Sterling Marine Instruments 6017 series User's Manual
Contents
1. gt i Operation and Installation Manual 6017 Series Large Hot Oil Temperature Control Units Important Read Carefully Before Attempting to Install or Operate Equipment Write down your unit serial number s here for future reference Sterling Sterlco is committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice Copyright Sterling Sterlco and Sterling Inc 2008 All rights reserved Effective 4 29 2008 Part No 682 91540 00 Revision 3 Bulletin No SC1 655 3 Page 2 GID 6017 Series Hot Oil Large Temperature Control Units Safety Considerations Sterling Sterlco 6017 Series large hot oil temperature control units are designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes To avoid possible personnel injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices WI M M Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Disconnect and or lock out power before servicing or maintaining the hot oil temperature control unit Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remo2. 6 Air and Oil will be vented through the automatic Blow Off Valve and into the reservoir tank 7 After the unit stops requiring more oil and has at least 5 psi of pressure open the Return Valve half way If the Blow Off cycle times out start the sequence again The timer is factory set at 5 minutes A longer time can be set if required The first time the unit is filled with oil it takes some time to vent out the air You should determine how long is appropriate for venting on a regular basis when the unit is already full 8 Once the unit has stopped requiring more oil again and has at least 10 psi of pressure select a set point of 100 F 38 C and switch unit into the Auto mode As the oil warms up viscosity will decrease and the pressure will fall 9 In 2 minute intervals increase the setpoint to 150 F 66 C and 200 F 93 C 10 If any water is present in the system it must be boiled off before continuing operation Select a setpoint of 215 F 102 C and observe the reservoir tank vent for any signs of escaping steam Continue to run at 215 F 102 C until no more steam appears and pressure has stabilized Restart the Blow Off cycle as necessary if it times out 11 When fluid level has stabilized and air and water are purged from the system open the Return Valve all the way And select a setpoint of 250 F 121 C Restart the Blow Off cycle as necessary if it times out 12 If the fluid level and pressure rem
3. HI HI ALARM Key LO LO ALARM Key Page 38 ENTER The ENTER key is used with the INDEX key menu to store the value or the item that was changed If this key is not pressed the previously stored value or item is retained Each press of the INDEX key advances the screen to the next menu item Refer to your Sterling Sterlco M2B Temperature Control Owner s Manual for a list of functions available using this key Press and hold the HI ALARM key then press the UP Arrow key to increase the alarm high limit value or press the DOWN Arrow key to decrease the alarm high limit value on the SET POINT LED screen Refer to your Sterling Sterlco M2B Temperature Control Owner s Manual for a list of functions available using this key LO Press and hold the LO ALARM key then press the UP Arrow key to increase the alarm low limit value or press the DOWN DOWN Arrow key to decrease the alarm low limit value on the SET POINT LED screen Refer to your Sterling Sterlco M2B Temperature Control Owner s Manual for a list of functions available using this key ES TERLCOJ 6017 Series Hot Oil Large Temperature Control Units DISPLAY Key Digital Flow Screen Optional DISPLAY Press the DISPLAY key to advance through the display menu Each key press increments to the next available function The screen returns to delivery temperature after thirty 30 seconds of inactivity Refer to your Sterling Sterlco M2B Temperature Control Owner
4. Open the external vent valve 2 Open the isolation valve that is delivering oil to the process from the unit Leave the isolation valve that is returning the oil from the process to the unit closed 3 Wait for all of the process to fill with heat transfer fluid and push the air and back to the reservoir 4 Once all of the air has been replaced with fluid and only oil is being dumped into the reservoir close the vent valve 5 Open the isolation valve that is returning the oil from the process SSTERLCO 6017 Series Hot Oil Large Temperature Control Units Page 25 3 4 Making Electrical Connections These units are designed for three phase voltage operation Refer to the unit nameplate for proper voltage and amperage requirements and make sure your electrical service conforms Check the unit nameplate for correct voltage and amperage before making electrical connections CAUTION Provide a correctly sized and protected power supply to the unit If an electrical supply disconnect is not installed as a factory option the customer is responsible to properly size and install a suitable disconnect Refer to National Electric Code NEC 430 24 26 for proper feed conductor and supply disconnect sizing Voltages must be within plus or minus ten percent 10 of the nameplate rating Maintain a safe ground and disconnect the power supply before servicing the unit A qualified electrician should make electrical co
5. s Manual for a list of menus available using this key The optional digital flow screen displays process flow in gallons per minute gpm No customer usable control is necessary Depending on option level and setup flows can be measured at rates reaching and exceeding 75 gallons per minute 284 Ipm 5 4 Identifying Control Panel Switches PUMP START PUMP STOP PUMP REVERSE MODE SELECT This section lists the descriptions and functions of the control panel switches These switches control the operation of the unit Figure 5 Control Panel Switches ALARM SILENCE AUDIBLE ALARM SSTERLCO 6017 Series Hot Oil Large Temperature Control Units Page 39 Pump Start Press the START button to start the pump in the normal forward direction Pump Stop Press the STOP O button to stop the pump and de energize the controller CAUTION Always press the Pump Stop O button and allow the pump to come to a complete stop before pressing the Pump Reverse button Failure to let the pump stop before reversing may damage the pump and drive Pump Reverse Press the REVERSE button to start the pump in the reverse direction Use this feature to purge oil from the mold Vent Cycle Start optional Press the VENT PO button to start the vent cycle timer Use this feature to purge air and water from the unit and process This is used when the Autovent Cycle Option is added to the unit Mode Select With the pump run
6. e NEMA 12 electrical enclosure e UL listed subpanel e To Process pressure gauge e Independent safety thermostat e Y strainer on From Process line e A packed positive displacement pumps capable of reversing to evacuate the process e Easily removable panels for quick access to internal components e Audible alarm Page 8 GID 6017 Series Hot Oil Large Temperature Control Units 1 5 Available Options e Drain valve e Manual bypass e Hour meter measures total pump run time hours e General fault visual alarm e Automatic venting sequence e Low level alarm for reservoir e M2B microprocessor controller options include 4 20 mA remote set point and retransmission SPI protocol RS 485 General protocols types RS 232 485 Remote sensor e Heat exchanger options of e 3 9 sq ft 0 3627 sq m e 6 7 sq ft 0 6231 sq m e 13 sq ft 1 21 sq m e 21 sq ft 1 96 sq m e 27 sq ft 2 51 sq m e Remote controller e Lexan cover e Mechanical Seal Pump e Optional operating voltages of 208 3 60 230 3 60 575 3 60 380 3 50 and 415 3 50 e Provisions for a Nitrogen Blanket on the Reservoir can drastically increase fluid life 1 6 Feature Descriptions Immersion Heaters The fluid is heated by the specially designed three phase low watt density electrical immersion heater and regulated by the controller The standard heater has a steel sheath for low watt density and good heat transfer These models can be su
7. 0 wo D Pon wo 1000 2500 4 5 6 8 74 2501 4000 3 8 5 7 3 6 4 1000 2500 5 4 8 0 5 8 4 2501 4000 47 7 0 7 860 2500 7 2 2501 4000 2 6 2 wn gt afao 12 0 16 0 3 860 2500 5 3 9 0 2501 4000 4 5 6 7 5 9 860 2500 5 3 4 12 6 2501 4000 6 0 9 3 10 7 3 500 1740 14 21 0 15 23 1741 3000 12 8 5 14 6 21 6 200 850 24 37 0 851 1500 21 2 1 3 D foz gt af gt gt cow NO w anfa a ww 18 0 20 0 2 2 2 4 4 12 6 90 D 200 850 30 5 2 851 1500 25 6 38 0 1000 2500 K 4 2501 4000 2 3 1000 2500 3 6 5 1 3 2 2501 4000 3 0 4 4 3 6 1000 2500 4 9 7 3 b 2501 4000 4 4 6 6 x A 500 1749 1750 3000 3001 4000 500 1740 2 1741 3000 Pale ine oN iow ao aa njoo ww NN eee a nowa DOR PSH on 12 18 14 11 16 1 11 8 16 0 12 5 17 0 500 1740 1741 3000 wu No Nh aa o j 3 7 6 Bs 1 109 5 18 0 22 4 Bo wolmuflnn NN z Pta loa 1 16 gelse wom a Page 51 7 Troubleshooting Condition Possible cause Solution _______ water lines Long connecting lines between and shorten connecting lines Connect lines for parallel flow SER Check mold for metal chips or cycling from hot to cold check valve valve Carbon build up in unit piping or Check unit by opening the manual bypass to determine if the TCU contols the set point temperature Reversed probes Switch Return and Delivery probes Pa Check all li
8. Series Hot Oil Large Temperature Control Units Page 29 10 If any water is present in the system it must be boiled off before continuing operation Select a setpoint of 215 F 102 C and observe the reservoir tank vent for any signs of escaping steam Continue to run at 215 F 102 C until no more steam appears and pressure has stabilized 11 When fluid level has stabilized and air and water are purged from the system open the Return Valve all the way And select a setpoint of 250 F 121 C 12 If the fluid level and pressure remain stable close the Blow Off Valve Do not open the Blow Off Valve above 250 F With the system properly purged only 4 6 of fluid should be visible in the sight glass This will allow for expansion of the fluid as it heats as well as capacity for process fluid when the pump is reversed and fluid withdrawn from the mold The 6017 is now ready for use All that is required is to select a process set point on the controller as described in the controller manual NOTE Ifall traces of water are not removed from the system severe cavitation may occur at elevated temperatures Indications are a gravely sounding pump fluctuating or dropping pressure or rapidly rising fluid level in the expansion tank Repeat Steps 9 12 if this occurs UNIT START UP WITH AUTOVENT SOLENOID The highly engineered controls and controller make this unit almost self operating Before you can begin heating it will be
9. at the time and place of shipment WI Notify the transportation company s local agent if you discover damage M Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods to Sterling Inc before the transportation company inspection and authorization M File a claim against the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill M Advise Sterling Inc regarding your wish for assistance and to obtain an RGA return goods authorization number BSTERLCO 6017 Series Hot Oil Large Temperature Control Units Page 17 2 3 If the Shipment is Not Complete Check the packing list The apparent shortage may be intentional Back ordered items are noted on the packing list You should have M 6017 Series hot oil large temperature control unit Bill of lading Packing list Operating and Installation packet Electrical schematic and panel layout drawings K ARRAK Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking Determine that the item was not inadvertently taken from the area before you checked in the shipment Notify Sterling Inc immediately of the shortage 2 4 If the Sh
10. pressure is not re established The pressure switch is preset at the factory do not tamper with it The safety thermostat is mounted on the side of the heater tank This is to guard against the unlikely event of runaway heating If overheating does occur the safety thermostat shuts down the heater outputs and sounds an audible alarm A red pilot light on the status board also illuminates The unit continues to pump fluid through the system to prevent heater damage Auxiliary factory installed alarms such as beacons and klaxons are available as options The safety thermostat is a manual reset type All controller functions are locked out until the red STOP button is pushed It is imperative that a qualified maintenance technician determine and correct the cause of the fault before resuming operation A reservoir tank with sight gauge is standard usable capacity is e 40 gallons 151 liters on 6017L amp 6017M units e 65 gallons 246 liters on 6017P amp 6017V units The tank permits thermal expansion of the heat transfer fluid and provides make up fluid BSTERLCO 6017 Series Hot Oil Large Temperature Control Units WARNING The reservoir tank may cause serious injury if it ruptures from not being properly vented Make sure that the reservoir tank is always properly vented to prevent tank rupture GID 6017 Series Hot Oil Large Temperature Control Units Page 15 Figure 1 6017 Series Hot Oil Large Temperature Cont
11. result in high temperature oil spray causing serious injury or death Make sure hoses valves and other components installed in your process can withstand maximum temperature and pressure of the 6017 unit check unit nameplate for specific capacities All components must be carefully inspected for condition before installing Make sure you have factory components if you have any doubt Electrical System Controls Page 12 The electrical controls of your 6017 unit are specially engineered for reliability safety and simplicity of operation The switches are clearly labeled as to their function Your 6017 unit has a system status board so you can evaluate the status and performance of the unit at a glance Pilot lights are provided to indicate key unit functions An audible alarm is standard with your unit The alarm will sound in the event of the following conditions e motor overload e safety thermostat trip over temperature e low fluid pressure e low fluid level optional e high fluid level optional Push the ALARM SILENCE button to silence the alarm See Chapter 4 for more information on control functions QGP 6017 Series Hot Oil Large Temperature Control Units Electrical Panel and System Components Air Purge The pump motor and immersion heater operate on three phase 50 60 cycle nominal voltage with the control circuit at 115 V single phase The control circuit voltage is provided by a single phase machi
12. will ensure that all air is vented from the system to prevent fluid degradation and damage to the heater 1 Open the Return Valve and the Blow Off Valve Make sure the drain valves are closed and plugged 2 Add fluid to the reservoir tank until the level is near the top of the sight glass 3 Close the Return Valve inside the unit 4 Depress the Pump Start button to start the pump Check motor rotation by observing the pressure gauge If the gauge indicates positive pressure rotation is correct If not disconnect power and reverse the incoming power leads 5 As fluid is drawn out of the reservoir tank to fill the process the fluid level will fall in the tank Continue to add fluid to maintain the level about 4 inches from the bottom of the sight glass CAUTION You must purge the system of air before the heating cycle Personal injury and system damage can occur from a pressurized system 6 Air and Oil will be vented through the Blow Off Valve and into the reservoir tank 7 After the unit stops requiring more oil and has at least 5 psi of pressure open the Return Valve half way 8 Once the unit has stopped requiring more oil again and has at least 10 psi of pressure select a set point of 100 F 38 C and switch unit into the Auto mode As the oil warms up viscosity will decrease and the pressure will fall 9 In 2 minute intervals increase the setpoint to 150 F 66 C and 200 F 93 C BSTERLCO 6017
13. IN GID 6017 Series Hot Oil Large Temperature Control Units Page 41 Use the status board to optimize unit performance For example if you observe a rapid cycling of the Heater and Cool Solenoid indicators the unit is operating with a process inefficiency see the Troubleshooting chapter for more information What follows is a description of system status board indicators Status Indicator Lights Pump Reverse Indicator Light The Pump Reverse indicator light illuminates when the unit pump runs in reverse Pump Forward Indicator Light The Pump Forward indicator light illuminates when the unit pump runs in the normal forward direction This indicator typically illuminates continuously during normal operation Heater On Indicator Light The Heater On indicator illuminates when the heater energizes This indicator illuminates intermittently when the controller energizes and de energizes the heater as the heating cycle requires Cool Solenoid Indicator Light The Cool Solenoid indicator illuminates when the cooling solenoid energizes This indicator illuminates intermittently as the controller energizes the cooling solenoid it is used only on the optional heat exchanger Vent Solenoid Indicator Light If the Autovent option is present The Vent Solenoid indicator illuminates when the venting solenoid energizes during venting sequences Mode Indicator Lights Select the unit operating mode by using the selection switch Power O
14. Indicators TO PROCESS Indicator The TO PROCESS indicator is on when the PROCESS LED screen on the controller displays the temperature of the outgoing fluid SSTERLCO 6017 Series Hot Oil Large Temperature Control Units Page 35 FROM PROCESS Indicator AT Indicator FLOW Indicator Alarm Indicators The FROM PROCESS indicator is on when the PROCESS LED screen on the controller displays the temperature of the incoming fluid The AT indicator is on when the PROCESS LED screen on the controller displays the difference in temperature between outgoing Delivery fluid and incoming Return fluid The FLOW indicator is on when the PROCESS LED screen on the controller displays the flow of fluid in liters per minute this function requires the optional flow sensor FLUID PRESSURE Indicator The FLUID PRESSURE indicator goes on when fluid pressure is low The TCU shuts down and resumes operation only when a proper level of fluid pressure is restored SAFETY THERMO Indicator HI LO ALARM Indicator PROBE FAIL Indicator Page 36 The SAFETY THERMO indicator is on when an over temperature condition occurs The heater outputs are then disabled the pump continues to operate and the COOL solenoid energizes This is a fatal fault condition requiring that main power be disconnected to reset the M2B controller The HI LO ALARM indicator is on when an individually set alarm condition occurs The HI deviation is 200 F about 93 C abov
15. LCOJ 6017 Series Hot Oil Large Temperature Control Units Technical Assistance Parts Department Call toll free 7am 5pm CST or call 800 423 3183 262 641 8610 or fax to 262 641 8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service Service Department Call toll free 8am 5pm CST 800 423 3183 or call 262 641 8610 Emergencies after 5pm CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most products Service contracts are available for most of our products www acscustomerservice com Sales Department Call 262 641 8610 Monday Friday 8am 5pm CST fax 262 641 8653 Our products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 262 641 8610 Monday Friday 8am 5pm CST Let us install your system The Contract Department offers any or all of these services project planning
16. Light The Safety Thermo indicator light illuminates when the unit is overheating This is an alarm condition so the audible alarm activates to notify you of the safety thermo fault and disables controller outputs permitting the pump to continue to circulate fluid to avoid damage SSTERLCO 6017 Series Hot Oil Large Temperature Control Units Page 43 Always correct this alarm condition before returning to normal operation High Level Indicator Light The high fluid level alarm is an available option The High Level indicator light illuminates when the heat transfer fluid level in the reservoir tank is too high Carefully remove just enough fluid so this indicator light shuts off and an adequate volume is maintained in the reservoir Low Level Indicator Light Page 44 The low fluid level alarm is an available option The Low Level indicator light illuminates when the heat transfer fluid level in the system is too low This is an alarm condition so the audible alarm activates to notify you of the low fluid level fault and the controller outputs are disabled Always correct the alarm condition before returning to normal operation BSTERLCO 6017 Series Hot Oil Large Temperature Control Units Notes dii 6017 Series Hot Oil Large Temperature Control Units Page 45 6 Preventive Maintenance WARNING Make sure that your maintenance technicians comply with lock out tag out procedures during any servicing or maintenance
17. R CHECK SUPPLY a RELEF ALYE PRESSURE WATER DRAIN VENT LINE Note The heat exchanger is optional and the Vent Valve is also known as the Blow Off Valve Vent Valve open for purge closed for run open for pump reverse Return Valve closed for purge open for run closed for pump reverse Reservoir Tank Open to atmosphere at all times unless nitrogen blanket provisions are present Page 24 GID 6017 Series Hot Oil Large Temperature Control Units Figure 4 Custom Process Piping VENT VENT VALVE VALVE TYPICAL FREQUENT SCENARIO PROCESS DISCONNECTION SCENARIO The optimum location for venting is on the top of the overhead return piping above the unit The customer is encouraged to add an extra vent Blow Off valve at this point With this new Blow Off Valve location the return valve and internal blow off valve should be closed completely during venting Otherwise air could be pulled into the piping by gravity instead of being removed The frequent process disconnection scenario has the vent line connected to the process side of the two isolation valves This allows the disconnected process to be vented without contaminating the rest of the piping and unit to be contaminated with air This is accomplished by the following steps once the process is reconnected to the unit and the isolation valves are still closed Note during this process the internal blow off valve is closed and the return valve can be open 1
18. ain stable allow the Blow Off Valve to close The vent valve will not open the Blow Off above 250 F With the system properly purged only 4 6 of fluid should be visible in the sight glass This will allow for expansion of the fluid as it heats as well as capacity for process fluid when the pump is reversed and fluid withdrawn from the mold The 6017 is now ready for use All that is required is to select a process set point on the controller as described in the controller manual NOTE If all traces of water are not removed from the system severe cavitation may occur at elevated temperatures Indications are a gravely sounding pump fluctuating or dropping pressure or rapidly rising fluid level in the expansion tank Repeat Steps 9 12 if this occurs SSTERLCO 6017 Series Hot Oil Large Temperature Control Units Page 31 4 2 Shutting Down the Unit UNIT SHUT DOWN WITH AUTOVENT SOLENOID OR MANUAL VENT VALVE Cool the unit down by switching the Mode switch to the Manual Cool position This will disable the heaters i e prevent the controller from turning them on and open the cool solenoid Fluid temperature can be monitored on the controller display during cool down When fluid temperature is below 120 F depress the PUMP STOP button to turn the unit off 4 3 Returning Fluid to the Tank RETURNING FLUID TO TANK If the unit is to be moved from one process to another i e mold changes etc the following steps must be take
19. anger is provided as optional equipment in this unit The design features U tube construction and copper nickel tubes for durability and optimal heat transfer The modular construction unique to Sterlco units allows the tube bundle to be easily removed for periodic cleaning Additionally check valves are installed on the water supply and drain lines to prevent water from back flowing into the heat exchanger from a closed drain or into the water supply piping The controller automatically regulates cooling by opening and closing the cooling solenoid This allows the proper amount of oil to pass over the tubes of the heat exchanger A water supply of 75 psi 517 1 kPa 5 2 bars maximum is required for connection to the heat exchanger Connection Lines Connections for TO PROCESS and FROM PROCESS lines are e 2 NPT 50 8 mm at 90 gpm 341 Ipm e 2 1 2 NPT 63 5 mm at 150 gpm 568 Ipm e 3 NPT 76 2 mm at 200 gpm 757 lpm Water connections for COOLING WATER SUPPLY and COOLING WATER DRAIN are e 34 NPT 19 1 mm for 3 9 amp 6 7 sq ft heat exchangers e 1 NPT 25 4 mm for 13 21 amp 27 sq ft heat exchangers See Chapter 3 The customer is responsible for conversions to metric standards iiD 6017 Series Hot Oil Large Temperature Control Units Page 11 Sterling stocks many lengths of flexible metal hose the part number is 572 16969 State the length of hose you want when ordering WARNING Component failure may
20. be about 1 3 full of grease and outboard bearing cavity should be about 1 2 full of grease Note Bearing is 1 3 full when only one side of bearing is completely full of grease 3 Assemble motor SSTERLCO 6017 Series Hot Oil Large Temperature Control Units Page 49 6 3 Draining the Unit for Storage You should thoroughly flush and drain the 6017 unit if you need to take it out of service for a long time or if you expect it to become exposed to freezing temperatures Sterling Inc recommends SterlFlush flushing fluid or equivalent for flushing your 6017 unit follow unit flushing instructions that comes with SterlFlush flushing fluid Drain plugs are provided at the base of the heater tank reservoir tank and on the pump You should also remove drain and reinstall the heat exchanger tube bundle before storage 6 4 Corrective Maintenance Pumps and Seals Page 50 Each 6017 unit is completely tested and calibrated before leaving the factory The unit is then cooled drained and packed for shipment If the unit stands idle for a long time before being installed in your factory gaskets can dry out and possibly leak when you start the unit In most cases these gaskets soon swell and form a tight seal If not you may need to tighten the bolts to stop the leak Similarly rough handling in shipping may sometimes cause minor leaks upon startup you may need to re tighten bolts or fittings to stop the leak You should expe
21. cape and become a potential fire and slip hazard Note Heat transfer fluids expand when heated Expansion rates vary depending on fluid types and temperatures For more information on expansion rates refer to specification information for the heat transfer fluid you select Generally most heat transfer fluids expand at the rate of 2 5 for every increase of 50 F from temperatures above 60 F 16 C Connect the TO PROCESS hookup to the entrance of the process and the FROM PROCESS hookup to the exit of the process Connect the COOLING WATER SUPPLY to your plant water supply Connect the COOLING WATER DRAIN line to an open drain or to the return line of your central water system If returning to a central water system use a condensate return tank to avoid a standing water column on the heat exchanger drain line CAUTION If you are routing the drain line to an open drain make sure that the line is directed away from personnel to avoid scalding Carefully select connecting lines and connectors between the 6017 unit and the process to best meet the needs and requirements of your application Make sure lines and connectors have a service rating of at least 100 psig 689 5 kPa 6 9 bars and a temperature rating at least equal to the maximum operating temperature of your 6017 unit GID 6017 Series Hot Oil Large Temperature Control Units Page 23 Figure 3 Typical Flow Schematic PRESSURE ees E DELIVERY VALVE WATE
22. ct to periodically adjust the packing or replace the pump seal If the pump is properly lubricated and used at moderate temperatures the seal should last several years The following section describes the proper procedures for replacing the seal Periodic replacement of the pump drive V belt is also to be expected Note If the pump motor wiring is disconnected for removal from the unit you must check the actual direction of rotation when the motor is rewired to the unit BSTERLCO 6017 Series Hot Oil Large Temperature Control Units How to increase Belt Life S lg of ge Keep sheaves and belts clean Abrasive dust rust oil and acids reduce service life Give drives elbow room Never let belts run against belt guards or other obstructions ry z Use large diameter sheaves and fewer belts You save money and increase drive life Not This Never force belts Move motor on adjustable base so belts can go on easily Eliminate slack Adjust motor and tighten belts in position Slack belts wear excessively cause slippage and deliver less power Use matched belts Matched belts run smoother and last longer because the load is evenly distributed Never replace just part of a set of belts Avoid belt idlers Belt idlers decrease belt life Always maintain proper tension through motor adjustment Mount belts straight Shafts must be parallel and sheave grooves in alignment to prevent unnecessary belt
23. e the set point The LO deviation is 100 F about 37 C below the set point Alarms reset automatically The PROBE FAIL indicator is on when a temperature sensing probe fails A delivery probe failure displays DEL on the screen and a return probe failure displays RET on the screen The alarm resets after the failed probe is replaced BSTERLCO 6017 Series Hot Oil Large Temperature Control Units MOTOR FAIL Indicator The MOTOR FAIL indicator is on during improper pump rotation motor out of phase or thermal motor overload conditions This is a fatal fault condition requiring that main power be disconnected to reset the M2B controller 5 3 Using M2B Controller Keys SET POINT Key SET POINT Press and hold the SET POINT key then press the UP Arrow key to increase the set point value or press the DOWN Arrow key to decrease the set point value displayed on the SET POINT LED screen UP Arrow Key Press the UP Arrow key to increment or advance the values or settings on the LED screens DOWN Arrow Key DOWN Press the DOWN Arrow key to decrement or reduce the values or settings on the LED screens Important Do not change any of the control settings without consulting the Sterling Sterlco Service Department The Sterling Inc warranty does not cover TCU failures from tampering with controller settings BSTERLCO 6017 Series Hot Oil Large Temperature Control Units Page 37 ENTER Key INDEX Key
24. e Control Units Motor Lubrication Procedure Be sure that the grease you are adding to the motor is compatible with the grease already in the motor Consult your Baldor distributor or an authorized service center if a grease other than the recommended type is to be used A high grade ball or roller bearing grease should be used Recommended grease for standard service conditions is Polyrex EM Exxon Mobil Equivalent and compatible greases include Texaco Polystar Rykon Premium 2 Pennzoil Pen 2 Lube and Chevron SRI 1800 RPM Lubrication Intervals in Hours Grease to be added upto 250 251 400 over 400 5 HP and Under 12 000 6 000 1 200 0 30 84 06 7 1 2 to 20 HP 10 000 5 000 1 000 25 40HP_ 8 000 4 000 Caution To avoid damage to motor bearings grease must be kept free of dirt For an extremely dirty environment contact your Baldor distributor or an authorized Baldor Service Center for additional information With Grease Outlet Plug 1 Clean all grease fittings 2 Remove grease outlet plug 3 If motor is stopped add the recommended amount of grease If motor is to be greased while running a slightly greater quantity of grease will have to be added Add grease slowly until new grease appears at shaft hole in the endplate or purge outlet plug 4 Re install grease outlet plug Without Grease Outlet Plug 1 Disassemble motor 2 Add recommended amount of grease to bearing and bearing cavity Bearing should
25. e of achieving extremely high pressures it is necessary to regulate the pressure through use of a regulating by pass line Fulflo valve Because the pump is a positive displacement pump it will supply the process with rated flow at or below the rated pressure The flow is constant until the pressure reaches the rated pressure The pressure however is a function of frictional losses through the process that it is attached to Systems with large process connections ports and piping will operate at low pressures While systems with small process connections ports and piping will operate at higher pressures Once the pressure requirements exceed the rated pressure the fulflow valve will open and bypass the necessary fluid to prevent high pressures A regulating by pass line featuring a Fulflo valve is standard in all units This is a safety device to prevent excessive pressure in the event that the delivery line is obstructed Each Fulflo is factory preset to limit system pressure as specified by the customer It must not be tampered with in any way BSTERLCO 6017 Series Hot Oil Large Temperature Control Units In the event of an obstruction in the line the Fulflo will open and divert fluid from the delivery TO PROCESS line to the return From Process line A constant flow of fluid is maintained through the heater tank to prevent damage to the heating elements and fluid Cooling Optional The Sterlco designed shell and tube heat exch
26. harts and Figures 1 6017 Series Hot Oil Large Temperature Control Unit and Specifications 16 2 6017 Unit Piping Setup 16 3 Typical Flow Schematic 24 4 Typical M2B Graphic and Button Control Panel 34 5 Control Panel Switches 39 6 System Status Board Indicators 41 Page 6 AIID 6017 Series Hot Oil Large Temperature Control Units 1 General Information 1 1 Introduction Your Sterling Sterlco 6017 Series hot oil temperature control unit circulates thermal transfer type oil through your process and to precisely automatically and reliably maintain it at a temperature you can select The operating range of your temperature control unit is from 100 F to 550 F 38 C to 288 C The unit is best suited for use with SterlTherm Heat Transfer Fluid A recommended list of commercially available heat transfer fluids can be obtained through Sterling Customer Service Rapid recirculation of the fluid provides a close and uniform temperature relationship between the TO PROCESS and FROM PROCESS lines This does of course depend on the configuration of your process and any restrictions within the mold This recirculation combined with the immersion heater and optional cooling capability gives fast and accurate response to bring the fluid up to temperature or to changes in the settings when needed Performance is assured through matching the unique Sterlco controllers to the Sterlco high temperature system The two systems are fully i
27. ient temperature ranges permitted for storage and operation Ambient storage range Ambient operation range ea e ee i 40 F to 185 F 40 C to 85 C 4 F to 120 F 20 C to 49 C You should preheat the process heat transfer fluid first if you want to start the unit below an ambient temperature of 30 F 1 C 3 3 Connecting Piping Page 20 Make sure that all external piping is properly sized to reduce external pressure drop as much as possible Do not install process or water supply drain piping smaller than the fittings on the unit If the water supply piping is larger than unit fittings reduce the pipe size at the unit QGP 6017 Series Hot Oil Large Temperature Control Units The following table lists 6017 TCU pipe sizes Connections for TO PROCESS and FROM PROCESS lines are e 2 NPT 50 8 mm at 90 gpm 341 Ipm e 2 1 2 NPT 63 5 mm at 150 gpm 568 Ipm e 3 NPT 76 2 mm at 200 gpm 757 lpm Water connections for COOLING WATER SUPPLY and COOLING WATER DRAIN are e 34 NPT 19 1 mm for 3 9 amp 6 7 sq ft heat exchangers e 1 NPT 25 4 mm for 13 21 amp 27 sq ft heat exchangers The customer is responsible for conversions to metric standards Notes Always use a backup wrench to support 6017 unit piping when making connections Make sure all external piping is supported independently of the 6017 unit Sterling Inc recommends that you have strainers installed on the cooling water inlets and cu
28. ipment is Not Correct If the shipment is not what you ordered contact the parts and services department immediately at 262 641 8610 Have item and order numbers ready Hold the items until you receive shipping instructions 2 5 Returns Important Do not return any damaged or incorrect items ou receive shipping instructions from Sterling Inc Page 18 GID 6017 Series Hot Oil Large Temperature Control Units 3 Installation 3 1 Work Rules The installation operation and maintenance of this equipment must be conducted in accordance with all applicable work and safety codes for the installation location This may include but is not limited to OSHA NEC CSA and any other local national and international regulations e Read and follow these instructions when installing operating and maintaining this equipment If the instructions become damaged or unreadable obtain additional copies from Sterling Sterlco e Only qualified personnel familiar with this equipment should work on or with this hot oil temperature control unit e Work with approved tools and devices e Disconnect the electricity before maintenance or service If the unit is installed with a power cord that can be un plugged unplug it If the unit is permanently wired to a power main make sure that a fused power disconnect is installed to allow the disconnect to be locked in the OFF position Open and lock out the disconnect installed in the control e
29. lange for tightness e Remove the heat exchanger tube bundle and check it for lime and mineral deposits Carefully clean the bundle as needed 6 2 Routine Servicing Your hot oil temperature control unit requires little in preventive maintenance and servicing To keep it in good reliable working order make sure you follow the following scheduled preventive maintenance procedures Keep surfaces clean and free of any excessive accumulations of dirt oil or debris This is especially true for the pump It relies on free air circulation for proper cooling Check the motor air intake screen for any accumulation of dirt clean it as needed SSTERLCO 6017 Series Hot Oil Large Temperature Control Units Page 47 Servicing the Unit Monthly or Every 500 Hours e Lubricate the pump at the grease fittings with a high quality polyurea grease rated at 320 F or higher Recommended Chevron Black Pearl do not over lubricate e Adjust the pump drive belt tension Use the belt tensioning specifications listed in this chapter on Page 51 Make sure that the motor pulley is properly aligned with the pump pulley use a straightedge to check Tighten motor mounting bolts after realignment e Inspect the screen in the Y strainer for accumulations of debris Clean as needed Servicing the Unit Every Three Months Remove and clean the screen in the Y strainer Replace the screen if it is damaged Page 48 GID 6017 Series Hot Oil Large Temperatur
30. n drain line Clear drain line or eliminate back pressure condition Unit overheats unable to cool Heat exchanger tubes plugged Remove tube bundles clean by lime deposits replace as required Test solenoid valve by switching to Manual Cool mode and listen for valve operation Replace if faulty ator Inspect replace faulty line or Leaks in connecting lines connection Faulty solenoid valve KASE pcia Perform venting sequence in Air in circulating lines Chapter 3 l Check fluid level in sight glass Low fluid Add fluid if required Drain water from low point in Water in fluid piping see Chapter 3 or boil water off Allow vent timer to run out or Vent solenoid open check valve operation when unit is cold by opening the fill port Check motor rewire if Pump running in reverse necessary See electrical diagrams Pump repair adjustment Adjust head spacing or replace needed worn pump components V belt broken worn Replace as required Drain water from low point in Water in fluid piping see Chapter 3 or boil Noisy pump water off Severely degraded fluid A and flush system Replace Rapid drop in pressure no pressure AIID 6017 Series Hot Oil Large Temperature Control Units Page 53 Service Notes Page 54 ES TERLCOJ 6017 Series Hot Oil Large Temperature Control Units Service Notes GID 6017 Series Hot Oil Large Temperature Control Units Page 55 Service Notes Page 56 ES TER
31. n Mode Indicator Light The Power On mode indicator light illuminates to indicate that the control circuit is energized in the unit Page 42 AIID 6017 Series Hot Oil Large Temperature Control Units Auto Mode Indicator Light The Auto mode indicator light indicates that the Auto mode is active and the controller is monitoring the system and controlling the process If the Auto light is off and the Cool Solenoid indicator light is illuminated the controller is disabled and the cooling solenoid is open permitting maximum cooling If the Auto and Cool Solenoid indicator lights are off the unit is in standby Fault Indicator Lights Pump Overload Indicator Light The Pump Overload indicator light illuminates when the pump is overloaded This is an alarm condition so the audible alarm activates to notify you of the pump overload fault and the unit shuts down Always correct the alarm condition before returning to normal operation Low Pressure Indicator Light The Low Pressure indicator light illuminates when the unit has low heat transfer fluid pressure This is an alarm condition so the audible alarm activates to notify you of the low pressure fault and disables controller outputs permitting the pump to continue to circulate fluid to avoid damage If low pressure continues past five minutes elapsed time the pump shuts off Always correct the alarm condition before returning to normal operation Safety Thermo Indicator
32. n eo manei note ae na d da aa ee datand aa e tdi d a at A 19 3 2 Installation Requirements nenea eee 19 3 3 Connecting PIPING secara sri iati 0 aia A 20 3 4 Making Electrical Connections nenea 26 Page 4 GID 6017 Series Hot Oil Large Temperature Control Units Table of Contents 4 Startup Preparations ccsccccsssccsesecsensesensneeneneeesees 29 4 1 Starting the Uni cca c i doina and cin en cin ein en cind ein cn eine 29 4 2 Shutting Down the Unit nana 32 4 3 Returning Fluid to the Tank eee eeeeeeeeeaaa 32 5 Using Controls and Indicators 11ccccseeecerneenees 34 5 1 The Microprocessor Controller 34 5 2 Identifying M2B Controller Panel Components 35 5 3 Using M2B Controller Keys eee 37 5 4 Identifying Control Panel SwitChes ssssssesssseeessteeeeeeeeeees 39 5 5 Identifying System Status Board Indicators ssseeeeeeeee 41 6 Preventive Maintenance 1 scccssscsssssssssesseseees 46 Bl PEROGICGNECKS a intime in aa bitii iat ieee di at iai 46 6 2 Routine Servicing cceeccccceeeeeeeeeseeeeeeeeeeeeeeeeeeeenaeeeeeeeeeeeeeneees 47 6 3 Draining the Unit for Storage 50 6 4 Corrective Maintenance ssssssssssssssessssssessssssssssseeeeeeees 50 6 5 Maintaining the POMP imersie eitat ata See Addendum 7 Troubleshooting mmmn onoarea nenea a 52 EST ERLCOJ 6017 Series Hot Oil Large Temperature Control Units Page 5 C
33. n to drain the mold and process lines Note that this is just the opposite of unit start up air purge 1 Cool fluid to 150 F 66 C maximum 2 Depress the PUMP STOP push button 3 Close the Return Valve 4 Open the Blow Off Valve with autovent the valve will open on its own 5 Depress and hold the PUMP REVERSE push button The pump will then run in reverse drawing fluid from the mold and lines and into the reservoir tank 6 Watch the sight glass to prevent overflow of the reservoir tank CAUTION The reservoir tank may not have adequate volume to contain the total system capacity of fluid An overflowing reservoir allows hot fluid to escape and become a potential fire and slip hazard The total capacity of the tank can be found on page 14 If it appears that the tank may overfill connect a line from the FILL port of the reservoir tank to a clean auxiliary container Page 32 QGP 6017 Series Hot Oil Large Temperature Control Units Notes dii 6017 Series Hot Oil Large Temperature Control Units Page 33 5 Using Controls and Indicators 5 1 Page 34 The Microprocessor Controller The M2B controller is an easy to operate microprocessor based PID control device When the process reaches the set point the PID control cycles the cooling valve and or immersion heater to maintain the proper leaving fluid temperature The controller is fully factory tested Set the process temperature set point y
34. nclosure 3 2 Installation Requirements Make sure that you meet the following requirements when installing and operating your 6017 hot oil temperature control unit Installation Location Considerations Locate the 6017 unit as close as possible to the process for proper circulation and temperature control Take care when selecting a location The area surrounding the unit must be free of obstructions to ensure proper ventilation of internal components Allow a minimum clearance of at least 30 inches 76 cm BSTERLCO 6017 Series Hot Oil Large Temperature Control Units Page 19 Make sure that the unit location is not in a confined space to ensure proper air circulation Special air circulation ventilation is required for units operating at temperatures exceeding 500 F 260 C Vapors can escape from areas such as the reservoir tank during high temperature operation CAUTION Harmful vapors may be generated from thermal fluid during high temperature operation Prolonged or repeated exposure of these hot generated vapors may result in eye and respiratory tract irritation Avoid contact or inhaling harmful amounts of material Consult the Material Safety Data Sheet MSDS for precautions and instructions for the thermal fluid you are using Note Before storing your 6017 temperature control unit make sure you remove all residual water with compressed air to avoid a potential freezing hazard Note the following table of amb
35. ne tool transformer with primary fuse protection and a grounded secondary A main power disconnect is included as for ease of service The electrical panel is UL listed and complies with NEC provisions All components are IEC rated for long life and reduced maintenance The heater elements are branch fused and protected from contactor welding by a separate primary voltage contactor The pump motor is controlled by a full voltage magnetic reversing starter with fused branch circuit overcurrent and thermal overload protection Many additional features are available as options A NEMA 12 enclosure is standard with NEMA 4 available as an option Upon initial start up and mold process change out you ll need to purge all air and water from the system The 6017 unit has appropriate valving to ensure complete purging Procedures are covered in Chapter 3 WARNING Failure to purge the system of air before heating may result in serious injury or critical system and equipment damage Make sure you properly purge the system of air before starting the heater cycle GID 6017 Series Hot Oil Large Temperature Control Units Page 13 Pressure Switch Safety Thermostat Reservoir Tank Page 14 A pressure switch is built into each unit to guard against heater damage This feature prevents the heater elements from being energized unless the pump is running and fluid is in the system After a preset time the pump shuts down if the fluid
36. necessary to perform the following start up procedures This will ensure that all air is vented from the system to prevent fluid degradation and damage to the heater The autovent solenoid operates just like the manual Blow Off valve however it opens electrically and for only a specified time The benefit is that it vents every time the unit is started and it will automatically shut off after a predetermined amount of time It is also convenient because the vent button is located on the front of the unit It has the added safety of being automatically prevented from opening above 250 F by a safety thermostat 1 Open the Return Valve Make sure the drain valves are closed and plugged 2 Add fluid to the reservoir tank until the level is near the top of the sight glass 3 Depress the Pump Start button to start the pump Check motor rotation by observing the pressure gauge If the gauge indicates positive pressure rotation is correct If not disconnect power and reverse the incoming power leads 4 Close the Return Valve inside the unit 5 As fluid is drawn out of the reservoir tank to fill the process the fluid level will fall in the tank Continue to add fluid to maintain the level about 4 inches from the bottom of the sight glass Page 30 GID 6017 Series Hot Oil Large Temperature Control Units CAUTION You must purge the system of air before the heating cycle Personal injury and system damage can occur from a pressurized system
37. nes connections Loss of fluid in process fitti ittings Allow vent timer to run out or Vent valve open check valve operation when unit is cold by opening the fill port Unit does not heat properly can Switch to Manual Cool mode not achieve set point Faulty dirty solenoid valve several times to flush valve If usually detected when there is a the leak continues disconnect steady stream or trickle of water the power to the unit turn off the out of the drain line water supply and clean or replace the solenoid Degraded fluid Drain and replace fluid Visual inspection of coil and Defective heater contactor contacts Repair replace defective contactors Check resistance on all three 3 legs of heater with an Defective immersion heater ohmmeter If not all equal Unit does not heat contact factory for replacement heater Check heater tank for scorched discolored paint Check Heater burnout resistance on all three 3 legs of heater with an ohmmeter Replace heater as needed Faulty Sterlco TCU Page 52 GID 6017 Series Hot Oil Large Temperature Control Units Check the heater output with an ohmmeter to ground It should Unit does not heat Controller heater output open read in the mega ohm range cont d Infinite or zero readings indicate a defective output Clogged Y strainer Clean Y strainer sit supply to unit is turned Open water supply Water drain is plugged or excessive back pressure i
38. ning you can select the AUTO position or the MAN COOL manual cooling position with the Mode Select switch Select AUTO mode to energize the controller permitting it to monitor and control the process The switch automatically returns to the OFF position when in AUTO mode The switch stays in the MAN COOL position in Manual Cooling mode CAUTION Always let the pump run for at least one 1 minute before switching to AUTO mode Never switch to AUTO mode when filling or venting the unit except as described in the Unit Startup chapter Improper switching can seriously damage the heater as it could become energized with air in the system Page 40 GID 6017 Series Hot Oil Large Temperature Control Units Alarm Silence Press the ALARM SILENCE button to silence the audible alarm on the console CAUTION After you silence the alarm make sure you ocate and correct the alarm condition before continuing with unit operation 5 5 Identifying System Status Board Indicators The system status board is located next to the controller panel It displays indicator lights to show current operation status letting you analyze system performance Figure 6 System Status Board Indicators PUMP OVERLOAD SYSTEM STATUS oo POWER ON PUMP REVERSE AUTO PUMP FORWARD BYPASS HEATER RELIEF VALVE LOW DELIVERY PRESSURE SAFETY THERMO HEAT STRAINER EXCHANGER HIGH LEVEL COOL RETURN Low VENT SOLENOID LEVEL SOLENOID DRA
39. nnections and disconnect the electricity when service calls are needed e Locate disconnects in an easily accessible location Operators should not have to squeeze around the 6017 unit to reach disconnects especially in case of emergency e When running conduit whips to the 6017 unit make sure that whips are routed away from hot piping Page 26 GID 6017 Series Hot Oil Large Temperature Control Units Check the unit nameplate for correct voltage and amperage before making electrical connections DANGER IMPROPER ELECTRICAL CONNECTIONS CAN DAMAGE THE UNIT AND CAUSE SERIOUS OPERATOR INJURY OR DEATH MAKE SURE THAT ALL ELECTRICAL CONNECTIONS ARE MADE BY A QUALIFIED ELECTRICIAN AND THAT ALL CONNECTIONS ARE TIGHT Make all electrical supply connections at the front of the unit An access panel covers all electrical connections Run electrical connections to the supply terminals from either side of the unit Make sure that all three phases are wired correctly The pump runs backwards if not wired properly GID 6017 Series Hot Oil Large Temperature Control Units Page 27 Notes Page 28 AID 6017 Series Hot Oil Large Temperature Control Units 4 Startup Preparations 4 1 Starting the Unit UNIT START UP WITH MANUAL BLOW OFF VALVE The highly engineered controls and controller make this unit almost self operating Before you can begin heating it will be necessary to perform the following start up procedures This
40. ntegrated to achieve accurate control 1 2 Necessary Documents The following documents are necessary for the safe installation operation and maintenance of your Sterling Sterlco 6017 Series hot oil large temperature control unit You can obtain additional copies from Sterling Inc Make sure that appropriate personnel are familiar with these documents M This manual M The electrical schematic and connection diagram in the control enclosure WI The manuals for accessories and options you ve selected WI The customer parts list in the control enclosure GED 6017 Series Hot Oil Large Temperature Control Units Page 7 1 3 Models Covered This manual lists installation operation and maintenance instructions for the 6017 Series hot oil large temperature control unit Model numbers are listed on the serial tag A model number followed by Q indicates a specially constructed unit and not all information in this manual may apply Make sure that you know the model number serial number and operating voltage of your unit if you contact Sterling Inc 1 4 Standard Features e M2B microprocessor controller with fuzzy logic includes diagnostic features with indicator and warning status lights e Non fused lockable rotary disconnect e Dual stage immersion heater with IEC contactors e 550 F 288 C maximum operating temperature e Branch fusing e System status graphic display e Pressure switch for low pump pressure shut down
41. of this unit and related equipment per OSHA article ART 1910 147 Before you begin servicing this unit disconnect all power to the unit let the unit cool down completely and turn off the water Failure to follow these directives can result in serious injury or death 6 1 Periodic Checks Making Daily Checks e Check fluid level add fluid as needed e Check all connecting lines hoses and connectors for wear or damage Making Monthly Checks e Check for leaks developing at the pump seal gaskets and other similar locations e Check the pump drive V belt for any wear e Check the reservoir tank vent for any obstructions Page 46 QGP 6017 Series Hot Oil Large Temperature Control Units Making Quarterly Checks e Check the heat transfer fluid for deterioration If the fluid is noticeably darker or it seems significantly thicker drain the system and replace the fluid with fresh new recommended heat transfer fluid Do a routine check of the fluid every 1 000 hours of operation or every three 3 months whichever comes first Contact Sterling Inc Service for information on fluid testing Making Six Month Checks e Inspect electrical connections for secure tight attachment points and ground connections Inspect the power cable especially at the entrance point to the electrical enclosure Have a qualified electrician perform this inspection e Check the mounting bolts on the pump the motor and the heater f
42. ou want and the controller does the rest Built in range of operation on the controller is 0 F to 550 F 18 C to 288 C Figure 4 Typical M2B Graphic and Button Control Panel STATUS DISPLAY KAR 185 omoes LO HEAT SET POINT PROCESS AT Fo oC O O ee COOL cit eno Ree a a SET POINT Fe ra m AUR Pere DISPLAY STERLING INC TEMPERATURE CONTROL SYSTEM M2B MILWAUKEE WI GID 6017 Series Hot Oil Large Temperature Control Units 5 2 Identifying M2B Controller Panel Components Screen Displays SET POINT Numeric LED During normal operation the SET POINT LED on the controller displays the process set point you want the unit to maintain It also displays parameter and pre set function values during setup PROCESS Numeric LED During normal operation the PROCESS LED on the controller displays the actual process temperature at the To Process thermocouple It also lists parameter symbols during setup and error messages if an error occurs Status Indicators RUN Indicator The RUN indicator is on during normal operation and flashes during the auto tuning sequence HI HEAT Indicator The HI HEAT indicator is on when fluid heaters are at 100 capacity to rapidly raise fluid temperature LO HEAT Indicator The LO HEAT indicator is on when fluid heaters are at 50 percent capacity COOL Indicator The COOL indicator is on when fluid temperature is above the set point and is being cooled Display
43. p hazard Never open pipe insulation that is smoking Adding oxygen can cause a fire Connecting Cooling Water Piping You must provide cooling water at 25 psi to 75 psi 172 4 kPa to 517 1 kPa 1 7 bars to 5 2 bars for proper operation Untreated water can foul or corrode the heat transfer surfaces slowing water flow and causing fluid temperature control problems Sterling Inc sells a complete line of water treatment equipment that can reduce downtime and maintenance costs Run properly sized cooling water lines never smaller than the outlets on the 6017 unit If external piping is larger than 6017 unit connections reduce the size of the piping at the unit Connecting Vent Piping You must leave the vent connection open to the atmosphere at all times The vent connection is located on top of the reservoir On systems with piping above the reservoir level you must run vent piping to a minimum height of one foot 1 31 cm above the highest point in the system Run the piping down into an auxiliary vented overflow chamber such as a vented covered 55 gallon 208 liter drum This practice ensures that overflow will not create a hazard to personnel Remember All external piping must be supported independently of the 6017 unit Page 22 QGP 6017 Series Hot Oil Large Temperature Control Units CAUTION The reservoir tank must be vented to prevent pressurization A pressurized reservoir could rupture allowing hot fluid to es
44. pplied with 50 60 75 100 120 150 and 200 kW low watt density immersion heaters depending upon the heating needs of the process All models are built to provide full or partial heat as required by the process and determined by the controller to provide more precise control SSTERLCO 6017 Series Hot Oil Large Temperature Control Units Page 9 Heater Tank Pump Ful Flo Valve Page 10 The 6017 features a single pass heater tank The tank is designed to maintain an optimum balance of fluid velocity versus watt density and turbulence for excellent heat transfer and minimal pressure drop The high fluid velocity will greatly prolong the life of the heater and fluid The pump is a packed positive displacement pump It features a nearly failure free design and has proven itself after years of dependable service It is well suited for use with a variety of commercially available heat transfer fluids The pump has only two internal moving parts and a specially designed seal to give years of trouble free service even at high temperatures The only routine maintenance required is weekly greasing and occasional packing and headspace adjustment see Chapter 6 on Page 47 for more information The pump is capable of running in either direction Thus the pump reverse feature can be used to draw fluids back from the process It is not necessary to install a service air line to purge the lines before changing molds Since the pump is capabl
45. rol Unit The unit shown below is a 6017P Model BLOW OFF VALVE Pom RETURN ALE 6017 Series Temperature Control Unit Specifications Model Heaters Pump Dimensions Shipping Number Available capacities Available capacities H W D Weighta 460 230 50 kW 100 kW 150 kW 200 kW 90 gom 150gpm 200gpm in cm in cm in cm lbs Kg v v v v v v n a n a 158 30 1 900 862 v n a n a n a 158 30 1 900 862 v v v v v v 158 46 153 3 200 1 452 v M v v M v 158 46 153 3 200 1 452 Theactual shipping weights may vary based on options selected The shipping weights listed are the maximum shipping weights for standard units of the listed cabinet size Page 16 GID 6017 Series Hot Oil Large Temperature Control Units 2 Shipping Information 2 1 Unpacking and Inspection You should inspect your Sterling Sterlco 6017 Series hot oil large temperature control unit for possible shipping damage If the container and packing materials are in re usable condition save them for reshipment if necessary Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In case of breakage damage shortage or incorrect shipment refer to the following sections 2 2 Inthe Event of Shipping Damages Important According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends
46. stomer supplied shut off valves on all piping connections Use common black welded pipe for permanent installations The 6017 is designed to operate with an open unrestricted drain line Steam rapidly expands within the heat exchanger so any overpressure condition from backpressure or standing columns of water against the drain must be avoided If you must use a pipe joint compound use a compound that can withstand the high temperatures and pressures of your 6017 unit Always insulate all piping to prevent burn hazards and to retain heat Make sure insulation is properly rated for maximum operating temperatures of your 6017 unit Piping Considerations for Mobile Installations Because your 6017 unit is not fitted with casters it should be secured to the floor with the appropriate hardware You can purchase high quality flexible metal hose from Sterling Sterlco to allow for thermal expansion of the process piping state the length you want when ordering SSTERLCO 6017 Series Hot Oil Large Temperature Control Units Page 21 Connecting Process Piping CAUTION Hoses valves and other components in your process must be able to withstand the 6017 unit s maximum temperatures and pressures Maximum temperatures and pressures are listed on the unit nameplate Carefully inspect all components before installation If in doubt about component suitability obtain factory components Fix all leaks Fluid can be a potential fire and sli
47. system packages including drawings equipment labor and construction materials and union or non union installations Sterling Inc 2900 S 160 Street New Berlin WI 53151 www sterlco com STER LCOS 6017 Series Hot Oil Large Temperature Control Units Page 57
48. ve the fuses and carry them with you Make sure the hot oil temperature control unit and components are properly GROUNDED before you switch on power Do not jump or bypass any electrical safety control Do not restore power until you remove all tools test equipment etc and the hot oil temperature control unit and related equipment are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment BSTERLCO 6017 Series Hot Oil Large Temperature Control Units Page 3 Table of Contents 1 General Information mmm numea nenea nenaasanne 7 AA introduction Sica aia ai aripii ata aia at aia aaa ue aa aa fu ad aa 7 1 2 Necessary Document mccu nenea nenea nana 7 Tea Models COVE OA re tates sate Gr tated aia aa ai a aa ai 8 1 4 Standard Features acestei a dea cita ta i det dan d a ded facil 8 1 5 Available Options meet neeennnanee eee ne 9 1 6 Feature Descriptions sait it ia aice e da 9 2 Shipping Information m neoane enee an eoooaneeneeaaee 17 2 1 Unpacking and INSPeCiONita wa i tie are ai ta aa 17 2 2 Inthe Event of Shipping Damages cnnnnneeeeeeeeee eee 17 2 3 Ifthe Shipment is Not Complete ccc nenea 18 2 4 Ifthe Shipment is Not Correct ccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 18 2 9 2 01g oaia dica de dat ci d ca ate cd ca du ci Ed au 18 3 ANSta lati Ossie 0 ia a 19 Od WV GRU Gia ete
49. wear Don t overload An overloaded belt drive is like a one ton truck with a two ton load both are sure to break down Always use ample capacity Operating drives without guarde In place can result In severe Injury or death Emerson Power Transmission Manufacturing L P 1998 1999 All Rights Reserved BST ERLCO 6017 Series Hot Oil Large Temperature Control Units BELT TENSIONING INSTRUCTIONS Disconnect power before Installation and maintenance Fallure to do so can result In severe Injury or death 1 Measure the belt span 2 Calculate deflection 3 See tables below for correct deflection force 4 Apply force at right angles to the center of the span see diagram below The BROWNING belt tension checker shown at left is ideal for this procedure 5 Check the tension at least twice during the first day of operation and periodically thereafter Be sure DEFLECTION BELT SPAN use the erie inexpensive BROWNING Belt Tension Checker See Form 5453 ala 2 for more detail The capacity of the BROWNING belt tension checker is 35 lbs Other means of applying force must be used if force requirement is greater than this SHEAVE DIAM INCHES DE FLECTION FORCE LBS Belt Deflection Force Super Gripnotch Gripbelts Belts and and Unnotched Notched Gripbands Gripbands Used New Used New Belt Belt Belt Belt 1000 2500 3 7 5 5 4 1 6 1 2501 4000 2 8 4 2 3 5
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