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Sterling Fan Royal User's Manual

1. 38 Set Point key 37 Up arrow key 37 Controller operation 42 Cool indicator 35 Cooling regulation 32 Cooling water connections 21 Copyright information 2 Corrective maintenance 50 52 Cutout switch low pressure 30 Deionized water applications 20 Delivery indicator 35 Digital flow meter 39 Disclaimer information 2 Display indicators 35 AT indicator 35 Delivery indicator 35 C flow indicator 35 Return indicator 35 Display key 38 Distilled water applications 19 Page 68 Down arrow key 37 Draining 49 Electrical connections 24 52 Electrical subpanel 28 Electncal wiring schematics 26 27 Electricals 32 Enter key 37 Expansion tank 21 External piping sizing considerations 17 Fiuid Pressure indicator 36 General information Available options 9 10 Models covered 8 Necessary documents 7 8 Standard features 9 Graphic and button panels 34 Graphic panel 34 Graphic pane buttons 39 Heater contactor 31 Heaters 30 Hi Alarm key 38 Hi Heat indicator 35 Hi Lo Alarm indicator 36 High mobility piping considerations 19 Identifying controls and features 29 42 Alarms 40 Auto tuning the controller 41 Communications 42 Controller factory setup 40 Controller keys 36 39 Controller operation 42 Graphic panel buttons 39 Identifying mechanical controls and features 29 33 Microprocessor controller 33 Identifying mechanical controls and features 29 33 Inc
2. Im Royal Series Water Temperature Control Units Page 61 Figure 10 Customer Recommended Spare Parts Lists cont d Controller and Communications Components Part number Description R R 232 communications 485 communications Motor Fuses Note Values in this table are the amperages of the fuses used for the correct sized motor running at the correct voltage o 298 20 J o ns J s RE ZE A OR a a E 7 E RR ERE EREI p Dex tee IE PEPI ERE SM EEE 2 E FII PI RER ENE E ng IPN Css ERE EEE IN E a O PE Part number Fuse amps Fuse voltage Part number Fuse amps Fuse voltage 725 00812 00 10amps 600v 725 00759 00 4amps 600V 5amps ho w 5 amps 725 00810 00 8amps 600V 725 00784 00 50amps 600V 725 00811 00 9 amps 600V _ 725 00785 00 60amps 600V Page 62 Tm Royal Series Water Temperature Control Units e Notes Im Royal Series Water Temperature Contro Units Page 63 7 Troubleshooting Condition Possible cause N Check main disconnect fuses power x wiring and power lead to unit Voltage must be within plus or Wrong voltage supplied to unit minus 10 of nameplate rating Unit does not turn on Defective on off switch Replace Control circuit fuse blown Replace Defective control transformer Check transformer Broken or loose wire
3. Solenoid coil circuit is open Modulating valve is not operating but OUT2 LED is on Insufficient pressure differential Find a means to get less back ae pa WATER IN and pressure in the WATER OUT line A R ooling valve wi Cooling valve is undersize oplage c g vave mina larger valve Foreign material under valve Manually open valve to clear seat seat of material Reduce WATER IN or MAKEUP water pressure Relief valve leaks High system pressure Unit runs continuously cooling or heating and cannot attain set point Unit under sized for application Call sales representative I Im Royal Series Water Temperature Contro Units Page 65 Condition_______ ____ Possibiecause Solution Visually inspect coil and Defective heater contactor contacts repair replace defective contactors Check resistance on all three 3 legs of the heater with an ohm meter If not all equal contact factory for replacement heater Check the heater output with an ohm meter to ground It should Controller heat output open read in the mega ohm range Infinite or zero readings indicate a defective output Heater contactors not Set process temperature to enerdizind but HEAT LED is on maximum and check for control gizing voltage at heater contactor Immersion heater elements Remove heater and clean dirty elements Check heater tank for scorched discol
4. Solution Undersized connectors water Increase size of connectors lines water lines Long connecting lines between Move the unit closer to the mold unit and mold and shorten connecting lines Connect lines for paralle flow Serpentine flow through mold instead of series flow T Check mold for metal chips or Blocked water line in mold lime buildup Clean mold Quick disconnect fitting with Remove and replace fitting or check valve valve Lime buildup in unit piping Clean or replace Temperature fluctuations rapid cycling from hot to cold Check unit by connecting Y line directly from To Process to From Process line Run unit to determine if TCU controls set point temperature Reversed probes E To and From Process Drain is plugged or excessive Clear drain line or eliminate Faulty TCU back pressure is in drain line back pressure condition Test solenoid valve by pressing VENT button and listen for valve operation Replace if faulty Faulty solenoid valve Controller Cool output relay open Replace output relay Set process temperature to minimum and check for mag netism on solenoid coil top Check coil resistance If MQ range replace solenoid coil Set process temperature to minimum and check for complete travel of valve Solenoid valve is not operating but COOL LED is on Unit overheats or does not cool
5. can be croded away in the area around the scat of the rotary seal This area should provide a straight smooth bearing surface for the cup seal Should your casting show signs of erosion in this area the casting needs to be replaced The replacement cost of the casting is very modest compared to thc down time and maintenance cost for frequently replacing the scal 4 Under some conditions the pump may not start After turning off the power supply check the motor shaft to be certain it is free to turn By removing the drip cover on top of the motor you ll have access to the end of the shaft It has been slotted to make it casy to turn with a screwdriver If the shaft is free to turn next check that the motor overloads are set check for blown fuses and finally check the power supply on cach leg to the motor A qualified electrician should check the motor and its circuit Important If the pump motor wiring is disconnected for removal from the unit make sure that you check the actual rotation direction when the motor is rewired to the unit A phase sensor does not always indicate proper rotation if motor wire leads are reversed at installation Consult the elementary wiring diagram for more information Page 52 III Royal Series Water Temperature Contro Units Heaters Heaters may need to be cleaned chemically or mechanically to remove deposits and dirt that reduce heat transfer and cause hot spots Hot spots cause premature
6. 000 ohm 1 KQ platinum RTD probes are included with your Royal temperature control unit One is located downstream from the heater to sense To Process temperature the other probe is located upstream from the pump to sense From Process temperature Safety Thermostat The safety thermostat mounted on the side of the heater tank protects against thermal runaway The thermostat guards against the unlikely event of runaway heating If overheating occurs the safety thermostat shuts down heater outputs The unit continues to pump water through the system to prevent heater damage Sterling recommends that you install an audible or visual alarm to the a terminals provided Factory installed alarms are available sec the electrical schematics in Figure 6 on Pages 26 and 27 for more information Pressure Relief Valve If the combined pressure of the cooling supply water and pump discharge exceeds 150 psig 1 034 25 kPa 10 34 bars the pressure relief valve opens and relieves the pressure This is a non adjustable ASME construction valve with a stainless steel spring Important Route a pipe from the pressure relief valve to a suitable drain to reduce potential scalding hazard The drain line must not have any restrictions or back pressure Page 30 Imm Royal Series Water Temperature Control Units Low Pressure Cutout Switch Pumps Heaters Solenoid Valves This switch set at 16 psig with a 2 psig differential 110
7. 250 Voltage must be within plus or minus ten percent 10 of the nameplate rating Make sure your installer provides external protection Page 26 Im Royal Series Water Temperature Control Units Figure 6 Typical Electrical Wiring Schematic Drawing 1 uuu NOTE CUSTOMER IS RESPONSIBLE FOR PROVIDING MAIN POWER DISCONNECT SWITCH AND OVERCURRENT PROTECTION PER NEC DISC SW SECTION 430 REQUIREMENTS 1H rl 1H HIGH HEAT 173 211 ml 2H LOW HEAT 213 10L EP J 3T1 PUMP PHASE 372 MONITOR 373 PUMP TRANSFORMER PRIMARY JUMPER CONNECTIONS 480V HI TO M2 240V H1 TO H3 H2 TO H4 208V 8 575 NO JUMPERS AVAILABLE Samrat MASTER 1 Ak INDICATES A DEVICE NOT MOUNTED ON THE ELECTRIC PANEL 2 LAST WIRE NO USED NO 53 86974b LINE 17 LINE 17 LINE 17 vara A C ip Royal Series Water Temperature Control Units Page 27 Figure 6 Typical Electrical Wiring Schematic Drawing 2 e TO unie o Check the electrical wiring schematic in your Customer Information packet for more information Page 28 zip Royal Series Water Temperature Control Units Figure 7 Typical Electrical Subpanel Layout O a ENEY TO ER ONT CRM 1CR 2CR 3CR 6CR 1PM mara epopee ap Royal Series Water Temperature Control Units Page 29 4 Identifying Controls and Features Y 4 1 Identifying Mechanical Controls and Features To and From Process Probes Two 2 1
8. C below the set point Alarms reset automatically PROBE FAIL Indicator D The PROBE FAIL indicator is on when a temperature sensing probe fails A To Process probe failure displays DEL on the screen and a From Process probe failure displays RET on the screen The alarm resets after the failed probe is replaced 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 thc M2B controller II Royal Series Water Temperature Contro Units Page 37 4 4 Using M2B Controller Keys SET POINT Key uP Press and hold the SET POINT kcy then press the DOWN 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 LI D screen UP Arrow Key UP Press the UP Arrow key to increment or advance the values or settings on the LED screens E DOWN Arrow Key Press the E 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 ENTER Key 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
9. Series Water Temperature Control Units Figure 8 Typical M2B Graphic and Button Control Panels Chewy STATUS DISPLAY LOHEATC SET POINT PROCESS Oat L eee FLUID SAFETY HILO PROBE MOTOR O FLOW O O PRESSURE THERMO ALARM FAI E O TEMPERATURE CONTROL SYSTEM M2B O O ip e pus Dod QUICK START STOP VENT SILENCE UE COOL LOCAL REMOTE E XOLG SY OS XE arame 4 3 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 paramcter and pre sct function values during setup PROCESS Numeric LED During normal operation thc 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 Im Royal Series Water Temperature Control Units Page 35 Status Indicators RUN Indicator HI HEAT Indicator LO HEAT Indicator COOL Indicator Display Indicators TO PROCESS Indicator The RUN indicator is on during normal operation and flashes during the auto tuning sequence The HI HEAT indicator is on when fluid heaters are at 100 capacity to rapidly raise fluid temperature The LO HEAT indicator is on when fluid heaters are at 50 percent capacity The COOL indicator is on when fluid temperature is above the set poi
10. UP Arrow key or thc DOWN Arrow key until the SET POINT screen displays the set point temperature you want Allow your process to reach the set point temperature then auto tune the controller See Section 4 8 on Pages 41 42 for more information Watch the drain for any bubbles or erratic flow which indicates if the system has been properly vented If the stream is steady the unit was properly vented and all air is out of the system Operate the unit checking for anything unusual that could indicate improper operation Note You can stop the Royal Series temperature control unit at any timc by pressing the STOP button dnm Royal Series Water Temperature Control Units Page 45 A CAUTION 1 Your Royal Series system operates with hot water under pressure To reduce the risk of scalding e Always wear work gloves and safety glasses when operating the unit e Never operate the unit with panels or shields removed e Pipe the relief valve to an open drain e Never install a fitting or hose that is rated less than 150 psig and 250 F 1 034 25 kPa 10 34 bars and 121 C 2 To reduce the risk of electrical shock e All electrical installation and repairs should be done by a qualified electrician e Ground the unit in accordance with electrical codes Never attempt any repairs without first opening and locking out the main disconnect Never deactivate or neutralize any safety device 5 4 Oper
11. Water Temperature Control Units Page 17 Note Use a backup wrench to support Royal Series system piping when making process piping connections e A CAUTION All external valves fittings and hoses must be rated at a minimum of 150 psig and 250 F 1 034 25 kPa 10 34 bars and 121 C The exception is when the temperature control unit is optionally rated for 300 F 149 C operation external valves fittings and hoses must then be rated at a minimum of and 300 F 1 034 25 kPa 10 34 bars and 121 C 3 4 Piping Considerations for Permanent Installations Sterling Inc recommends an optional or customer installed strainer on the COOLING WATER IN inlet The unit must have at least 16 psig 110 32 kPa 1 1 bars water supply pressure to prevent pump cavitation that can be caused by the water flashing to steam To avoid damage to the pump or e other components make sure that maximum supply pressure does not exceed 55 psig 379 2 kPa 3 79 bars Keep restrictions to a minimum by using proper inlet pipe sizing If the water supply piping is larger than 74 reduce the size at the unit The table below contains the pipe sizes that are used in the unit Pipe sizes for Ye hp to 10 hp 0 56 kW to 7 46 kW units Common black pipe is recommended for permanent installations Royal Series water circuit piping is primarily ferrous iron and reacts electro chemically with non ferrous metallic materials such as copper Some wate
12. iex os boe L3 ea so 2271 35 243 5 373 75 2839 54 3723 74 560 90 4542 63 4344 2010 9 kW heater mm Royal Series Water Temperature Control Units Page 11 Figure 2 Typical Royal Upright Series Water Temperature Control Unit and Specifications Dimensions Shipping number Ww D weight 460 230 letter h kW gpm ipm psig kPa in cm in cm in cm Ibs Ke C Ya 30 1136 1724 i 35 132 5 206 9 210 96 2012 50 189 3 A 206 9 M gt 2 3 2 9kW heater E ci IE A A CLUB apra H 5 373 75 2839 4 3723 240 109 J TA 5 60 90 3407 63 4 34 4 K 10 746 120 4542 55 3792 270 123 Figure 3 Royal Series Unit Full Load Amps Model Full load amps at 460 volts hp kW 100hplO75kW 13 1 amps 169amps 244amps 320amps 478amps 628amps 16 1 amps 1000 hp 7 46kW 260amps 300amps 370 amps 450amps 60 0 amps Page 12 mm Royal Series Water Temperature Control Units 2 Shipping Information 2 1 Unpacking and Inspection You should inspect vour Sterling Sterlco Royal Series 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 brcakage damage shortage or
13. new unit unless the seal has been damaged because the unit was started without water Our pump seals have a long period of service life Some conditions of course can shorten seal life including the presence of grit operation of the unit without water sustaincd high water temperature or presence of certain chemicals in the water Our pump seal assembly has been developed to resist abrasive particles that are present in many water systems This is done by a special flushing system that uses water exiting the pump to constantly wash the seal area nm Royal Series Water Temperature Control Units Page 51 It is also fitted with high temperature flexible components for maximum hcat resistance These same components remain flexible e even at low temperatures Thus the standard scal is a fine combination of heat resistant and wear resistant components Unfortunately even under normal use the seal will eventually wear and require replacement A small puddle underneath the unit is a sign of rotary seal wear and if investigation confirms the pump as the source the seal should be replaced as soon as practical The water slinger is intended to provide temporary protection against this but a continued and substantial leak will ruin the motor bearing and cause further damage After the unit has been in service for a period of ycars where abrasive conditions are present you may find that the pump bracket the top half of the pump casting
14. policy Consult your Sterling Sterlco sales representative for specific details Sterling Inc PO Box 245018 e 5200 W Clinton Avenue e Milwaukee WI 53224 9518 USA Phone 414 354 0970 e Fax 414 354 6421 http www sterico com df TD Service Department Call Toll Free 800 783 7835 Sterling Inc Auxiliary Equipment for the Process Industries PO Box 245018 5200 West Clinton Avenue e Milwaukee Wi 53224 9518 414 354 0970 e Fax 414 354 6421 dnm STERLTECH 4 ROBOTICS Process Heating Automated Recovery Systems Cooling Parts Removal
15. pressed the previously stored value or item is retained Page 38 II Royal Series Water Temperature Control Units e INDEX Key HI ALARM Key LO ALARM Key DISPLAY Key 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 ur AN Press and hold the HI ALARM key then press the UP Arrow kcy to increase the alarm high limit value or press the E 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 UP LO Press and hold the us LO ALARM key then press the sia UP Arrow key to increase the alarm low limit value or press the E DOWN Arrow key to decrease the alarm low limit valuc 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 Press the DISPLAY key to advance through the display menu Each key press increments to the next available function The screen returns to To Process temperature after thirty 30 seconds of inactivity Refer to your Sterling Sterlco M2B Temperature Control Owner s Manual for a list of menus available using this key mip Royal Series Water Temperature Control Units Page 39 Digital Flow Screen Optionai The opti
16. slow closing Im Royal Series Water Temperature Control Units Page 31 Motorized Modulating Valves Optional Optional motorized modulating valves are recommended for large cooling applications where the process temperature is very near the cooling water supply temperature and the temperature controller unit pump is used as a booster The gradual shutoff they provide also eliminates water hammer The option includes a complete valve and motor package in place of a long life solenoid valve The motorized modulating valve has infinite positioning It fully opens in one 1 minute and fully closes in 15 seconds Water Hammer Arrestor Shock Stop Optional Pump Starter Transformer Heater Contactor Page 32 Shock waves from fast operating solenoid valves may damage some process systems For these applications a welded metal bellows type shock stop with a pre charged and sealed nitrogen blanket can be installed in the cooling piping Royal Series high quality IEC rated pump motor starters are industrial grade motor controls with overload protection and manual reset High quality industrial design transformers arc specified to suit incoming voltage on the application and provide 115 VAC control voltage The 115 VAC circuit is protected by primary fusing and secondary grounding Your Royal Series unit uses high quality IEC rated industrial grade electromechanical contactors for heater controls IND Royal Series Water T
17. supply below 15 psig 103 43 kPa 1 03 bars may allow water to flash to steam cavitate the impeller and damage the pump which prevents the unit from cooling properly Operation above 55 psig 379 2 kPa 3 79 bars may cause premature opening of the relief valve from pump pressure and pressure surges PRESSURE RELIEF 74 The pressure relief valve located at the back of the unit is pre piped to approximately four inches 4 or 10 cm above the floor This piping reduces the chance of scalding nearby personnel if the relief valve should trip 3 9 Making System Purge Connections Royal Series systems equipped with the System Purge option have a compressed air inlet marked MOLD PURGE Connect to a clean dry 100 psig 689 50 kPa 6 90 bars air line Install your own shutoff valve to prevent process liquid from backing up into thc plant air piping if the compressed air is turned off and thc check valve fails Don t depend on the solenoid valve to hold water pressure in the temperature control unit Page 22 Im Royal Series Water Temperature Control Units Figure 3 Typical Piping Schematic e 3 DIMRAY 20 NAL OCT ky PRESSURE SAfETY SENSOR GKE Pr49uos a LUCAS vi TER D gt Q Me ATER O ee ES Gd 1 I M CPCULATING 1 H MOTOR PRESSURE T i PS bd s EO l OP TONAL h Re TUON ANSOR I mau a _ TANK L3 1 ARPTSICO oP TIONAL la Qasar 7 OP TONA i 1 E E10 A GU id Ca
18. 3 kPa 1 10 bars with a 13 79 kPa 0 14 bars differential shuts down the unit if the COOLING WATER IN or MAKEUP water pressure drops below 16 psip 110 3 kPa 1 10 bars Pumps range in power from hp to 10 hp 0 56 kW to 7 46 kW and are equipped with 3 phase ODP motors and seal flush lines as standard The pump is a bronze fitted closc coupled centrifugal type It features a split casc design to facilitate replacement of the seal It has a high output capacity with excellent discharge pressure helping it facilitate turbulence to maximize heat transfer and is well suited for the conditions under which it was designed to operate The specially designed 9 kW three phase low watt density electrical immersion heater heats the water and the controller regulates the temperature The standard heater has an incolloy sheath for best heat transfer and low fouling properties Low watt density immersion heaters at 12 kW 18 24 kW 36 kW and 48 kW arc available options for these models 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 providing more precise temperature control Royal Series systems use rugged industrial design solenoids with replaceable coils and or internal components Depending on required cooling capacity solenoid valves are available in sizes ranging from A to 4 x Ve and x 24 solenoid valves are
19. 4 00181 00 Primary transformer 230 460 V with primary fuse block Lm Royal Series Water Temperature Control Units Page 59 Figure 10 Customer Recommended Spare Parts Lists cont d Motor Contactors Partnumber Description Cd 726 00264 02 Motor contactor Y hp to 5 hp 0 373 kW to 3 73 kW 208 V 230 V 460 V 575 V except as follows 7 5 hp 5 60 kW 575 V i Motor contactor 3 hp 2 24 kW 208 V and 230 V 5 hp 3 73 kW 380 V 726 00266 02 and 415 V 7 5 hp 5 60 kW 480 V 726 00267 02 Motor contactor 5 hp 3 73 kW 208 V and 230 V 726 00267 02 bes E 7 5 hp 5 60 kW 380 V and 415 V 10 hp 7 46 kW 480 V 726 00265 02 Motor contactor 7 5 hp 5 60 kW 230 V 10 hp 7 46 kW 380 V and 415 V 726 00268 02 Motor contactor 7 5 hp 5 60 kW 208 V 10 hp 7 46 kW 208 V and 230 V Motor Overload Elements 731 00376 02 Motor overload element 12 0 to 32 0 FLA full load amps Solenoid Valves 732 00024 02 V approx 6 35 mm valve with 5 2 approx 3 97 mm orifice 115 V coil i 0 150 300 0 1 034 kPa 10 34 bars 149 C 732 00095 02 732 00093 02 718 00383 00 72 Ig 183 cm 18 mm DIN cable Coil Only for Solenoid Valves Partnumber Description Page 60 UP Royal Series Water Temperature Control Units Figure 10 Customer Recommended Spare Parts Lists cont d Sensing Probes Part num
20. AFETY GLASSES and WORK GLOVES 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 Sterling Inc recommends following OSHA Lock Out Tag Out Standard 29 CFR 1910 147 Make sure the unit is properly GROUNDED before switching power on When welding or brazing in or around this equipment be sure VENTILATION is ADEQUATE PROTECT adjacent materials from flame or sparks by shielding with sheet metal An approved FIRE EXTINGUISHER should be close at hand and ready for use 1f needed Do not jump or bypass any electrical safety control Do not restore power until all tools test equipment ctc have been removed and the panels replaced ENP Royal Series Water Temperature Control Units Page 3 Table of Contents 1 General Information DP lt T Tet o A a aa ii a ali dl ua 7 1 2 Necessary Documents eene nte 8 153 Models Covered ecese ornaris unei CP Sia 8 1 4 Standard TCU Features nene eene 8 1 5 Available Options sis ocs e Ferca a 9 2 Shipping Information SP 13 2 1 Unpacking and Inspectiob sa nas ei romero EE DP etie oh eod 13 2 2 In the Event of Shipping Damagges sssssssen 13 2 3 If the Shipment is Not Complete eee 14 2 4 If the Shipment is Not Correct 14 2 9 REIMS es tete de cad denota acc a ceu tn
21. CL SRamiR 1 PROS O nA zl TIS bess ae ae Lo det SOCI n SOL NOD vALVE SOLTO VAL A OPONA HTK COONS PROCESS WATR wa TR out ven I OP TONAL Pa 1 t COOUNG IN 1 mama I js 4 PRESSURE J 1 1 REQULATOR VALVE m m R o SS SS SS OP TNA xm 1 tor nonn ary COQUNG Y SIRAM O I 1 PROCESS WATER an a DP Ie m waite x T N i LE b o Ac A cac 1 l PRESSURE di ctc il mer var d 1 wire CT s E i iu cu 1 hor 4 OPTICAL REGIS ATOR RLUE Im Royal Series Water Temperature Control Units Page 23 Figure 4 Pump Curves 60 Hz metal HEAD PERFORVANCE CURYL 1 0 EE a 3800 RPM 42S ER EE 50S 55 T 49 43 37 Figure 5 Pressure Drops Asi org tow ipm sees Toss ta 12 Tames S00gpm tii pm o 0psi coke 100 hp 075 kw Oa Tamps 50 0 gpm 1893m 15psi 10 3kPa __161amps 600gpm 227z pm 20psi 138kPa 223amps 900gpm 3407ipm 50psi 344kPa 10 00 hp 7 46 kW Page 24 Imm Royal Series Water Temperature Control Units a 3 10 Making Electrical Connections Royal Series systems are designed for three phase voltage operation Refer to the unit nameplate for proper voltage and amperage requirements Make sure you provide a correctly sized and protected supply of electrical power to the unit Important Refer to National Electric Code NEC Article 430 24 through 430 26 for proper feeder conductor and s
22. E Retain the crating in case reshipment is necessary due to hidden shipping damage mp Royal Series Water Temperature Control Units Page 15 Page 16 Notes CUP Royal Series Water Temperature Control Units 3 Installation 3 1 Installation Location Considerations Royal Series systems are portable and can be installed almost anywhere As with all equipment installations follow all applicable codes and regulations M The recommended ambient temperature range for Royal Series installations is from 14 F 10 C to a maximum operating ambient temperature of 131 F 55 C Recommended ambient storage temperature range is from 13 F to 149 F 25 C to 65 C If storing the unit below freezing temperatures make sure the unit has an antifreeze mixture circulated inside EM Provide a minimum of twelve inches 12 or about 30 cm clearance on all sides of the cabinet to allow circulation of cooling air Vl Locate the unit as close to the process as is practical 3 2 Process Approach Temperature Considerations If the differential A between COOLING WATER IN and TO PROCESS temperatures is less than 10 F 7 C consult our Sales Department for advice on how to control low approach applications 3 3 External Piping Sizing Considerations M All external hose and piping should be adequately sized to assure minimum external pressure drop M Low external piping pressure drop is needed for best operation mp Royal Series
23. FOB the factory any parts that are returned prepaid within three 3 years of equipment shipment to the original purchaser and which in the Company s opinion are defective Any replacement part assumes the unused portion of this warranty Your Sterling unit is also provided with a five 5 year controller warranty and a lifetime warranty on wetted pump components and pump seal subject to factory review This warranty does not apply to any equipment which in the Company s opinion has been subjected to misuse negligence or operation in excess of recommended limits or which has been repaired or altered without the Company s express authorization If the serial number has been defaced or removed from the component the warranty on that component is void Defective parts become the property of the warrantor and are to be returned The Company is not liable for any incidental consequential or special damages or expenses The Company s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manufacturers of said parts Any sales use excise or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser The company neither assumes nor authorizes any other persons to assume for it any liability in connection with the sale of its equipment not expressed in this warranty Many types of Sterling Inc equipment carry an additional one year service
24. MI Pumps Partnumber Description 075 00708 00 hp 208 230 460 3 60 voltage 250 121 C 075 00709 00 1 hp 208 230 460 3 60 voltage 250 F 121 C 075 00710 00 2 hp 208 230 460 3 60 voltage 250 F 121 C Seal Repair Kits Partnumber Description 162 00024 104 Repair kit for hp to 3 hp pumps EPDM NEResist 162 00024 105 Repair kit for 5 hp and 7 hp pumps EPDM NEResist Pilot Lights Control Board 522 87728 01 Control board for 1 16 DIN controllers Page 58 IEP Royal Series Water Temperature Control Units Figure 10 Customer Recommended Spare Parts Lists cont d Rotation Sensor Relays Partnumber Description O Z 701 00066 00 Rotation sensor relay 208 V to 575 V Casters Partnumber Deseription 042 00016 00 3 76 2 mm swivel caster 042 00017 00 3 76 2 mm stationary caster Push Buttons Partnumber Description 2 position selector switch Pressure Switches Partnumber Ss Description 733 00045 00 Water supply pressure switch Transformers Partnumber Descripion 704 00178 00 Primary transformer 208 V with primary fuse block 704 00179 00 Primary transformer 380 415 V with primary fuse block 704 00180 00 Primary transformer 575 V with primary fuse block 70
25. Only use components rated at a minimum of ig and 250 F 1 034 25 kPa 10 34 bars and 121 C E All outer panels must be in place Y All external process valving should be set for proper operation of the unit amp Cooling and or makeup water between 16 psig and 55 psig 110 32 kPa 1 1 bars and 379 2 kPa 3 79 bars must be available for the unit to operate properly Page 44 ENP Royal Series Water Temperature Control Units e v Connect the main power to the unit disconnect switch and press the START switch to check for proper pump rotation direction as described in Section 5 6 on Page 47 Pump rotation should be clockwise viewed from the motor end Check your work and proceed to the Startup Procedure section on the following page 5 3 Starting the Temperature Control Unit e e Turn ON the water supply turn the rotary disconnect to the ON position and push the START button The unit automatically executes a one minute venting sequence to expel air trapped in the process piping Sterling Inc recommends a longer venting sequence on larger process systems Press and hold the VENT button to force thc cooling vent valve open and eliminate air trapped in the process piping in larger process systems The controller is OFF and the Vent Cycle indicator is lighted during the vent sequence Set the microprocessor controller to the process temperature you want by pressing and holding the SET POINT key then pressing the
26. actory set at 16 psig 110 kPa l 1 bars e 150 psig 1 034 kPa 10 3 bars pressure relief valve e Choice of 230 or 460 operating voltages e Y water supply and drain connections 1 process connections e Automatic vent sequence e 3 76 mm casters e Operating range of O F to 250 F 17 C to 121 C e Three 3 year parts and labor warranty at the factory five 5 year controller warranty and limited lifetime warranty on wetted pump components and pump seal subject to factory review 1 5 Available Options Royal Series systems are available with options to tailor the unit to your requirements Some are factory installed some can be retro fitted in the field Consult your Sterling Inc sales representative for more information Available Royal Series options include e M2B controller with integral flow meter with B Upto 30 gpm 114 lpm flow indicator or B 30 to 75 gpm 114 to 284 Ipm flow indicator B 0 20 mA and 4 20 mA current control output aii Roya Series Water Temperature Control Units Page 9 Page 10 B Remote set point and retransmission 0 20 mA and 4 20 mA B RS 232 or RS 485 communications B Remote sensor 10 ft 3 m Remote controller enclosure Heaters available in 12 kW 18 kW 24 kW 36 kW and 48 kW on direct injection compact models 36 kW and 48 kW heaters available on direct injection upright models Closed loop heat exchanger available in 3 7 sq ft 0 344 sq m on compact mode
27. al Piping Schematic 23 4 Pump Curves 60 Hz and 50 Hz 24 5 Pressure Drops 24 6 Typical Electrical Wiring Schematic Drawings 1 and 2 27 28 7 Typical Electrical Subpanel Layout 29 8 Typical M2B Graphic and Button Control Panels 35 9 Pressure Switch Side View and Top View 55 1 0 Customer Recommended Spare Parts Lists 56 62 Page 6 DI Royal Series Water Temperature Control Units 1 General Information 1 1 Introduction Sterling Sterlco Royal Series water temperature control units are reliable accurate and easy to use process temperature control units They are self contained portable and shipped ready to use The Royal Series water temperature control unit is designed to circulate water through your process and to precisely automatically and reliably maintain it at a specified temperature Standard unit operating range is from 0 F 17 C to 250 F 121 C or up to 300 F 149 C as an option The unit is suited for use with city water water from portable or central chillers or towers or well water These units are designed for rapid recirculation of a relatively small amount of water to provide close and uniform temperature relation between To Process and From Process lines This performance of course depends on the configuration of your process and any restrictions within the mold The recirculation combined with the large immersion heater and cooling capability gives fast and accurate response to bring t
28. ating the Unit with the M2B Controller To change the process temperature set point e Press and hold the SET POINT key then press thc up UP Arrow key to increase the set point value of the temperature you want e Press and hold the SET POINT key then press the E DOWN Arrow key to decrease the set point value of the temperature you want The set point automatically updates Page 46 m Royal Series Water Temperature Control Units e 5 5 Sequence of Operation The simplicity of design and the highly engineered controller make this unit almost self operating The START STOP and VENT buttons and the temperature controller buttons arc all that is required to operate this unit After you complete all connections turn the water supply ON then turn control power ON The unit automatically vents for a preset time of one 1 minute f you need additional vent time press the VENT button on the control pancl As thc water comces in the water supply line the water must enter the pump up through the tank and out through the TO PROCESS line through the process back through the FROM PROCESS line and through the solenoid line and out the drain line At this time watching the drain for bubbles or erratic flow will indicate whether or not the system has been properly vented If a steady stream flows from the drain line it is certain that all the air is out of the system If you have the unit connected to a central syste
29. ber Description 692 07369 25 Heating and cooling sensing probe 1 KOhm 0 0385 coefficient 701 00110 00 Heating and cooling sensing probe type J remote thermocouple Spare Parts Kit for Solenoid Valves 162 00001 55 Spare parts kit used on Ye approx 6 35 mm solenoid valve w Teflon seats special applications onl l Spare parts kit used on all Y approx 6 35 mm valves at 300 F 149 C 162 00001 49 maximum temperature 732 000241 162 00001 07 Spare parts kit used on Y approx 12 70 mm valve part no 732 00012 00 at 300 F 149 C maximum temperature 162 00001 60 Spare parts Kit used on Y and 74 approx 12 70 mm and 19 05 mm slow close solenoid valves Modulating Valve Replacement Parts Partnumber 1 Description 044 00510 03 Y approx 12 70 mm valve body with booster spring 044 00510 05 4 approx 19 05 mm valve body with booster spring 044 00509 01 Actuator with 72 approx 12 70 mm conduit fitting 72 to 174 approx 12 70 mm to 31 75 mm Pressure Relief Valves Partnumber 1 Description r Ye approx 19 05 mm pressure relief valve rated at 150 psig 044 00138 00 1 034 25 kPa 10 34 bars Transformer Primary Fuses Partnumber Description 725 00751 00 Transformer primary fuse 0 5 amp 725 00753 00 Transformer primary fuse 1 0 amp
30. dm u Operation and Installation Manual Royal Series Water Temperature Control Units Important Read Carefully Before Attempting to Install or Operate Equipment Part No 682 88105 00 Revision D Bulletin No SC1 610 4 Write down your unit serial number s here for future reference Sterling Sterico is committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice Copyright Sterting Sterico and Sterling Inc 2002 All rights reserved Effective 8 26 02 Part No 682 88105 00 Revision D Bulletin No SC1 610 4 Page 2 mp Royal Series Water Temperature Control Units D Safety Considerations Sterling Inc Royal Series 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 personne injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices m Q 8 Only PROPERLY TRAINED pcrsonnel familiar with the information within this manual should work on this equipment Follow all local SAFETY CODES Royal Series cabinets and piping are hot and are a BURN HAZARD Do not operate a Royal Series system without all outer panels installed Pressurized hot water leaks can cause serious injury Wear S
31. emperature Control Units Cooling Electricals Automatic Vent The controller automatically regulates cooling by opening and closing the solenoid valve or modulating valve For direct injection the unit cools by removing the required amount of warm water from the system This process permits an equal amount of cool plant water to enter the system well ahead of the pump allowing it to blend with the system water The water supply temperature governs the minimum operating temperature of the unit For closed circuit operation the unit cools by automatically releasing cooling water through the tubes of the specially designed tube bundle heat exchanger in each zonc The process fluid such as water glycol or other similar fluid is circulated through the shell of the heat exchanger Note The plant water supply temperature governs the minimum operating temperature of the unit The pump motor and the immersion heater operate on three phase 50 60 cycle nominal voltages with the control circuit operating at 115V single phase The control circuit voltage is provided by a single phase machine tool transformer with a grounded secondary The 115V control circuit and controller outputs are fuse protected The pump motor is controlled by a full voltage magnetic non reversing motor starter with fused branch circuit overcurrent and thermal overload protection This feature automatically triggers the purging of air from the system bef
32. er carefully remove the plug at the top of the switch Figure 9 Pressure Switch Side View and Top View Le 48 Phillips head screw Under the plug is a Phillips head adjusting screw B Tum the screw counterclockwise to reduce the pressure OF 8 Turn the screw clockwise to increase the pressure A quarter turn 90 rotation approximates 15 psi 103 4 kPa 1 0 bars m Replace the plug on the top of the switch If the plug gets damaged the switch is still sealed internally mmm Royal Series Water Temperature Control Units Page 55 Make sure that the high limit on the controller is set to the values listed in the following table based on the switch adjustment This prevents the pump from cavitating and damaging the seal the switch and heater element s 5psig 344kPa 227F_ 108C Safety Thermostat Disconnect main power Open the electrical enclosure and disconnect the neutral lead on the safety thermostat from the terminal strip Protect the stripped lead to prevent short circuits Close the enclosurc reconnect main power and push the START button The heater should not turn on and the Over Temperature indicator should illuminate Disconnect main power before reconnecting the thermostat lead 6 6 Cleaning and Storage e Inspect the unit daily for leaks Wipe down the unit periodically to remove dirt and dust buildup especially the motor casing e Drain and fl
33. eshooting 63 65 Typica piping schematic 22 Uncrating 15 Unit drawing 11 12 Unpacking and inspection 13 Up arrow key 37 Vent button 39 Water hammer arrestor 31 Page 69 Parts Department Call toll free 7am 6pm CST 800 783 7835 or call 414 354 0970 The Sterling Stertco Parts Department at Sterling Inc is ready to provide the parts to keep your systems up and running Sterling Sterico replacement paris ensure operation at design specifications Please have the model and serial number of your equipment when you call Consult the Customer Parts List included in your information packet for replacement part numbers Service Department Call toll free Bam 5pm CST 800 783 7835 or call 414 354 0970 Sterling Sterlco has a qualified service department ready to help Service contracts are available for most Sterling Sterlco products Sales Department Call 414 354 0970 Monday Friday 8am 5pm CST Sterting Sterico products are sold by a network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Sterling Sterico 2 A Sterling Inc w sza 414 354 0970 e Fax 414 354 6421 Page 70 III Royal Series Water Temperature Control Units Sterling Inc warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions The Company s obligation is limited to repair or replace
34. ggers such as Jow water pressure over temperature or pump overload A signal trom any of the safety devices activates a hom and flashing strobe o B Push the ALARM SILENCE button to silence the alarm The optional mechanical high temperature safety alarm is interlocked with the heater When triggered the heater cuts out and the pump continues to run 4 7 Controller Factory Setup The controller is set up and tested at the factory for optimum operation and doesn t need to bc adjusted If the controller does not work properly or vou suspect someone has accidentally changed some settings you can do two things First perform the Auto Tune Procedure described in the following section If that doesn t work restore the controller to the original factory settings as described in your Sterling Sterlco M2B Temperature Control Owner s Manual m Royal Series Water Temperature Control Units Page 41 4 8 Auto Tuning the M2B Controller Page 42 The Auto Tune function lets you fine tune the M2B controller to process requirements Activate the Auto Tune function whenever the process under control changes The controller automatically evaluates the process and selects the P 1 D and fuzzy logic values It s best to do auto tuning before you run any product For best results start this procedure with a stabilized process temperature with no rapid rises or drops in temperature To auto tune the M2B controller i Switch on the cont
35. he water up to temperature or to changes in the settings when needed The 2010 Series water temperature control unit is a self contained system consisting of a centrifugal pump electric immersion heater cool vent solenoid valve and electrical control including a PID microprocessor controller and thermocouple It is designed for use in process temperature control applications using water or a water glycol mix Any other use or fluid is prohibited Some standard safety devices include a mechanical overtemperature safety thermostat a pressure relief valve motor overload protection a low pressure cutout switch branch fusing and non fused lockable rotary disconnect A properly installed operated and maintained Royal Series system provides years of reliable operation Please read and follow the instructions in this manual to get the most satisfaction from your Royal Series system III Royal Series Water Temperature Control Units Page 7 1 2 Necessary Documents The following documents arc necessary for the operation installation and maintenance of Sterling Sterlco Royal Series water temperature control units Additional copies are available from Sterling Inc Familiarize the appropriate personnel with these documents E This manual W The controller operation manual E The electrical schematic and connection diagram placed inside the control enclosure V The operation and installation manuals for accessories and
36. heater failure Install a new gasket when reassembling Make sure a qualified electrician disconnects and reconnects heater wires Solenoid Valves M Clean annually more often if using high mineral content water or on high service leve units M Sluggish operation excessive leakage and or noise indicate cleaning is necessary Inspect the components for excessive wear while the valve is disassembled V Rebuild kits are available from the Sterling Inc Parts Department 6 3 Restoring the Controller to Factory Setup If the preset parameters on the controller have been tampered with and it no longer properly controls temperature you can restore the controller to factory setup parameters For more information on controller restoration consult the Sterling Sterlco M2B Temperature Control Owner s Manual 6 4 Electrical Connections Make sure that a qualified electrician inspects all electrical components and connections every six 6 months for secure attachment and ground connections Inspect all wiring for fraying or damage especially power lines where they enter the unit All wiring connections must be fight dU Royal Series Water Temperature Control Units Page 53 6 5 Safety Devices Caution Make sure that only qualified electricians test safety devices Motor Overload Pressure Switch Safety devices should be tested for function every six 6 months Perform the following procedures for testing Disconnect mai
37. iewed from the motor end Note Make sure that a qualified electrician performs the following steps To change rotation direction l Disconnect and lock out power at the fused disconnect 2 Reverse any two incoming leads at the power terminal blocks 3 Donot switch leads at the motor or motor starters 5 7 Shutting Down the Temperature Control Unit Cool the unit down by selecting a set point of zero Let the unit stabilize at one temperature close to the incoming water a temperature then press the STOP button Now press thc VENT button to relieve any remaining pressure in the system Page 48 III Royal Series Water Temperature Control Units e Notes Imm Royal Series Water Temperature Control Units Page 49 Unit Maintenance A CAUTION Never attempt to service a unit until a qualified electrician has opened and locked out the main disconnect using OSHA 1910 147 standards The water supply should be turned off and internal pressure should be relieved before you remove panels All electrical connections must be done by a qualified electrician A WARNING Disconnect all power to the unit let the unit cool down and turn off the water prior to any servicing Failure to do so can result in SERIOUS INJURY OR DEATH 6 1 Preventive Maintenance Draining Page 50 Drain the unit thoroughly if you arc taking it out of service for a long period of time or you expose it to freezing Drain plug
38. in pump Locate and repair motor control circuit Pump motor contactor holding S Repair or replace Check for at least 16 psig 110 32 kPa 1 1 bars water pressure on WATER IN or CITY WATER MAKEUP Unit does not run Low water pressure light on ne supply to unit is turned Open water supply Reset and test each leg for Pump overload light on balanced amo draws Verify proper rotation If not Pump running in reverse clockwise reverse any two incoming power leads Low pump pressure System has minimal back As long as there is satisfactory pressure and is operating at the process temperature control far end of the pump curve there is no problem Foreign matter obstructing Cleanihesvstem system y 3 Check for closed valves etc Be sure all lines are properiy sized Restricted water flow PgR pump pressure System has high back pressure and is operating at the near end of the pump curve a low flow condition As long as there is satisfactory process temperature control there is no problem Check for 25 psig 172 38 Insufficient cooling or kPa 1 72 bars water pressure makeup water pressure on WATER IN or CITY WATER MAKEUP Jump power across switch and see if unit starts Replace switch if needed Pressure switch circuit is open Switch is broken Page 64 ftm Royal Series Water Temperature Control Units __________ Condition _____ Possibie cause
39. incorrect shipment refer to the following sections 2 2 In the Event of Shipping Damages Important According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment 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 E File a claim against the transportation company Substantiate the claim by referring to the apent 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 contact Sterling at 414 354 0970 for a receipted transportation bill E Advise Sterling Inc regarding your request for assistance and to obtain an RGA return goods authorization number mn Royal Series Water Temperature Control Units Page 13 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 Sterling Sterlco Royal Series water temperature control unit Bill of lading Packing list OR Operating and Installation packet 68 Electrical schematic and panel layout drawings E Component instruction manuals Re inspect the container and
40. ls 3 7 7 4 11 2 18 1 and 27 0 sq ft 0 135 0 688 1 042 1 683 and 2 511 sq m on upright models Quick Cool function Auto system water purge mold purge Y strainer Hammer arrestor water hammer shock stop Remote start stop control Rubber feet available in licu of casters Non ferrous brass construction Slow close cooling solenoid valves available in x A Cy 3 5 and Y x Y Cy 5 5 Modulating valves available in Cy 0 4 1 3 2 2 or 4 4 Y Cy 5 5 or 7 5 1 Cv 10 or 14 and 1 A Cy 20 Two zone stack rack with casters common wiring and piping available compact units only 300 F 149 C operation includes graphite impregnated silicon carbide seal Audible and visual general fault alarm Electrical operation available in 208 230 460 and 575 volts 60 Hz 200 380 and 415 volts 50 Hz UL cUL listed electrical subpanel Inm Royal Series Water Temperature Control Units Figure 1 Typical Royal Series Water Temperature Control Unit and Specifications Direct Injection FROM PROCESS TO PROCESS COOLING WATER OU t COOL NO WATERIN 28 y4 Closed Circuit L COOLING WATER OUT 115 16 a FROM PROCESS COOLING WATER IN La TO PROCESS PROCESS WATER VENT PROCESS WATER N Model tree Shipping number weight 460 230 E EN NN M ela lbs Kg EUNEKIEE NETZE NIS 1 ore 3s 1325 30 2069 T xiv lose
41. m watch thc pressure gauges for erratic pressure changes If D the gauge is steady all the air is out of the system V TCU systems provide temperature control on processes by directly heating the process water and injecting cooling water into the process water When the unit is energized the pump starts and a one minute vent sequence opens the cooling vent valve to remove any air trapped in thc process piping E If the cooling water supply pressure is insufficient the low cooling water pressure cutout switch set at 16 psig 10 psig differential 110 32 kPa 1 10 bars 68 95 kPa 0 69 bars differential opens thc LOW WATER PRESSURE indicator lights and the unit does not operate until the pressure is 16 psig 110 32 kPa 1 10 bars or more You need at least 16 psig 110 32 kPa 1 10 bars for the best cooling capacity and to prevent water boiling in the process circuit at high temperatures particularly at the pump suction M After venting the microprocessor controller monitors the TO PROCESS RTD probe cycling open the cooling vent valve to discharge warm water or energizing the immersion heater to maintain the process set temperature Im Royal Series Water Temperature Control Units Page 47 5 6 Checking Motor Rotation Direction e Check for correct pump rotation direction by looking at the top of the motor Press the START button and the STOP button and note the direction that the motor turns Rotation should be clockwise when v
42. n power Open the electrical enclosure and rotate the manual TEST button on the motor overload to the tripped position Close the enclosure and reconnect main power Push the START button The unit should not start and the Pump Overtoad indicator should illuminate Press the RESET button The unit 1s now ready for operation With the unit running program a set point of 30 F 1 C Allow the process temperature to drop under 100 F 38 C When the process temperature reaches that point turn off the water supply The pump should stop and the Low Water Pressure indicator should illuminate Turn the water supply on to reset the pressure switch Adjusting the Pressure Switch Tools Required Page 54 The pressure switch used in your Royal Series water temperature control unit is factory set at 16 psig 110 3 kPa 1 1 bars However if the process docs not require the unit to operate at 250 F 121 C you can adjust the switch to meet your process needs e Small flat blade screwdriver e 2 Phillips head screwdriver ID Royal Series Water Temperature Control Units A CAUTION HAZARDOUS ELECTRICAL CURRENT PRESENT Maintain a safe ground and disconnect the power supply before servicing the unit Make sure a qualified electrician makes electrical connections disonnect lock out electricity using OSHA 20CFR 1910 147 standards when servicing the unit To adjust the pressure switch B Using a small flat blade screwdriv
43. ng the M2B Controller mmm 42 4 9 Operating the Unit with the Controller oo eee cence ees 43 4 10 Communications setea ad astea edu et oana ae ia E roata tale 43 5 Startup and Operation NE m MOT 44 5s INTO suero te a ur pae ai demas Sae atata De a 44 5 2 Stamp Checklist 44 5 3 Starting the Temperature Control Unit 45 5 4 Operating the Unit with the M2B Controller 46 5 5 Sequence of Operation ae eoi tito os 47 5 6 Checking Motor Rotation Direction enma 48 a 5 7 Shutting Down the Temperature Control Unit 48 6 Unit Maintenance cs PERE 6 1 Preventive Maintenance sse een 50 6 2 Corrective Maintenance 2 0 00 o eee 51 6 3 Restoring the Controller to Factory Setup 53 6 4 Electrical Connections nente aaa eee rn oa inele ana anna 53 6 5 Safety Devices iecore ees per oti ddd natia at 54 6 6 Cleaning and Storage cico pei erret e iad ab da Dea pt za da 56 7 Troubleshooting MG TUS 64 index 22525523409 0 282200980088082 0 088808a8808520 9 97 209 asenussansasca esesese esesusassase 68 Imm Royal Series Water Temperature Control Units Page 5 Charts and Figures a 4 Typical Royal Series Water Temperature Control Unit and Specifications 11 2 Typical Royal Upright Series Water Temperature Control Unit and Specifications 12 3 Typic
44. nt and is being cooled The TO PROCESS indicator is on when the PROCESS LED screen on the controller displays the temperature of the outgoing fluid FROM PROCESS Indicator AT Indicator FLOW Indicator Page 36 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 the To Process fluid and the From Process 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 III Royal Series Water Temperature Control Units e Alarm Indicators FLUID PRESSURE Indicator The FLUID PRESSURE indicator goes on when fluid pressure is low The TCU shuts down and resumes opcration only when a proper level of fluid pressure is restored SAFETY THERMO Indicator 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 HI LO ALARM indicator The HI LO ALARM indicator is on when an individually set alarm condition occurs The HI deviation is 200 F about 93 C above the set point The LO deviation is 100 F about 37
45. omplete shipment 14 Incorrect shipment 14 Index key 38 Installation information 17 28 Cooling water connections 21 Electrical connections 24 External piping sizing considerations 17 High mobility piping considerations 19 Location considerations 17 Permanent piping considerations 18 Process approach temperature considerations 17 Process water connections 20 Process water considerations 19 System purge connections 22 Lo Alarm key 38 Lo Heat indicator 35 Local Remote button 40 Location considerations 17 Low pressure cutout switch 30 M2B control panel 34 M2B Controller Keys 36 39 M2B controller panel components 34 36 Maintenance Cleaning and storage 55 Corrective maintenance 50 52 Draining 49 Electrica connections 52 Heaters 52 Motor overload 53 Parts lists 55 61 Periodic checks 50 Pressure switch 53 Preventive maintenance 49 Pumps and seals 50 Safety devices 53 52 55 Safety thermostat 55 Solenoid valves 52 Microprocessor controller 33 Models covered 8 Motor Fail indicator 36 Motorized modulating valves 31 Necessary documents 7 8 C flow indicator 35 Operation 45 Options 9 10 e ari Royal Series Water Temperature Control Units Parts lists 55 61 Periodic checks 50 Permanent piping considerations 18 Pipe sizes for Y hp to 7 hp units 18 Pressure drops 23 Pressure relief valve 29 Pressure switch 33 Preventive maintenance 49 Probe Fail indica
46. onal digital flow screen displays process flow in gallons per minute gpm No customer usable control is necessary Depending on option level and sctup flows can be measured at rates reaching and exceeding 75 gallons per minute 284 Ipm 4 5 Using Graphic Panel Buttons Figure 7 START Button Push the START button to energize the unit and begin the temperature control cycle STOP Button Push the STOP button to dc energize the unit and stop the temperature control cycle VENT Button Push the VENT button for additional manual venting The VENT CYCLE indicator lights during the vent cycle ALARM SILENCE Button Optional Push the ALARM SILENCE button to silence the alarm You should investigate the alarm condition and restore the unit to normal operation before continuing with thc temperature control cycle AIR PURGE Optional UP DOWN Press the UP Arrow kcy and thc DOWN Arrow key on the M2B controller to purge the system of air The PURGE VALVE ON indicator lights during thc air purge cycle Page 40 II Royal Series Water Temperature Control Units amp QUICK COOL Button Optional Press the QUICK COOL button to open the cooling valve and quickly cool the process LOCAL REMOTE Switch Optional Press the LOCAL REMOTE switch to toggle between local and remote temperature sensor probe operation 4 6 Alarms Audible Visual General Fault Alarm Optional The audible visual general fault alarm sounds if any fault tri
47. options selected by the customer The Customer Parts List included in the information packet 1 3 Models Covered This manual provides operation installation and maintenance instructions for the Royal Series water temperature control unit Model numbers arc 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 temperaturc control unit if you contact Sterling Inc 1 4 Standard Royal Series Features e Compact rugged cabinet with easy access side panels e Cast and flange design to reduce connection points e Half and full heat automatic switching capability e Dual stage Incoloy immersion heater with IEC contactors e NEMA 12 electrical enclosure e M2B microprocessor controller with fuzzy logic includes diagnostics features with indicator and warning status lights CE and cUL Page 8 f m Royal Series Water Temperature Control Units e Forward facing liquid filled To and From Process pressure gauges e Independent high temperature safety thermostat e Non fused lockable rotary disconnect e Branch fusing e 4 cooling solenoid valve on to 3 hp 0 56 to 2 24 kW models 4 slow close cooling solenoid valve on 5 7 5 amp 10 hp 3 73 5 60 amp 7 46 kW models e EPDM NI Resist pump seal e Adjustable low supply water pressure switch f
48. ore you start the unit The vent actuates the solenoid valve and forces trapped air and water out through the drain properly filling and priming the unit prior to startup Complete venting is necessary to prevent damage to the pump and heater The vent process is controlled through a timer If you have a large process you may need to complete the venting process by pressing the VENT button on the front mounted switch panel Im Royal Series Water Temperature Control Units Page 33 Pressure Switch e A pressure switch built into cach unit keeps the system from starting until the water supply is tumed On and subjected to the minimum water supply pressurc This feature protects the pump scal and the heater from damage through attempted operation without water The pressure switch is set at approximately 16 psig 110 32 kPa 1 10 bars for 250 F 121 C units or 55 psig 379 23 kPa 3 79 bars for 300 F 149 C units prior to leaving the factory 4 2 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 water temperature The controller is fully factory tested Set the process temperature set point you want and the controller does the rest Built in range of operation on the controller is 0 F to 250 F 18 C to 121 C e Page 34 III Royal
49. ored paint Check resistance on all three 3 legs of the heater with an ohm Immersion heater element is meter Replace heater as burned out required Check for balanced amp draws and supply voltage If not present replace immersion heater voltage on heater contact controller Set process temperature to Solenoid valve is not operating minimum and check for but COOL LED is on magnetism on top of solenoid coil Magnetism on coil Clean coil Faulty dirty solenoid valve Pross VENT OUND severaklimes yramy to flush the valve Defective immersion heater Unit does not heat cannot achieve set point Page 66 TIE Royal Series Water Temperature Control Units 9 Service Notes Ip Royal Series Water Temperature Control Units Page 67 Index O AT indicator 35 Air Purge button 39 Alarm indicators 35 36 Fluid Pressure indicator 36 Hi Lo Alarm indicator 36 Motor Fail indicator 36 Probe Fail indicator 36 Safety Thermo indicator 36 Alarm Silence button 39 Alarms 40 Audible visual general fault alarm 40 Automatic vent 32 Auto tuning the controller 41 Available options 9 10 Button panel 34 Checking motor rotation direction 47 Cleaning and storage 55 Closed circuit direct injection connections 20 Communications 42 Controller factory setup 40 Controller keys 36 39 36 39 Display key 38 Down arrow key 37 Enter key 37 H Alarm key 38 Index key 38 Lo Alarm key
50. ost computer for RS 232C and RS 485 communications The connection port is a direct pin to pin extension from the back of the controller For pin outs consult the Sterling Sterlco M2B Temperature Control Owner s Manual mm Royal Series Water Temperature Control Units Page 43 5 Startup and Operation 5 1 introduction The checklist below outlines start up procedures for Royal Series water tempcrature control units This list assumes that installation information located in this manual has been read and followed 5 2 Startup Checklist M Check the shipping papers against the serial tag to make sure that system size type and voltage is correct for the process under control M Check the transformer primary voltage connections to be sure they are configured for the electrical power you are using The voltage at the main power connection must be within plus or minus ten percent 10 of the voltage listed on the serial tag Electrical connections must conform to all applicable codes Make sure that a qualified electrician checks all electrical connections y The safety thermostat is preset at the factory to 250 F or 300 F 121 C or 149 C depending on configuration It trips at 265 F or 315 F 129 C or 157 C depending on configuration RS The relief valve should be piped to an open unrestricted drain TO PROCESS FROM PROCESS WATER IN WATER OUT and MOLD PURGE connections should be complete g N CAUTION
51. 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 Shipment is Not Correct If the shipment is not what you ordered contact Sterling Inc immediately Include the order number and item Hold the items until vou receive shipping instructions 2 5 Returns Important Do not return any damaged or incorrect items ou receive shipping instructions from Sterling Inc Page 14 IBID Royal Series Water Temperature Control Units 9 2 6 Uncrating Your New Royal Series System W Royal Series water temperature control units are shipped fastened to a skid and covered with a cardboard box Carefully remove the staples on the bottom of the box lift off the box and remove the bolts holding the unit to the skid Caution Be careful when cutting straps Straps may spring back and cause inju M From the side slip two lifting straps between the skid and temperature control unit Spread the straps from the center line so it is balanced Loop the straps over a fork truck fork Lift slowly and only high enough to clear the skid Use a pry bar if necessary to remove the skid from the unit E Carefully slide the skid from beneath the unit and lower the unit Lower slowly The unit should land on its casters and can e bc rolled into position
52. r contains dissolved minerals that greatly accelerates the reaction between dissimilar metals Page 18 mm Royal Series Water Temperature Control Units Ferrous piping is recommended to minimize galvanic action If piping must be copper use dielectric unions at the unit 3 5 Piping Considerations for High Mobility Installations Mobile Royal Series systems must use high quality hose rated for at least 150 psig and 250 F 1 034 25 kPa 10 34 bars and 121 C Special 300 F 149 C high temperature Royal Series systems must use hosing rated at 150 psig and 300 F 1 034 25 kPa 10 34 bars and 149 C or greater Quick disconnects may be used for mobility although they cause a drop in pressure If used they must be sized carefully to minimize pressure drop Don t use quick disconnects with check valves unless absolutely necessary N CAUTION Non relieving quick connect fittings or check valves on the water supply must have a pressure relief piped to the drain Failure to do so could result in a dangerous over pressure condition 3 6 Process Water Considerations Raw Water Water treatment is vital in any piping system In some cases raw water may be used in the system without problems in other cases it can result in large deposits of scale and corrosion Sterling Inc offers a complete line of water treatment equipment Contact your Sterling Inc sales representative for water testing and trcatment options Di
53. r tee LE 14 2 6 Uncrating Your New Royal Series System eee 15 3 Installation a o s 8t80a00 en pp esses eecesgasusesaoses 0000009 17 3 1 installation Location Considerati0MS ooooooooococcccccccccncccccnonanonos 17 3 2 Process Approach Temperature Considerations ss T 3 3 External Piping Sizing Considerations eee 17 3 4 Piping Considerations for Permanent Installations 18 3 5 Piping Considerations for High Mobility Installations 19 3 6 Process Water ConsideratiONS oooooooccconococcccccococcccnononocononnnns 19 3 7 Making Process Water Connections 20 3 8 Making Cooling Water Connections iii 21 3 9 Making System Purge Connections 22 3 10 Making Electrical Connections 25 4 Identifying Controls and Features MN 30 4 1 Identifying Mechanical Controls and Features 30 4 2 The Microprocessor Controller 34 4 3 Identifying M2B Controller Panel Components 35 Page 4 ILI Royal Series Water Temperature Control Units e Table of Contents 4 Identifying Controls and Features 222 Cont d 4 4 Using M2B Controller Keys eese reote hohen aaa 38 4 5 Using Graphic Panel Buttons eee 40 4 6 ANS A reor dev asada at d dedo i dati M vase d tae 41 4 7 Controller Factory Setup iaca teen Hide ca ASen TONE donde qd 41 4 8 X Auto Tuni
54. roller m Press and hold the SET POINT key then press the UP zs UP Arrow key to increase the sct point value Or B Press and hold thc SET POINT key then press the DOWN DOWN Arrow key to decrease the sct point value Allow the Autovent cycle to be completed the screen displays the AY message W Repeatedly press the INDEX key until the screen displays the TUM message up DOWN Press thc UP Arrow key or the DOWN Arrow key until the screen displays the SLF message Press the ENTER key The Auto Tune cycle executes The RUN indicator flashes during the Auto Tune cycle ILI Royal Series Water Temperature Control Units B Repeatedly press the INDEX key until the screens display the 4KYYand YES messages ENTER Press the ENTER kcy Do not attempt to reprogram the M2B controller or press any keys while the RUN indicator flashes during the Auto Tune cycle Doing so cancels the Auto Tune cycle 4 9 Operating the Unit with the Controller To change the process temperature set point SET POINT e Press and hold the SET POINT key then press the uP UP Arrow key to increase the set point value of the temperature you want e Press and hold the SET POINT key then press the DOWN DOWN Arrow key to decrease the set point value of the temperature you want The set point automatically updates 4 10 Communications A connection port on the electrical cabinet permits easy hook up to the h
55. s and connectors should have a service rating of at least 250 F 121 C and 150 psig 1 034 25 kPa 10 34 bars If it has a maximum temperature of 300 F 149 C the lines and connectors should have a service rating of at least 300 F 149 C and 150 psig 1 034 25 kPa 10 34 bars NPT This s the outlet for the tempered water leading to the process being controlled AID Royal Series Water Temperature Control Units 9 FROM PROCESS 1 NPT Water from the process re enters the Royal Series system to be tempered and re circulated back into the process 3 8 Making Cooling Water Connections WATER IN 4 The cooling water supply inlet from a cooling tower a chiller or a city water supply A CAUTION If a non relieving device such as a regulator ball valve or check valve is installed on the WATER IN line you MUST install an expansion tank of at least Y gallon about 2 liters capacity Failure to do so can result in system overpressure from thermal expansion e Install the tank configured as shown below Royal Series unit Non relleving device Check the expansion tank frequently to make sure it is not flooded IEP Royal Series Water Temperature Contro Units Page 21 Water Out a Size Depends on Solenoid Used The cooling water outlet leading back to the cooling tower chiller or drain Net supply pressure must be between 25 psig and 55 psig 172 38 kPa 1 72 bars and 379 2 kPa 3 79 bars Net
56. s are provided at the base of the heater tank and at the base of the pump III Royal Series Water Temperature Control Units Periodic Checks Every Six Months Inspect all electrical connections for secure attachment and for safe and secure ground connections nspect the power cable especially at the entrance point to the unit This inspection should be made by a qualified electrician Check for leaks especially under the pump as it may indicate a worn pump seal 6 2 Corrective Maintenance Pumps and Seals Before leaving our factory we test cach unit extensively then we calibrate cach unit Afterwards the unit is drained and blown out with air to remove water from piping systems If the unit is allowed to stand idle for a long time before being installed in your factory the housing gasket at the pump can dry out and can possibly leak when the unit is started In most cases these gaskets will soon swell and form a tight seal In other cases it may be necessary for you to tighten the pump bolts to stop a leaking condition Pump scal surfaces can separate slightly because of rough handling or from vibration during transit This could cause a leak at the pump seal when the pump is started but in most cases the surfaces will mate again after the pump is allowed to run for a short period of time If they do not reseal you may need to open the pump and frec the scal by hand It 1s seldom necessary to install a replacement scal in a
57. stilled Water Non ferrous brass copper or hiph temperature plastic piping is recommended for distilled water processes SIERD Royal Series Water Temperature Control Units Page 19 Deionized Water Stainless steel 316 SS minimum or PVC plastic components must be used with deionized water Sterling Inc recommends stainless steel because of the temperature constraints with plastic 3 7 Making Process Water Connections Closed Circuit Direct Injection TO PROCESS 1 Page 20 On the back of each unit the connections are labeled appropriately For Direct Injection units 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 IN to your plant water supply Connect the COOLING WATER OUT linc to an open drain or to the return line of your central water system For Closed Circuit units make the connections as stated above and it there is a separate supply for the process and cooling make the following connections Connect the PROCESS WATER SUPPLY hookup to the water source for the process Connect the PROCESS WATER VENT hookup to return the water back to the process source Make sure vou carefully select the connecting lines and connectors between the temperature control unit and the process to suit the needs and requirements of your application If your unit has a maximum operating temperature of 250 F 121 C the connecting line
58. tor 36 Process approach temperature considerations 17 Process screen 34 Process water connections 20 Process water considerations 19 Pump curves 50 Hz pump curves 23 60 Hz pump curves 23 Pump starter 31 Pumps 30 Pumps and seals 50 Quick Cool button 40 Raw water treatment 19 Return indicator 35 Returns 14 Run indicator 35 Safety considerations 3 Safety devices 52 55 Safety Thermo indicator 36 Safety thermostat 29 Screen displays 34 Process screen 34 Set Point screen 34 Sequence of operation 46 Set Point key 37 Set Point screen 34 Shipping damages 13 Shipping information Incomplete shipment 14 Incorrect shipment 14 Returns 14 Shipping damages 13 Uncrating 15 Unpacking and inspection 13 Shock stop 31 Shutting down the unit 47 Solenoid valves 30 Specifications 12 Standard features 8 9 Start button 39 Starting the unit 44 Startup and operation Checking motor rotation direction 47 Operation 45 Sequence of operation 46 Shutting down the unit 47 IND Royal Series Water Temperature Control Units Starting the unit 44 Startup checklist 43 Startup checklist 43 Status indicators 35 Cool indicator 35 Hi Heat indicator 35 Lo Heat indicator 35 Run indicator 35 Stop button 39 Subpanel 28 System purge connections 22 TCU drawing 11 TCU specifications 12 TCU Upright drawing 12 Thermocouple 29 Thermostat 29 To Process thermocouple 29 Transformer 31 Troubl
59. upply disconnect sizing Maintain a safe ground and disconnect the power supply before servicing the unit A qualified electrician should make electrical connections and disconnect and lock out electricity using OSHA 29CFR 1910 147 standards when you need a service call Check serial tag voltage and amperage requirements and make sure your electrical service conforms before making any electrical connections Total running amps for Royal Series systems are e listed on the nameplatc Customer connections can be run to the supply terminals from either side of the unit Make sure that all three phases are wired correctly If not wired properly the unit will run backwards Again check the unit nameplate for correct voltage and amperage A DANGER Improper electrical connections can damage the unit and cause serious operator injury or death CUP Royal Series Water Temperature Control Units Page 25 Bring properly sized power leads and ground from a fused disconnect installed by your electrician to the unit Provide external overcurrent protection to the unit using circuit breakers or fuses If you use fuses make sure that thcy are dual element timc delay fuses sized according to your electrical code Make sure that all electrical connections are tight Important 1 Electrical connections must comply with all applicable electrical codes 2 The temperature control unit must be grounded in accordance with NEC Article
60. ush the unit every six 6 months to remove sediment buildup e Completely drain the unit and carefully blow out the piping with pressurized air before placing the unit in storage Figure 10 Customer Recommended Spare Parts Lists Immersion Heaters Compact Models Part number Voltage Kilowatts Partnumber Voltage Kilowatts 722 00137 07 722 00137 12 722 00137 18 722 00137 24 722 00137 23 380 V 9 kW 722 00137 08 575 V 9 kW 722 00137 14 380 V 12 kW 722 00137 22 575 V 12 kW Page 56 amp Royal Series Water Temperature Control Units Figure 10 Customer Recommended Spare Parts Lists cont d Immersion Heaters Upright Models Part number Voltage Kilowatts Part number Voltage Kilowatts 18 kW 24 kW Heater Contactors Unit operating voltage 726 00271 02 726 00269 02 726 00269 0 726 00270 02 726 00270 0 2 118 kW 1726 0027 1 02 6 kW 26 00272 02 726 00271 02 726 00271 02 726 0027 1 0 8 kW 26 00273 0 26 00272 0 Note Add the 02 suffix to part numbers for Allen Bradley contactors Heater Gaskets 542 00007 08 Heater gasket Tanks 615 86192 00 Iron tank 9 kW and 12 kW models Thermostats Description 724 00665 00 Safety thermostat auto reset amm Royal Series Water Temperature Control Units Page 57 Figure 10 Customer Recommended Spare Parts Lists cont d Gauges 037 00158 00 To and From Process pressure gauge 0 160 psig 0 1 103 KPa 0 11 bars

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