Sterling Sterlco M-6410 User's Manual
Contents
1. PUMPS AND SEALS Before leaving our factory each unit is operated for a considerable period of time and calibrated After this test the unit is drained and blown out with warm air to remove most of the water from the 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 will possibly leak when the unit is started In many cases these gaskets will soon swell and form a tight seal while in other cases it may be necessary for you to tighten the pump screws to stop a leaking condition it is possible to have the pump seal surface separate slightly because of rough handling or considerable vibration during transit from our plant to yours This of course would cause a leak at the pump seal when the pump is started but in most cases the surface will mate again after the pump is allowed to run for short periods of time If they do not mate you might find it necessary to open the pump and free the seal by hand It is seldom necessary to install a replacement seal in a new unit unless the seal has been damaged because the unit has been started without water Our pump seals should give a long period of service life There are condi tions of course which tend to shorten the seal life such as presence of grit operation of the unit without water sustained high water temperatures or the presence of certain chemicals in the water Our pump seal ass2. undoubtedly ruin the motor bearing Even though your maintenance people may hav had many years of experience in dealing with pumps in general we would strongly suggest that they follow our Form I 4100 El when overhauling the pumps Careful attention to these instruct ons will help assure a proper installation and minimum downtime Under some conditions users find that the pump will not start After turn ing off the power supply it would be well to check the motor shaft to be cer tain that it is free to turn By removing the drip cover atop the motor access is provided to the end of the shaft which has been slotted so that it might be turned with a screwdriver If the shaft is found free to turn we would suggest that the power supply to the unit be checked on all legs to be certain that the power is available to the motor If these two items have been checked we would then recommend that a competent electrician be called upon to check the motor and its circuit M 1 SOLID STATE DIGITAL CONTROLLER cont 5 Self diag nostic capabilities when a problem is detected by the computer circuits such as a loose probe wire the controller automatically turns off all heating and cooling functions then flashes the temperature display to indicate immediate attention is required 6 Microprocessor design Each M 1 is a miniature computer turning our analog world into digital pulses Problems of guessing at temperature or set point
3. are eliminated Customer requested options and specialties are easier to produce 7 Temperature and set point are continuously dis played and large enough to be read from a dis tance 8 Various colored lights to indicate the heat and cool functions along with a red colored lamp to indicate power to the controller and the Sterl Tronic pump 9 Manual VENT push button switch to aid you in purging all air from your system prior to start up 10 Extremely tight deadband control under normai operation the M 1 has a deadband of 5 1 E For example if your set point is 150 heating and cooling functions are kept in the OFF state only if the process temperature is 149 150 or 151 A more lenient deadband of 5 39 is obtainable by operating the deadband toggle switch This switch is inside the access hole located on the right side of the controller cover 11 Available in Fahrenheit or Centrigrade calibrations as well as maximum temperatures of 250 F M 1 SOLID STATE DIGITAL CONTROLLER Cont Whenever power is applied to the motor pump power is also connected to the digital thermostat At this time a red light will be activated on the controller labeled pump and the controller will begin to execute temperature control procedures The customer will dial in through the directional push button set point switch the temperature at which he desires to operate The temperature of th amp delivery line or in other
4. line plus a water supply line and a drain line for cooling The Sterl Tronic Temperature Control Unit is designed to circulate water through your process and to precisely automat cally and reliably ma n tain this water at the selected temperature The operating range of the Steri Tronic unit is from supply water temperature up to 250 F maximum The unit is well suited for use with a city water supply water from portable or central chillers towers or with well water Many new improved designed features have been incorporated into the Sterl Tronic including the solid state electronic thermostat with automatic mechanical proportioning of heating and cool ng dual electronic sensing probes and push button air vent The relatively small total amount of water rapidly circulated by the Sterl Tronic provides assurances of a close and uniform temperature re lationship between the delivery and return lines of the unit This assures uniform and stable temperature control as well as very even temperature throughout the work area Also the high rate of circulation combined with the large mmersion heater and high cooling rate gives the unit ex ceptionally fast response in bringing the process up to temperature and in mak ng changes of settings when necessary These standard units may have many variations of optional features added to them relative to the customers application of specific desires MODEL M 6410 DESCRIPTION WA
5. words at the point of the heat probe will be displayed in degrees Fahrenheit on the digital thermometer THERMOSTAT DIAGNOSTICS The M L digital controller does have built in probe sensing diagnostics Should you encounter a defective probe whereby the sensor either shorts out or is mechanically disconnected from the temperature controller the display will start to flash a 1 for a defective heat probe or a 2 for a defective cool probe indicating that immediate action is required When a defective probe is detected heating and cooling functions are disabled Normal operation is resumed when the probe defect is corrected If a problem occurs such that the controller seems to be operating properly however the indication of the heating and cooling lights appear both to be on this would be an indication that there is a mechanical disconnection of electrical power between the controller and the solenoid or heater contactor If in fact these connections are good and both heater contactor and solenoid are operating properly a problem would exist internally in the controller and tne controller should be returned to Sterling Inc for immediate repair If the customer applies power to the pump motor and notices a red light on the controller but no heating or cooling functions and no display in the digital thermometer the customer should attempt to restart the pump motor If this fails the digital controller is defective and should be re
6. 3435 E PART NO 729 00045 601 00185 05 725 00626 725 00512 725 00694 722 00044 08 720 09159 720 09168 691 00003 15 695 00007 01 695 00030 03 721 00104 726 00005 726 00030 632 02858 704 00015 704 00051 044 00138 732 00024 736 00005 STERLING INC 5200 W Clinton Ave Milwaukee WI 53223 PARTS LIST 622 S 0 8429 August 17 1981 MODEL M 6410 DESCRIPTION Contactor Imm Heater Controller Thermostat Fuse Control MDA 15 15 amp Fuse Control MDL 1 1 amp Fuse Control AGC 3 3 amp Immersion Heater 4 1 2 KW 480V Motor 1 2 HP Motor 3 4 HP Probe Sensing Temp Pump amp Motor Assembly Pump amp Motor Assembly Push Button Start amp Stop Starter Motor Starter Motor Switch Pressure Transformer Transformer Valve Safety Solenoid Valve 1 4 Alarm
7. STERLCO TEMPERATURE CONTROL UNIT SERVICE AND INSTRUCTION MANUAL MODELS M 6410 Engineered and manufactured by INDUSTRIAL CONTROL DIVISION STERLING INC 5200 West Clinton Avenue Milwaukee Wisconsin 53223 Manufacturers of Temperature Control Equipment Since 1916 INTRODUCTION DESCRIPTION PERFORMANCE INSTALLATION ry ELEMENTARY DIAGRAM CIRCULATION Flow Diagram Dwg OPERAT ION CALIBRATION TROUBLE SHOOTING MODEL A682 00407 THERMOSTAT TROUBLE SHOOTING M PARTS LIST M6410 PAGE 1 4 5 6 B682 8 A682 00407 10 M S ries TS 1 to 4 IM Series MP MS 1 1 4100 1E 622 MODEL M 6410 INTRODUCTION We are pleased to provide a Water Circulating Temperature Control Unit for your application It is built by skilled craftsmen with the most modern and precision machines available today The simplicity of design and compact ness engineered into the unit resulted in less maintenance and less floor space The Sterl Tronic High Temperature Control Unit designed and tested over a period of many years represents one of the most significant advances ever in the field of self contained direct injection type portable units for heating water and circulating it at controlled temperatures through molds rolls or jackets of processing equipment The Model M 6410 is a complete single zone heating cooling circulating and control unit with one delivery and one return
8. TER HEATING H ating of the water is accomplished through the specially designed low watt density electric immersion heater inserted into the heater tank the immersion heater temperature is controlled by the manual indicating thermostat mounted on the front of the control panel These Models are supplied with 4 1 2 KW low watt density immersion heaters 2 heater tanks are used for 4 1 2 KW KW ratings of the immersion heaters are rated at the following standard voltages 208V 240V 380V 415V 480V 600V 4 1 2 KW 15 368 BTU hr PUMP The pump is a 1 2 H P straight centrifugal type bronze fitted It has a high output capacity with good discharge pressure and is well suited for the conditions under which the unit is designed to operate The circulating capacity available to the user outside the unit is 15 GPM 20 PSI A Special seal flush system in the pump helps keep the seal clean thereby extending seal life The seal itself is the finest type available for this type of service and provides an excellent combination of long wearing ability high abrasion resistance and heat resistance COOLING C oling is accomplished by automatic release of the required amount of warm water from the system to the drain This permits an equal amount of cool water to enter the system from the plant water supply Naturally the plant water supply temperature will govern the minimum operating temperature of the unit The cool water enters the syst
9. e the cause 1 Check to see that the water supply is open at all times while the unit is in operation i 2 Check to see if water flows to the drain when the unit calls for cooling 3 Check the solenoid valve for proper operation observe the drain Water should flow to drain in response to solenoid action If the drain cannot be seen a simple method of check is by feel of the drain piping at the unit with the solenoid alternately open and closed 4 If the solenoid valve is operating properly a no flow condition could be the result of a plugged heat exchanger which could reduce or stop the cooling water flow on those units which contain heat exchangers 5 High back pressure from the drain could easily cause a limited ability to cool since the unit depends upon the pressure differential between the water supply and drain for the amount of cooling which it can provide TROUBLESHOOTING HEATER BURN OUT A direct visual indication of heater burn out is the presence of scorched or discolored paint on the heater tank In most cases the water level inside the tank at the time of burn out can be determined because the paint on the exterior of the tank below the water level will not be scorched Causes of heater burn out are generally traceable to 1 The unit not being filled with water and purged of air prior to startup 2 A faulty heater tank discoloration not always present 3 A plugged system or badly obstructed flow
10. em immediately ahead of the pump which blends it with system water Return Line 59 1 ou we 4 Modification of Platen For Manifold Sug x x D MODEL M 6410 PERFORMANCE The Model M 6410 A is an easy unit to operate The simplicity of design and tlie highly engineered controller make these units almost self operated The ON OFF control the VENI button and the TEMPERATURE CONTROLLER are all that is required to operate these units Connect the water supply to the WATER SUPPLY LINE and check to insure that the pressure is in excess of 20 PSI and preferably over 25 PSI but does not exceed 50 PSI When the VENT button is depressed and held the solenoid valve opens electrically and should be held in this position for at least on minute The water comes in the water supply line and enters the pump passing thru the heater tank and out the DELIVERY LINE to the process back to the RETURN LINE With the VENT button depressed the solenoid valve is open allowing a flow of water to the drain and by watching the drain for bubbles or erratic flow will indicate whether or not the system has been properly purged If a steady stream flows from the drain line it is certain that all the air is out of the system ON OFP SWITCH ON POSITION When the switch is in the ON position the starter is manually energized and supplies the power to the motor and the temperature controller which in turn re
11. embly has been developed to resist abrasive particles which we find present in many water systems It is also fitted with high temperature flexible components for a maximum amount of heat resistance These same components remain flexi ble even at low temperatures Thus the standard seal has a fine combination of heat resistance and wear resistance TROUBLESHOOTING s After the unit has been in service for a period of years where abrasive conditions are present you may find that the pump casting which is desig nated as our bracket can be eroded away in the area around the seat of the rotary seal This area should provide a straight smooth surface against which the O ring of the seal seat should bear Should your casting show signs of erosion in this area we would strongly recommend that the casting be re placed since the replacement cost of the casting is a very modest investment when compared with downtime and maintenance cost for replacing a seal which has been installed in a worn out pump A small puddle underneath the unit is a sign of rotary seal wear and if your investigation confirms the pump as the source of the leak we would recommend that the seal be replaced as Soon as practical If allowed to leak the water will eventually find its way to the lower motor bearing and cause further damage The water slinger is intended to provide temporary protection against this possibility but a continued and substantial leak will
12. gulates either heating or cooling OFF POSITION When the switch is in the OFF position the starter is de energized cutting the voltage to the motor and the temperature controller MODEL M 6410 CIRCULAT ION FLOW DIAGRAM See Dwg C682 03930 With the ON OFF switch in the ON position and the temperature controller set to the required heat the water is drawn into the pump past the cooling sensor into the bottom of the tank As the water is circulated up through the tank it is heated by the immersion heater where it passes the heating sensor which is recorded on the temperature controller and out to the delivery line After it is routed through the process supply the heated water which has cooled down a bit comes back into the return line for recirculation through the pump and back into the tank where it is reheated The by pass line is a safety feature in theevent there is a malfunction in the system external of the unit proper The by pass line allows a small amount of water to recirculate internally to the unit MODEL M 6410 OPERAT TON Vent the unit as described on page 4 position the ON OFF switch to the ON position Set the control knob on the temperature controller to the desired set point When the unit is in the heating cycle the Heat Ind cator Light will illuminate AMBER If the temperature of the water is above the set point the unit will automatically switch to the cooling cyc
13. having the operator adjust the set point up and down scale several times to open and close the solenoid lf it continues to leak the unit should be stopped and the electric power and water turned off and the solenoid valve should be taken apart and cleaned or replaced as required TROUBLESHOOTING Another cause would be traceable to a leaking hose or fitting somewhere in the system It is also possible that the immersion heater might be inoperative or defective Most any qualif ed electrician can check this out readily Heater terminals are readily accessible for checking NO HEAT AT ALL Check to be sure that the contactor goes in and out in response to signals from the controller This can be done by adjusting the controller up and down the scale The contactors should be made to go in and out as the setting passes unit temperature If it does not function the controller may be faulty and the section of this manual dealing with controller diagnosis should be studied and followed If the contactor does function but if no heat is produced the problem is likely within the heater itself assuming of course that the steps listed under Unable to Properly Heat have been followed first UNABLE TO COOL In order to cool the unit must pass water to the drain directly or through the heat exchanger if the unit has a heat exchanger Therefore if your unit does not provide cooling the following steps should be taken to help locat
14. le and the Cooling Indicator Light will illuminate WHITE SHUTDOWN Prior to shutdown the water supply to the unit should be shut off Depress the VENT button for a few seconds to relieve the internal pressure Water supply and drain lines delivery and return l nes and the electrical supply may then be disconnected DRAINING If your Sterl Tronic is to be taken out of service for long time or it will be exposed to freezing it should be thoroughly drained Drain plugs are Provided at the base of the heater tank and water supply and drain lines 10 MODEL M 6410 PREVENTIVE MAINTENANCE EVERY 6 MONTHS inspect all electrical connections for secure attachment and for safe and Secure ground connections Inspect the power cable especially at entrance point to the unit EVERY 4 MONTHS Check to be sure that ali removable panels are in place and securely attached especially those which enclose the electricals Check the calibration of the thermostat partically the span between Heat amp Cool correct as required per the Calibration section of this manual STERL TRONIC Series 6300 amp 6400 TROUBLESHOOTING TEMPERATURE FLUCTUATIONS Alternate Overheating and Overcooling While the user might be inclined to believe the trouble to be in the control ler this fluctuation can most always be traced to poor water flow resulting from one or more of the following conditions 1 Small connectors or small water passage
15. linger Q B 615 00001 Bracket R 081 00024 Rotary Seal Assembly S Impeller specify part no and dia See pump nameplate T 525 00001 Lock Washer U 535 00001 Impeller nut E by V 345 00002 Housing Gasket W A 615 00003 Threaded Inlet Casting zm W B 615 00002 Tank Inlet Casting I X A 001 05915 Pump Screw for pump w threaded suction 8 req d X B 001 05915 Pump Screw for pump w tank suction 6 req d X B 001 05923 Pump Screw for pump w tank suction 7 req d l Above parts illustrated on Form MP 1 l M 160 00005 Motor Drip Cover ow N 720 09003 Electric Motor 1 HP 3 60 230 460 V open N 720 09009 Electric Motor 1 HP 3 60 230 460V TEFC N 720 09004 Electric Motor 1 1 2 HP 3 60 230 460V open f N 720 09010 Electric Motor 1 1 2 HP 3 60 230 460V TEFC ic N 720 09005 Electric Motor 2 HP 3 60 230 460 V open N 720 09011 Electric Motor 2 HP 3 60 230 460V TEFC ic N 720 09285 Electric Motor 3 HP 3 60 230 460V open L N 720 09012 Electric Motor 3 HP 3 60 230 460V TEFC pos Used only on drip proof motors State Motor Manufacturer State Motor Manufacturer if preferred i State special specification i e 7EQ Spec 7E Spec etc Sterling part numbers apply to non special motors Consult Parts List in your unit manual for specific motor requirements R b STERLING INC 5200 West Clinton Ave Milwaukee Wisconsin 53223 0435 Phone 414 354 0970 Telex 2 6805 P O Box 2
16. s Slow water flow will create a long reaction time which causes overheating and overcooling 2 Very long connecting linesor long serpentine flow of water in and out of the mold in series rather than in parallel Refer to the page on installation 3 Blocked water line in the mold New molds sometimes contain metal chips or other foreign particles inside the water lines Old molds sometimes contain lime or rust accumulations 4 Quick disconnect fitting with check valves A source of very serious obstruction The check valves should be removed 5 Lime buildup in the piping or fittings NOTE The unit itself can be checked out for normal control by the use of a short line of 3 4 or 1 2 hose connected directly from the delivery to the return line This will provide a condition of very good flow and will establish whether the blockage is in the unit or the piping RAPID CYCLING FROM HEAT TO COOL This condition is traceable to the same causes as the temperature fluctuations indicated above UNABLE TO HEAT PROPERLY When the temperature will not rise above a certain temperature the cause vill generally be traced to continuous loss of water from the system allowing cooling water to enter This can be checked by observing the drain Under some conditions it s possible to have the solenoid valve close on a particle of grit which of course will allow the valve to continuously leak Tbis solenoid valve can be flushed out easily by
17. turned for immediate repair The loss of the display on the digital thermometer at anytime during normal operation would also dictate turning the unit off and then turning power back on to give automatic reset If the display heating and cooling functions are not returned again the controller is defective and should be returned M 1 SOLID STATE DIGITAL CONTROLLER AUTO VENT MODE FEATURE If desired a customer may select a M 1 controller with auto venting The controller faceplate will then be equipped with a small push button switch on the faceplate i When the customer turns on the pump switch and presses the small auto vent push button switch on the faceplate simultaneously the controller automatically goes into an auto vent sequence The Seven Segment display will indicate a zero During automatic venting all other operations of the controller are disabled The venting solenoid in an indirect cooling system or the cooling solenoid in a direct cooling system is activated for 60 seconds 4 An attempt to depress the auto vent push button again or a drop in control voltage will not send the controller into an automatic venting cycle again should the customers process be up to temperature which might result in a spoiled product cud T PARTS LIST 111 Rev 8 March 4 1987 STERLING INC PARTS LIST B G STERLCO PUMP 1 to 3 HP ITEM PART NO DESCRIPTION 0 001 05915 Motor Screw 4 req d 3 P 542 10404 Water S
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