Panel Replacement

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

32 Replacement Procedures 101333-003

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

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.

Back Panel Replacement

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

101333-003 Replacement Procedures 33

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

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.

Front Panel Replacement

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

34 Replacement Procedures 101333-003

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

For ABB Employee Use Only

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

101333-003 Replacement Parts List 35

Blank Page
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Index

B R
Back Panel Replacement Procedure, 33 Regulated Power Supply Replacement Procedure,
24
Replacement Parts List, 35
C Replacement Procedures, 17
Connecting LCU after Servicing, 19 back panel, 33
connecting LCU after servicing, 19
D digital thermometer, 25
drain and refill, 20
Digital Thermometer Replacement Procedure, 25 flow control valve, 28
Digital Thermometer, Troubleshooting, 13 flow switch, 30
Drain and Refill, 20 front panel, 34
full light and fill light, 22
F power switch, 23
preparing LCU for servicing, 18
Flow Control Valve Replacement Procedure, 28 pump assembly, 31
Flow Switch Replacement Procedure, 30 regulated power supply, 24
Flow Switch, Troubleshooting, 12 reservoir assembly, 26
Front Panel Replacement Procedure, 34 top panel, 32
Full Light and Fill Light Replacement Procedure, water pressure regulator, 29
22 Reservoir Assembly Replacement Procedure, 26

M T
Maintenance, 7 Temperature Adjustment, 5
Theory of Operation, 1
O Top Panel Replacement Procedure, 32
Troubleshooting, 9
Operating Parameters, 14 digital thermometer, 13
Operation, 3 flow switch, 12
operating parameters, 14
P wiring diagram, 14
Power Switch Replacement Procedure, 23
Preparing LCU for Servicing, 18 W
Pump Assembly Replacement Procedure, 31 Water Pressure Regulator Replacement, 29
Wiring Diagram, 14

101333-003 Index 37
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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