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Sterling 682.88107.00 Model Vehicle User Manual

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1. ca N Upright Portable Hot Oil TCUs Chapter 7 Appendix 42 Figure 8 Thrust Bearing Assembly MECHANICAL SEAL 13 SEAL HOLDER 15 LIP SEAL 11 N WUT 28 BOLT 9 24 Dun til SEAL HOLDER 12 Upright Portable Hot Oil TCUs Chapter 7 Appendix 43 Figure 9 Belt Tensioning Instructions How to increase Belt Life S BELT TENSIONING INSTRUCTIONS AWARNING Disconnect power before Installation and maintenance Fallure to do so can result In severe Injury or death Keep sheaves and belts clean Abrasive dust rust oil and acids reduce service life Give drives elbow room Never let belts run against belt guards or other obstructions 1 Measure the belt span 2 Calculate deflection 3 See tables below for correct deflection force 4 Apply force at right angles to the center of the span see diagram below The BROWNING belt tension checker shown at left is ideal for this procedure 5 Check the tension at least twice during the first day of operation and periodically thereafter Use large diameter sheaves and fewer belts You save money and increase drive life Be sure DEFLECTION BELT SPAN E the BELT SPAN Never force belts eec Move motor on adjustable base ga pesas so belts can go on easily BRO
2. Upright Hot Oil Temperature Control Units Part Number 682 88107 00 Bulletin Number SC1 660 3 Effective 10 22 2009 Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No Copyright 2009 Shipping Info Unpacking and Inspection You should inspect your portable hot oil tcu for possible shipping damage 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 the Event of Shipping Damage 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 Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a claim with the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise customer service regarding your wish for ass
3. or boil water off Allow vent timer to run out or Vent solenoid open check valve operation when unit is cold by opening the fill port Check motor rewire if Pump running in reverse necessary See electrical diagrams Pump repair adjustment needed EE worn pump components V belt broken worn Replace as required Drain water from low point in Water in fluid piping see Chapter 3 or boil Noisy pump water off Severely degraded fluid Ge and flush system Replace Air in circulating lines Rapid drop in pressure no pressure Upright Portable Hot Oil TCUs Chapter 6 Troubleshooting 38 Chapter 7 Appendix 7 1 Optional Components The following is a list of options which your portable hot oil tcu may have been equipped with e e Drain valve Hour meter measures total pump run time hours General fault visual alarm Autovent sequence deducts available Low level alarm deducts available High level indicator light Manual bypass deducts available M2B microprocessor controller options include e 4 20 mA remote set point and retransmission e SPI protocol RS 485 e General protocols types RS 232 485 e Remote sensor 10 Ft 3m Heat exchanger options of 3 9 sq ft 0 3627 sq m and 6 7 sq ft 0 6231 sq m Remote controller Lexan cover Optional operating voltages of 208 3 60 230 3 60 575 3 60 380 3 50 and 415 3 50 Upright Portable Hot Oil TCUs Chapter 7 Appendix 39 7 2 Technical Specificatio
4. must be avoided If you must use a pipe joint compound use a compound that can withstand the high temperatures and pressures of your Upright unit Always insulate all piping to prevent burn hazards and to retain heat Make sure insulation is properly rated for maximum operating temperatures of your Upright unit Piping Considerations for Mobile Installations Because your Upright unit is fitted with casters its portability is well suited for multiple applications You can purchase high quality flexible metal hose from the manufacturer to enhance the mobility of your Upright unit state the length you want when ordering Although they cause a drop in pressure you can also install quick disconnects to your Upright unit However do not install check valves with quick disconnects unless absolutely necessary Upright Portable Hot Oil TCUs Chapter 3 Installation 19 Connecting Process Piping When connecting process piping ensure that the Cautions listed below are observed and followed Caution e Hoses valves and other components in your process must be able to withstand Upright unit maximum temperatures and pressures e Maximum temperatures and pressures are listed on the unit nameplate e Carefully inspect all components before installation e If in doubt about component suitability obtain factory components e Fix all leaks Fluid can be a potential fire and slip hazard Connecting Cooling Water Piping You must provide cooli
5. system After a preset time the pump shuts down if the fluid pressure is not re established The pressure switch is preset at the factory do not tamper with it Safety Thermostat The safety thermostat is a J thermocouple sensing adjustable fail safe device located in the heater tank This is to guard against the unlikely event of runaway heating If over heating does occur the safety thermostat shuts down the heater outputs and sounds an audible alarm A red pilot light on the status board also illuminates The unit continues to pump fluid through the system to prevent heater damage Auxiliary factory installed alarms such as beacons and klaxons are available as options AII controller functions are locked out until the main supply power is disconnected Resetting the alarm condition is initiated by depressing the red pump stop button The reset button is located inside the electrical enclosure mounted on the left wall of the enclosure It is imperative that a qualified maintenance technician determine and correct the cause of the fault before resuming operation Reservoir Tank A reservoir tank with sight gauge is standard usable capacity is seven 7 gallons 26 5 liters The tank permits thermal expansion of the heat transfer fluid and provides makeup fluid WARNING The reservoir tank may cause serious injury if it ruptures from not being properly vented Make sure that the reservoir tank is always properly vented to prevent t
6. Ge GC one ton truck with a two ton E 120 160 eem 212 313 load both are sure to break 180 200 rio 29e 0 down Always use ample capacity 32 94 1000 2500 i 33 49 325 2501 4000 28 43 1000 2500 36 51 42 62 AWARNING IX 265 395 2501 4000 30 44 38 56 1000 2500 49 73 53 73 4 12 690 2501 4000 44 66 43 73 Operating drives without guarda 500 1749 E 2 102 152 In place can reeuit In 44 67 1750 3000 88 132 severe Injury or death 30014000 i 58 SS 5V 5VX 71 109 300 1740 127 18 9 148 22 1 SR 1741 3000 112 16 7 13 7 20 1 118 160 500 1740 15 5 23 4 17 1 25 5 8 160 4741 3000 146 218 16 8 250 T A 125 170 2282 29 3 i Emerson Power Transmission Manufacturing L P 1998 1999 av 851 1500 265 395 All Rights Reserved 180 224 m 393 22 Upright Portable Hot Oil TCUs Chapter 7 Appendix 44 7 4 Spare Parts List Immersion Heaters HTR IMM 12 KW 208 V 3 6 ELE HTR IMM 12 KW 240 V 3 6 ELE HTR IMM 12 KW 380 V 3 6 ELE HTR IMM 12 KW 415 V 3 6 ELE HTR IMM 12 KW 480 V 3 6 ELE HTR IMM 12 KW 600 V 3 6 ELE Note 6KW heaters are modified 12 kW heaters jumpers are remove from one leg 542 00007 08 GASKET FLANGE 3 H Description 572 87548 00 TANK HEATER Upright 342 Heate ket Description eate k r Gas r Tan Manual Reset Safety Thermostat Part number Description 724 00041 00 THERMOSTAT 200 F 550 F Note Please give model and
7. Make sure the rotor shaft turns freely If it does not repeat steps 1 and 2 PUMP Turn Outer End Cap C C W SIZE No of Notches or Length on O D Inches G 0 75 HL HV 6 1 KK 10 1 38 Each small notch on outer end cap represents 001 inch end clearance WARNING Before starting the pump make sure that all drive equipment guards are in place y Failure to properly install the guards may result in serious injury or death d Installation of Carbon Graphite Bushings When installing carbon graphite bushings extreme care must be taken to prevent breaking Carbon graphite is a brittle material and easily cracked If cracked the bushing will quickly disintegrate Using a lubricant and adding a chamfer on the bushing and the mating part will help in installation The additional precautions listed below must be followed for proper installation 1 2 3 4 A press must be used for installation Be certain bushing is started straight Do not stop pressing operation until bushing is in proper position Starting and stopping will result in a cracked bushing Check bushing for cracks after installation Carbon graphite bushings with extra interference fits are freguently furnished for high temperature operation These bushings must be installed by a shrink fit 1 2 3 Heat bracket or idler to 750 F Install cool bushings with a press If facilities are not available to reach 750 F te
8. Temperature Control Unit Specifications Full load amps 460 3 60 VAC 12 kW heater 18 kW heater 24 kW heater 36 kW heater 48 kW heater Reservoir capacity in gallons liters TEFC pump Flow ud a VA em 6e 91 2 Pressure Dimensions in inches mm 62 1 575 Depth 34 864 lt 24 kW 44 1 Cm 24 KW O Each zone requires 15 gallons minimum to run properly Upright Portable Hot Oil TCUs Chapter 7 Appendix 41 7 3 Drawings and Diagrams Figure 7 18 24 GPM Pump Construction 075 00370 02 ROTOR amp SHAFT ASSEM BRKT CAPSCREW i JEL N CASING BRKT BUSHING HEAD W IDLER PIN IDLER PIN IDLER BUSHING IDLER W BUSHING ASN 418 BRACKET GASKET van 47 BRACKET es zf PART NUMBER AG t Y LIP SEAL S N 15 UN N ra COLLAR 4 h S yd LOCK WASHER 2 AN LOCKNUT 1 VLA 6 sj 16 1 CPSC PRESS RLF VLV SET OF 4 17 1 BRKT amp GSKT FLNC 19 5 PLUG PIPE STL S PIN IDL PIN HEAD amp ID DP 1 CPSC RLF VLV S OF 4
9. Upright Portable Hot Oil TCUs Chapter 1 Safety iii 4 2 Controller Description amp Operation 24 Identifying Control Panel Switches eese sees e nnns 25 Identifying System Status Board Indcatorg esses 26 Status Indicator e de 27 lee eege 27 Fault Indicator ed 27 4 3 Returning Fluid to the TAAK sadi eerie fe eet rs Et ero ge mde reete tf Saee 28 4 4 Shutting Down the Hot Oil TOW sect aere oet ond ka aaasta 28 CHAPTER 5 MAINTENANCE eeeeenenen enne nnn 30 5 1 Maintenance Ze Iesch EE 30 9 2 Preventative Maintenance oec s iced codd meet ateluet etre s acu E Eo Pipe e dde ha e a 31 Ho lina SEMGING E 31 Draining the Unit for E 31 Preventative Pump Maintenance eese sese nnns 31 5 3 Corrective Maintenance ior teer Ra pa ed bonne bodie telas tala te 32 PODS AO EE 32 Maintaining th PUMP WEE 33 Thrust Bearing E E 35 Installation of Carbon Graphite BUSHINGS sse 35 CHAPTER 6 TROUBLESHOOTING eee 36 61 NE ue le tr m 36 CHAPTER 7 APPENDIX deseen nun ror rra da tu an Fanta aea anne 39 1511 Optional Corporis coit amm dt pe gU e eee 39 7 2 Technical Specificatloris ese eem o metere nerd nter e aa tae 40 Annex B Information MEC 40 7 3 Drawings and RE Ti EE 42 194 Spare Parts EE 45 7 5 Returned Material PollGy a orit ere Por re reru eda sco aja 48 Credit EEN 48 Warranty Returns
10. clean or replace the solenoid Degraded fluid Drain and replace fluid Visual inspection of coil and Defective heater contactor contacts Repair replace defective contactors Check resistance on all three 3 legs of heater with an ohmmeter If not all equal contact factory for replacement heater Check heater tank for scorched discolored paint Check Heater burnout resistance on all three 3 legs of heater with an ohmmeter Replace heater as needed Check the heater output with an ohmmeter to ground It should Controller heater output open read in the mega ohm range Infinite or zero readings indicate a defective output Clogged Y strainer pes supply to unit is turned Open vates eR Water drain is plugged or excessive back pressure in drain line Unit overheats unable to cool Heat exchanger tubes plugged Remove tube bundles clean by lime deposits replace as required Test solenoid valve by switching to Manual Cool mode and listen for valve operation Replace if faulty Defective immersion heater Unit does not heat Clear drain line or eliminate back pressure condition Faulty solenoid valve Upright Portable Hot Oil TCUs Chapter 6 Troubleshooting 37 Problem Possible cause Corrective action i S Inspect replace faulty line or connection Perform venting seguence in Chapter 3 Check fluid level in sight glass Drain water from low point in Water in fluid piping see Chapter 3
11. death or serious injury WARNING WARNING indicates a potentially hazardous situation or practice that if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice that if not avoided may result in minor or moderate injury or in property damage Upright Portable Hot Oil TCUs Chapter 1 Safety 5 1 2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes This may include but is not limited to OSHA NEC CSA SPI and any other local national and international regulations To avoid possible personal injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices M A HR RR H M M Read and follow these operation and installation instructions when installing operating and maintaining this equipment If these instructions become damaged or unreadable additional copies are available from the manufacturer Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Work only with approved tools and devices Disconnect and or lock out power before servicing or maintaining the equipment Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS b
12. escape from areas such as the reservoir tank during high temperature operation Caution Harmful vapors may be generated from thermal fluid during high temperature operation Prolonged or repeated exposure of these heat generated vapors may result in eye and respiratory tract irritation Avoid contact or inhaling harmful amounts or material Consult the Material Safety Data Sheet MSDS for precautions and instructions for the thermal fluid you are using Note Before storing your Upright temperature control unit make sure you remove all residual water with compressed air to avoid a potential freezing hazard See Section 5 2 on Page 39 for more information Note the following table of ambient temperature ranges permitted for storage and operation Ambient storage range Ambient operation range 40 F to 185 F 40 C to 85 C 4 F to 120 F 20 C to 49 C You should preheat the process heat transfer fluid first if you want to start the unit below an ambient temperature of 30 F 1 C Upright Portable Hot Oil TCUs Chapter 3 Installation 17 3 3 Electrical Connections These units are designed for three phase voltage operation Refer to the unit nameplate for proper voltage and amperage requirements and make sure your electrical service conforms Check the unit nameplate for correct voltage and amperage before making electrical connections Caution 1 Provide a correctly sized and protected power supply to the unit
13. necessary refer to the parts catalog section Problem Possible cause Corrective action d Increase size of connectors Undersized connectors lines water lines Long connecting lines between Move the unit closer to the mold unit and mold and shorten connecting lines A onnect lines for parallel flow Serpentine flow through mold e s instead of series flow SA Check mold for metal chips or Blocked line in mold P deposits Clean mold Temperature fluctuations rapid Quick disconnect fitting with Remove and replace fitting or cycling from hot to cold check valve valve Carbon build up in unit piping Clean or replace affected piping or fittings Replace fluid Check unit by opening the manual bypass to determine if the TCU contols the set point temperature Reversed probes Switch Return and Delivery probes Faulty TCU Upright Portable Hot Oil TCUs Chapter 6 Troubleshooting 36 Problem Possible cause Corrective action Loss GF Haid i procese Check all lines connections fittings Allow vent timer to run out or Vent valve open check valve operation when unit is cold by opening the fill port Unit does not heat properly can Switch to Manual Cool mode not achieve set point Faulty dirty solenoid valve several times to flush valve If usually detected when there isa the leak continues disconnect steady stream or trickle of water the power to the unit turn off out of the drain line the water supply and
14. should be inside the enclosure for maintenance Doors can be opened with a screwdriver but no keys are required Two hand control is not required or provided All tcus should be moved around and set in a place with a lift truck or equivalent There are no frequent repetitive cycles that require manual control Trepetitive functions are automatic while the tcu is operating An inspection report detailing the functional test is included with the tcu The machine is not equipped with cableless controls Color coded harmonized power cord is sufficient for proper installation Upright Portable Hot Oil TCUs Chapter 7 Appendix 40 Figure 6 Upright Series Hot Oil Portable Temperature Control Unit RESERVOIR TANK FILL PORT SUB ASSEMBLY PLUG WHEN RUNNING IMMERSION HEATE amp HEATER TANK K i ASSEMBLY VENT SOLENDID MANUAL BYPASS _ Vi CG 1 r TA Ch L a OLT d eu HA t RESERVDIR TANK TO PROCESS VENT OVERFLOW TEMP PROBE DO NOT PLUGO TANK DRAIN PLUG SIDE PANEL TOP PANEL Y STRAINER FROM PROCESS TEMP PROBE RETURN CHECK VALVE PRESSURE GAUGE VENT TEMP SWITCH FRONT PANEL COOLING WATER SUPPLY CONSOLE SUB ASSEMBLY COOLING WATER DRAIN PANEL SUB ASSEMBLY HEAT EXCHANGER SUB ASSEMBLY FROM PROCESS e H 3 S TO PROCESS lt a BACK PANEL auf DRIVE SUB ASSEMBL Y PUMP SUB ASSEMBLY UNIT DIL DRAIN Ba d Ais zi N BASE SUB ASSEMBLY Upright Series
15. tighten the bolts to stop the leak Similarly rough handling in shipping may sometimes cause minor leaks upon startup you may need to re tighten bolts or fittings to stop the leak You should expect to periodically replace the pump seal If the pump is properly lubricated and used at moderate temperatures the seal should last several years The following section describes the proper procedures for replacing the seal Mechanical seal part no 162 00030 160 Periodic replacement of the pump drive V belt is also to be expected Note If the pump motor wiring is disconnected for removal from the unit you must check the actual direction of rotation when the motor is rewired to the unit Consult Elementary Diagrams provided in unit for additional information Upright Portable Hot Oil TCUs Chapter 5 Maintenance 32 Maintaining the Pump Disassembling the Pump WARNING Before opening the pump chamber e Make sure that any pressure in the chamber has been completely vented e Make sure that the motor cannot be inadvertently started while you work on the pump Failure to follow these precautions may result in serious injury or death 1 10 11 12 13 14 Mark the head and casing before disassembly to insure proper reassembly The idler pin which is offset in the pump head must be positioned toward and equal distance between port connections to allow for proper flow of liquid through the pump Remove the head from
16. tighten with a spanner wrench Tighten the radial set screws that lock the end cap in place Using the snap ring pliers install the snap ring onto the shaft Thread the thrust bearing assembly into the bracket Turn in until hand tight This forces the rotor against the head Put lockwasher and locknut on shaft Insert length of hardwood or brass through port opening between rotor teeth to keep shaft from turning Tighten locknut to 50 70 ft Ibs torque and bend one tang of lockwasher into slot Adjust pump end clearance Refer to section on Thrust Bearing Adjustment Lubricate all grease fittings with Dow Corning 44 high temperature silicon grease Upright Portable Hot Oil TCUs Chapter 5 Maintenance 34 Thrust Bearing Adjustment l Loosen axial setscrews in face of end cap on the thrust bearing assembly If rotor shaft cannot be turned by hand back off the thrust bearing assembly until there is a noticeable drag of the shaft Note mechanical seal will provide some drag and this is a normal condition The thrust bearing assembly must be turned in until it can just be turned over by hand This ensures the rotor is against the head and a zero end clearance condition exists Make a mark on the OD of the bearing housing and a corresponding mark on the bracket Back off thrust bearing housing the required number of marks or distance on the OD as shown below Tighten the axial setscrews in the face of the thrust bearing assembly
17. toll free 7am 5pm CST 800 423 3183 or call 262 641 8610 Fax 262 641 8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service Service Department Call toll free 8am 5pm CST 800 423 3183 or call 262 641 8610 Emergencies after 5pm CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most of our products Sales Department Call 262 641 8610 Monday Friday 8am 5pm CST Our products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 262 641 8610 Monday Friday 8am 5pm CST Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations Upright Portable Hot Oil TCUs Chapter 7 Appendix 49
18. turning them on and if so equipped opens the Cool solenoid 2 Youcan monitor fluid temperature on the controller display during cool down Upright Portable Hot Oil TCUs Chapter 4 Operation 28 When fluid temperature dips below 120 F 49 C press the PUMP STOP button to turn off the unit Upright Portable Hot Oil TCUs Chapter 4 Operation 29 Chapter 5 Maintenance 5 1 Maintenance Schedule The checklist below contains a list of items which should be inspected and or replaced to keep your Portable Hot Oil TCU operating at peak efficiency Perform each inspection at the regular intervals listed below Date Date Date Date Date Date Date Date Date Date ood s Date Every week E Ka Check connecting lines hoses amp conectors for wear or damage pq ocyus joe doces p E Every month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Check for leaks at pump seal gaskets etc mu 1 SSES ES Se V belt for wear Check reservoir tank vent for obstructions Next scheduled Actual inspection Next scheduled Actual inspection Every Quarto Check the heat transfer fluid for deterioration Do a routine check of the fluid every 1 000 hours of operation or every three 3 months whichever comes first Contact the Service Department for information on fluid testing Every Six Months Next scheduled Actual inspection Next scheduled Actual inspection inspection Date By inspect
19. with efficient production The operator usually has the most daily contact with the equipment and intimately knows its capabilities and limitations Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates or through a casual attitude toward machinery formed over a period of months or years Your employer probably has established a set of safety rules in your workplace Those rules this manual or any other safety information will not keep you from being injured while operating your equipment Learn and always use safe operation procedures Cooperate with co workers to promote safe practices Immediately report any potentially dangerous situation to your supervisor or appropriate person REMEMBER e NEVER place your hands or any part of your body in any dangerous location e NEVER operate service or adjust the temperature control unit without appropriate training and first reading and understanding this manual Before you start the temperature control unit check the following e Remove all tools from the tcu e Be sure no objects tools nuts bolts clamps bars are laying in the TCUs operating area e If your TCU has been inoperative or unattended check all settings before starting the unit e At the beginning of your shift and after breaks verify that the controls and other auxiliary equipment are functioning properly e Keep all safety guards in place and in good repair NEVER attempt to byp
20. 2 Ifan electrical supply disconnect is not installed as a factory option the customer is responsible to properly size and install a suitable disconnect 3 Refer to National Electric Code NEC 430 24 26 for proper feed conductor and supply disconnect sizing 4 Voltages must be within plus or minus ten percent 10 of the nameplate rating 5 Maintain a safe ground and disconnect the power supply before servicing the unit A qualified electrician should make electrical connections and disconnect the electricity when service calls are needed Locate disconnects in an easily accessible location Operators should not have to squeeze around the Upright unit to reach disconnects especially in case of emergency e When running conduit whips to the Upright unit make sure that whips are routed away from hot piping DANGER Improper electrical connections can cause damage to the unit and cause serious operator injury or death Make sure that ALL electrical connections are made by a qualified electrician and that ALL connections are tight Make all electrical supply connections at the front of the unit An access panel covers all electrical connections Run electrical connections to the supply terminals from either side of the unit Make sure that all three phases are wired correctly The pump runs backwards if not wired properly Upright Portable Hot Oil TCUs Chapter 3 Installation 18 3 4 Setup Procedures This section provides the
21. Unit Monthly or Every 500 Hours e Lubricate the pump at the grease fittings with a high quality lithium grease rated at 400 F 204 C or higher Use only Dow Corning 44 or a high temperature grease rated at 400 F or higher that is compatible with Dow Corning 44 Do not over lubricate Adjust the pump drive belt tension Make sure that the motor pulley is properly aligned with the pump pulley use a straightedge to check Tighten motor mounting bolts after realignment Inspect the screen in the Y strainer for accumulations of debris Clean as needed Servicing the Unit Every Three Months Remove and clean the screen in the Y strainer Replace the screen if it is damaged Draining the Unit for Storage You should thoroughly flush and drain the Upright unit if you need to take it out of service for a long time or if you expect it to become exposed to freezing temperatures The manufacturer recommends using a flushing fluid or equivalent for flushing your Upright unit follow unit flushing instructions that comes with the flushing fluid Drain plugs are provided at the base of the heater tank reservoir tank and on the pump You should also remove drain and reinstall the heat exchanger tube bundle before storage Preventative Pump Maintenance You can extend the life of your pump and reduce the cost per gallon pumped if you perform a few preventive maintenance procedures Lubricating the Pump Using 2 ball bearing grease and a ha
22. WNING Belt Tension Checker See Form 5453 T ab Eliminate slack Adjust motor and tighten belts in position Slack belts wear excessively cause slippage and deliver less power for more detail The capacity of the BROWNING belt tension checker is 35 Ibs Other means of applying force must be used if force requirement is greater than this SHEAVE DIAM INCHES DEFLECTION FORCE LBS Use matched belts Matched belts run smoother and last longer because the load is Belt Deflection Force GE Super Gripnotch evenly distributed Never replace NP Smallest Gripbeks E j She RPM ani an just part of a set of belts gos Diameter Range Unnotched Notched on Range Gripbands Gripbands Avoid belt idlers Used New Used Now Belt idlers decrease belt life ET e SS Fi Se Always maintain proper tension 30 38 25014000 28 42 34 50 i 1000 2500 4 5 68 50 74 through motor adjustment AAX 38 48 2561 4000 38 57 PE 64 50 70 1900 2500 54 80 57 84 2501 4000 A7 70 51 76 Mount belts straight 34 42 260 2500 E 43 22 Shafts must be parallel and 950 2500 23 73 21 05 sheave grooves in alignment to 8 BX 44 38 2501 4000 45 67 61 81 860 2500 63 94 85 126 prevent unnecessary belt wear 58 86 360 Z 8 23 108 20 90 500 1740 11 5 17 0 14 7 21 8 CCX 7 i 1741 3000 94 13 8 11 9 17 5 Don t overload 95 160 22 70 1 210 153 Bs A ta M 1741 12 18 d AR An overloaded belt drive is like a Ce
23. and serial numbers when ordering parts Prices are subject to change without notice Upright Portable Hot Oil TCUs Chapter 7 Appendix 46 Solenoid Valves 732 00007 03 4 VALVE 115 V COIL 0 125 PSI 300 F 732 00013 01 34 VALVE 115 V COIL 0 125 PSI 300 F Sensing Probe Equipment 692 07369 05 HEAT amp COOL M2B 701 00003 00 TYPE T THERMOCOUPLE Disconnect Switches Description 728 00153 00 SWITCH DISCONNECT 45 AMP 728 00168 00 SWITCH DISCONNECT 100 AMP Heater Tank Insulation Part number Description 542 88062 00 INSULATION TANK HEATER Ful Flo Relief Valves Part number Description 044 00239 00 VALVE RELIEF FUL FLO 1 Breather Cap Part number Description 161 00072 00 CAP BREATHER 1 Note Please give model and serial numbers when ordering parts Prices are subject to change without notice Upright Portable Hot Oil TCUs Chapter 7 Appendix 47 7 5 Returned Material Policy Credit Returns Prior to the return of any material authorization must be given by the manufacturer A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given ALL returned material purchased from the manufacturer returned is subject to 1596 75 00 minimum restocking charge ALL returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied No credit will be issued for material
24. ank NES rupture SW The reservoir tank drain is extended beyond the base of the unit for ease of draining Optional ball valves are available to further simplify draining Upright Portable Hot Oil TCUs Chapter 2 Functional Description 14 Cooling Optional The manufacturer designed shell and tube heat exchanger is provided as optional equipment in this unit The design features U tube construction and copper nickel tubes for durability and optimal heat transfer The modular construction unique to our units allows the tube bundle to be easily removed for periodic cleaning Additionally check valves are installed on the water supply and drain lines to prevent water from back flowing into the heat exchanger from a closed drain or into the water supply piping The controller automatically regulates cooling by opening and closing the cooling solenoid This allows the proper amount of cooling water to pass through the tubes of the heat exchanger and out the drain A water supply of 75 psi 517 1 kPa 5 2 bars maximum is required for connection to the heat exchanger 2 6 Safety Devices and Interlocks This section includes information on safety devices and procedures that are inherent to the portable hot oil tcu This manual is not intended to supersede or alter safety standards established by the user of this equipment Instead the material contained in this section is recommended to supplement these procedures in order to provide a safer worki
25. ass modify or remove safety guards Such alteration is not only unsafe but will void the warranty on your equipment e When changing control settings to perform a different mode of operation be sure selector switches are correctly positioned Locking selector switches should only be adjusted by authorized personnel and the keys removed after setting e Report the following occurrences IMMEDIATELY e unsafe operation or condition e unusual temperature control unit action e leakage e improper maintenance e NEVER stand or sit where you could slip or stumble into the temperature control unit while working on it e DO NOT wear loose clothing or jewelry which can be caught while working on a tcu In addition cover or tie back long hair Upright Portable Hot Oil TCUs Chapter 1 Safety 8 e Clean the tcu and surrounding area DAILY and inspect the machine for loose missing or broken parts e Shut off power to the tcu when it is not in use Turn the switch to the OFF position or unplug it from the power source Maintenance Responsibility Proper maintenance is essential to safety If you are a maintenance worker you must make safety a priority to effectively repair and maintain equipment Before removing adjusting or replacing parts on a machine remember to turn off all electric supplies and all accessory equipment at the machine and disconnect and lockout electrical power Attach warning tags to the disconnect switch When yo
26. below the rated pressure The flow is constant until the pressure reaches the rated pressure The pressure however is a function of frictional losses through the process that it is attached to Systems with large process connections ports and piping will operate at low pressures While systems with small process connections ports and piping will operate at higher pressures Once pressure requirements exceed the rated pressure the Ful Flow valve will open and bypass the necessary fluid to prevent high pressures Ful Flo Valve A regulating bypass line featuring a Ful Flo valve is standard in all units This is a safety device to prevent excessive pressure in the event that the delivery line is obstructed Each Ful Flo valve is factory preset to limit system pressure as specified by the customer It must not be tampered with in any way In the event of an obstruction in the line the Ful Flo valve will open and divert fluid from the delivery TO PROCESS line to the return FROM PROCESS line A constant flow of fluid is maintained through the heater tank to prevent damage to the heating elements and fluid Upright Portable Hot Oil TCUs Chapter 2 Functional Description 12 Connection Lines Connections for TO PROCESS and FROM PROCESS lines are 1 NPT 25 4 mm Water connections for COOLING WATER SUPPLY and COOLING WATER DRAIN are 4 NPT 19 1 mm see Section 3 4 on Page 20 for more information The customer is responsible for conversions to met
27. ble alarm activates to notify you of the pump overload fault and the unit shuts down Note Always correct the alarm condition before returning to normal operation Low Pressure Indicator Light The Low Pressure indicator light illuminates when the unit has low heat transfer fluid pressure This is an alarm condition so the audible alarm activates to notify you of the low pressure fault and disables controller outputs permitting the pump to continue to circulate fluid to avoid damage If low pressure continues past five minutes elapsed time the pump shuts off Note Always correct the alarm condition before returning to normal operation Safety Thermo Indicator Light The Safety Thermo indicator light illuminates when the unit is overheating This is an alarm condition so the audible alarm activates to notify you of the safety thermo fault and disables controller outputs permitting the pump to continue to circulate fluid to avoid damage Note Always correct this alarm condition before returning to normal operation Upright Portable Hot Oil TCUs Chapter 4 Operation 27 High Level Indicator Light Optional The High Level indicator light illuminates when the heat transfer fluid level in the reservoir tank is too high Carefully remove just enough fluid so this indicator light shuts off Low Level Indicator Light The Low Level indicator light illuminates when the heat transfer fluid level in the system is too low This is an alar
28. cuit at 115 V single phase The control circuit voltage is provided by a single phase machine tool transformer with primary fuse protection and a grounded secondary A main power disconnect is included for ease of service The electrical panel is UL listed and complies with N F P A 79 provisions All components are IEC rated for long life and reduced maintenance The heater elements are branch fused and protected from contactor welding by a separate primary voltage contactor The pump motor is controlled by a full voltage magnetic reversing starter with fused branch circuit overcurrent and thermal overload protection Many additional features are available as options A NEMA 12 enclosure is standard with NEMA 4 available as an option Upright Portable Hot Oil TCUs Chapter 2 Functional Description 13 Air Purge Upon initial start up and mold process change out you ll need to purge all air and water from the system The Upright unit has appropriate valving to ensure complete purging Procedures are covered in Section 3 5 on Page 23 WARNING Failure to purge the system of air before heating may result in serious injury or critical system and equipment damage Make sure you properly purge the system of air before ws starting the heater cycle AN Pressure Switch A pressure switch is built into each unit to guard against heater damage This feature prevents the heater elements from being energized unless the pump is running and fluid is in the
29. dicator light illuminates when the unit pump runs in reverse Pump Forward Indicator Light The Pump Forward indicator light illuminates when the unit pump runs in the normal forward direction This indicator typically illuminates continuously during normal operation Heater On Indicator Light The Heater On indicator illuminates when the heater energizes Cool Solenoid Indicator Light The Cool Solenoid indicator illuminates when the cooling solenoid energizes It is used only on the optional heat exchanger Vent Solenoid Indicator Light The Vent Solenoid indicator illuminates when the venting solenoid energizes during venting sequences Mode Indicator Lights Select the unit operating mode by using the selection switch Power On Mode Indicator Light The Power On mode indicator light illuminates to indicate that the control circuit is energized in the unit Auto Mode Indicator Light The Auto mode indicator light indicates that the Auto mode is active and the controller is monitoring the system and controlling the process If the Auto light is off and the Cool Solenoid indicator light is illuminated the controller is disabled and the cooling solenoid is open permitting maximum cooling If the Auto and Cool Solenoid indicator lights are off the unit is in standby Fault Indicator Lights Pump Overload Indicator Light The Pump Overload indicator light illuminates when the pump is overloaded This is an alarm condition so the audi
30. efore working on equipment You should remove the fuses and carry them with you Make sure the equipment and components are properly GROUNDED before you switch on power When welding or brazing in or around this equipment make 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 if needed Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality Upright Portable Hot Oil TCUs Chapter 1 Safety 6 1 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Each individual must take responsibility for observ
31. f the sight glass Air and thermal fluid vent through the vent solenoid or the manual vent valve and into the reservoir tank Caution You must purge the system of air before the heating cycle Personal injury and system damage can occur from a pressurized system Make sure that the reservoir tank vent port is not plugged The reservoir tank must never be pressurized 5 When the unit has built at least five 5 psi 34 5 kPa of pressure wait two 2 minutes then select a set point of 100 F 38 C and switch the unit into AUTO mode As the oil warms up viscosity decreases and pressure falls Increase the set point to 150 F then 200 F 65 C then 93 C at two minute intervals 7 Any water present in the system must boil off before continuing operation Select a set point of 215 F 102 C and observe the reservoir tank vent for any signs of escaping steam Continue to run at this set point temperature until no more steam appears and pressure stabilizes 8 When fluid level stabilizes and the air and water are purged from the system allow the vent timer to run out or If so equipped close the vent valve Do not open the vent valve at temperatures exceeding 250 F 121 C With the system properly purged only four to six inches 4 to 6 10 cm to 15 cm of fluid should be visible in the sight glass This lets the fluid expand as it heats also permitting process fluid additional capacity when the pump reverses and flu
32. id is withdrawn from the mold Upright Portable Hot Oil TCUs Chapter 3 Installation 22 The Upright unit is now ready for use All that is now required is to select a process set point on the controller Note If all traces of water are not removed from the system severe cavitation may occur at elevated temperatures Indications are a rough sounding pump fluctuating or dropping pressure or a rapidly rising fluid level in the expansion tank Repeat Step 3 if this occurs Upright Portable Hot Oil TCUs Chapter 3 Installation 23 Chapter 4 Operation 4 1 Start up Push the PUMP START button to start the pump 2 When the unit has built at least five 5 psi 34 5 kPa of pressure wait two 2 minutes then select a set point of 100 F 38 C and switch the unit into AUTO mode As the oil warms up viscosity decreases and pressure falls 3 Four to six inches 4 to 6 10 cm to 15 cm of fluid should be visible in the sight glass 4 Selecta process set point on the controller 4 2 Controller Description amp Operation 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 temperature The controller has been fully factory tested Set the desired process temperature set point and the controller does the rest Built in range of operation on the controller i
33. ing the prescribed safety rules as outlined All warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor General Responsibility No mater who you are safety is important Owners operators and maintenance personnel must realize that every day safety is a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in a negative way following an accident The following are some of the ways that accidents can affect your production e Loss of a skilled operator temporarily or permanently e Breakdown of shop morale Costly damage to equipment e Downtime An effective safety program is responsible and economically sound Organize a safety committee or group and hold regular meetings Promote this group from the management level Through this group the safety program can be continually reviewed maintained and improved Keep minutes or a record of the meetings Hold daily equipment inspections in addition to regular maintenance checks You will keep your equipment safe for production and exhibit your commitment to safety Please read and use this manual as a guide to equipment safety This manual contains safety warnings throughout specific to each function and point of operation Upright Portable Hot Oil TCUs Chapter 1 Safety 7 Operator Responsibility The operator s responsibility does not end
34. ion Date By Inspect electrical connections for secure tight terminations and ground connections Inspect the power cable at the entrance point to the electrical enclosure Check the mounting bolts on the pump the motor and the heater flange for tightness Remove the heat exchanger tube bundle and check it for lime and mineral deposits Carefully clean the bundle as needed Photocopy this page for your maintenance records Upright Portable Hot Oil TCUs Chapter 5 Maintenance 30 5 2 Preventative Maintenance WARNING Make sure that your maintenance technicians comply with lock out tag out procedures e during any servicing or maintenance of this unit and related equipment per OSHA article ART 1910 147 Before you begin servicing this unit disconnect all power to it let the unit cool down completely and turn off the water Failure to follow these directives can result in serious injury or death Routine Servicing Your hot oil temperature control unit requires little in preventive maintenance and servicing To keep it in good reliable working order make sure you follow the following scheduled preventive maintenance procedures Keep surfaces clean and free of any excessive accumulations of dirt oil or debris This is especially true for the pump It relies on free air circulation for proper cooling Check the motor air intake screen for any accumulation of dirt clean it as needed Servicing the
35. istance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list You should have M Portable Hot Oil TCU M Bill of lading M Packing list M Operating and Installation packet M Electrical schematic and panel layout drawings M Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered please contact the parts and service department immediately at 262 641 8610 Have the order number and item number available Hold the items until you receive shipping instructions Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department Upright Portable Hot Oil TCUs Chapter 1 Safety il Table of Contents CHAPTER 1 SAFETY GEN 5 14 How to Use This Manual Teen re tee eo tr E Rud dee 5 Safety Symbols Used in this Manual sese 5 1 2 Warnings and Pre eau loris eege Ee Ee va lama tume eria ihkad en 6 13 Responsipility UE DO 7 General FIOSDORDSIDIITVS iios Saude reet er edel 7 Operator HespornsiDIlily e tr e OR REM tlk v ka 8 Maintenance HesporisiDilily ERR EU Eo Rete eee need lauta kaa 9 Reporting a Safety Defects EEN 9 CHAPTER 2 FUNCTIONAL DESCRIPTION 10 2 1 Models C
36. lowed before commencing with operation of the portable hot oil TCU These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the portable hot oil TCU safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your portable hot oil TCU provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics parts lists and available options A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in
37. lt in serious injury No one but the person who installed the lockout may remove it Upright Portable Hot Oil TCUs Chapter 2 Functional Description 16 Chapter 3 Installation 3 1 Uncrating the Equipment Portable hot oil temperature control units are shipped mounted on a skid enclosed in a plastic wrapper and contained in a cardboard box 1 Pry the crating away from the skid Note Remove the nails holding the box to the skid and lift the box off carefully avoiding staples in the 1 x 4 wood supports Cut the steel banding 2 Use a pry bar to remove the blocks securing the unit to the skid 3 Lift unit from sides Use a pry bar if necessary to carefully remove the skid from the unit 4 Lower slowly 3 2 Rigging and Placing the TCU Make sure that you meet the following requirements when installing and operating your Upright hot oil temperature control unit Installation Location Considerations Locate the Upright unit as close as possible to the process for proper circulation and temperature control Take care when selecting a location The area surrounding the unit must be free of obstructions to ensure proper ventilation of internal components Allow a minimum clearance of at least 30 inches 76 cm Make sure that the unit location is not in a confined space to ensure proper air circulation Special air circulation ventilation is required for units operating at temperatures exceeding 500 F 260 C Vapors can
38. m condition so the audible alarm activates to notify you of the low fluid level fault and the controller outputs are disabled Note Always correct the alarm condition before returning to normal operation 4 3 Returning Fluid to the Tank If you want to move the unit from one process to another like mold changes perform the following steps to drain the mold and process lines Note This procedure is just the opposite of the unit startup air purge procedure Cool the heat transfer fluid to no more than 100 F 38 C If so equipped open the manual vent valve to add air into the pipes Press the PUMP STOP button Press and hold the PUMP REVERSE button NS A 10 ccs The pump runs in reverse drawing fluid from the mold and lines then drains the fluid into the reservoir tank 5 Watch the sight glass to prevent overflow of the reservoir tank Caution The reservoir tank may not have adequate volume to contain the total system capacity of fluid An overflowing reservoir allows hot fluid to escape and become a potential fire and slip hazard The total capacity of the tank is 7 gallons 26 5 liters If it appears that the tank may overfill connect a line from the FILL port of the reservoir tank to a clean auxiliary container 4 4 Shutting Down the Hot Oil TCU 1 Cool down the unit by switching the CONTROL MODE switch to the MAN COOL manual cooling position This step disables the heaters prevents the controller from
39. mperature it is possible to install with 450 F temperature however the lower the temperature the greater the possibility of cracking the bushing Upright Portable Hot Oil TCUs Chapter 5 Maintenance 35 Chapter 6 Troubleshooting 6 1 Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components All normal trouble shooting must be accomplished with the power off line fuses removed and with the machine tagged as out of service The use of good quality test equipment cannot be over emphasized when troubleshooting is indicated Use a good ammeter that can measure at least twice the AC and DC current that can be encountered for the machine Be sure that the voltmeter has at least minimum impedance of 5 000 OHMS per volt on AC and 20 000 OHMS per volt on DC scales Popular combination meters VOM and VTVM can be selected to provide the necessary functions Before making haphazard substitutions and repairs when defective electrical components are malfunctioning we recommend that you check the associated circuitry and assemblies for other defective devices It is common to replace the obviously damaged component without actually locating the real cause of the trouble Such hasty substitutions will only destroy the new component Refer to wiring diagrams and schematics Locating mechanical problems should they occur is relatively straightforward When
40. nd operated grease gun gently lubricate all grease fittings after every 500 hours of operation or after 60 days whichever comes first If pump service occurs in severe conditions lubricate more frequently Use an appropriate type of grease for hot or cold applications Upright Portable Hot Oil TCUs Chapter 5 Maintenance 31 Adjusting End Clearance After long periods of service the running clearance between the end of the rotor teeth and head may be increased from wear The pump may lose some capacity of pressure as a result If you reset the end clearance pump performance should improve Examining Internal Parts Remove the head occasionally and examine the idler bushing head and pin for wear Replace the idler bushing and idler pin after moderate wear to avoid replacing more expensive parts later Note Make sure the idler doesn t slide off the idler pin during head removal to avoid damage and personal injury Cleaning the Pump A clean pump is easier to inspect lubricate and adjust it runs better and looks better 5 3 Corrective Maintenance Pumps and Seals Each Upright unit is completely tested and calibrated before leaving the factory The unit is then cooled drained and packed for shipment If the unit stands idle for a long time before being installed in your factory gaskets can dry out and possibly leak when you start the unit In most cases these gaskets soon swell and form a tight seal If not you may need to
41. ng environment At the completion of this section the operator and maintenance personnel will be able to do the following e Identify and locate specific safety devices e Understand the proper use of the safety devices provided e Describe the function of the safety device Safety Circuit Standards Safety circuits used in industrial systems protect the operator and maintenance personnel from dangerous energy They also provide a means of locking out or isolating the energy for servicing equipment Various agencies have contributed to the establishment of safety standards that apply to the design and manufacture of automated equipment The Occupational Safety and Health Administration OSHA and the Joint Industrial council JIC are just a few of the organizations that have joined with the plastics industry to develop safety standards Every effort has been made to incorporate these standards into the design of the portable hot oil tcu however it is the responsibility of the personnel operating and maintaining the equipment to familiarize themselves with the safety procedures and the proper use of any safety devices Upright Portable Hot Oil TCUs Chapter 2 Functional Description 15 Fail Safe Operation If a safety device or circuit should fail the design must be such that the failure causes a Safe condition As an example a safety switch must be a normally open switch The switch must be held closed with the device it is
42. ng water at 25 psi to 75 psi 172 4 kPa to 517 1 kPa 1 7 bars to 5 2 bars for proper operation Untreated water can foul or corrode the heat transfer surfaces slowing water flow and causing fluid temperature control problems The manufacturer sells a complete line of water treatment equipment that can reduce downtime and maintenance costs Run properly sized cooling water lines never smaller than the outlets on the Upright unit If external piping is larger than Upright unit connections reduce the size of the piping at the unit Connecting Vent Piping You must leave the vent connection open to the atmosphere at all times The vent connection is located on top of the reservoir On systems with piping above the reservoir level you must run vent piping to a minimum height of one foot 1 31 cm above the highest point in the system Run the piping down into an auxiliary vented overflow chamber such as a vented covered 55 gallon 208 liter drum This practice ensures that overflow will not create a hazard to personnel Note All external piping must be supported independently of the Upright unit Caution The reservoir tank must be vented to prevent pressurization A pressurized reservoir could rupture allowing hot fluid to escape and become a potential fire and slip hazard Note Heat transfer fluids expand when heated Expansion rates vary depending on fluid types and temperatures For more information on expansion rates refer to s
43. ns Annex B Information The following design information is provided for your reference l ER U sod CONI UC E e nm N ken c 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 No modifications are allowed to this equipment that could alter the CE compliance Ambient temperature 40 degrees Celsius Maximum 104 degrees Fahrenheit Humidity range 50 relative humidity Altitude Sea level Environment Clean dust free and non explosive Radiation None Vibration Minimal i e machine mounting Allowable voltage fluctuation 10 Allowable frequency fluctuation Continuous 1 Intermittent H 2 Nominal supply voltage 460 3 60 Verify on serial number tag Earth ground type TN system has one point directly earthed through a protective conductor Power supply should include a ground connection Over current protection is supplied in the tcu but additional protection should be supplied by the user The door mounted disconnect serves as the electrical disconnect device Tcu is not equipped with local lighting Functional identification Tcu is equipped with a CE mark Tcu is supplied with an operating manual in the language of the destination country Cable support may be required for power cord depending on final installation No one is required to be in the interior of the electrical enclosure during the normal operation of the unit Only skilled electricians
44. nual Cooling mode Caution Always let the pump run for at least one 1 minute before switching to AUTO mode Never switch to AUTO mode when filling or venting the unit except as described in the Unit Startup Improper switching can seriously damage the heater as it could become energized with air in the system Alarm Silence Press the ALARM SILENCE button to silence the audible alarm on the console Caution After you silence the alarm make sure you locate and correct the alarm condition before continuing with unit operation Identifying System Status Board Indicators The system status board is located next to the controller panel It displays indicator lights to show current operation status letting you analyze system performance Figure 5 System Status Board Indicators C PUMP OVERLOAD C PUMP REVERSE BYPASS RELIEF VALVE TO PRESSURE PROCESS SAFETY THERMO EXCHANGER N FROM PROCESS WATEK COOL DRAIN aT SOLENOID VENT WATER LEVEL sorgNoOD BH sUPPLY Use the status board to optimize unit performance For example if you observe a rapid cycling of the Heater and Cool Solenoid indicators the unit is operating with a process inefficiency see the Troubleshooting section for more information What follows is a description of system status board indicators Upright Portable Hot Oil TCUs Chapter 4 Operation 26 Status Indicator Lights Pump Reverse Indicator Light The Pump Reverse in
45. overed in This Manual eeessesssssseeeesseeeene nennen nennen 10 2 2 General MR EEN 10 259 Standard Re 10 Mechanical Features a c cct d sen eer 10 Elogitical E 11 Controller e 11 2L OPUONS aad date ata E Ae en tos dme LE UE LE 11 2 5 Feature Descriptions ER cm 12 Immersion Heaters C m 12 lulu Ee dc CE 12 ee 12 EER Valve e rr DOE deum 12 Connection EIOS e E ge ee Ee 13 Electrical System e 13 Electrical Panel and System Components sss 13 gum PKT P Es CET 14 Press re SWMIG M Lm 14 Safety Thermostat n eiut dads date RS EAS RID Ee 14 Hesbrvolt Tank co d xo iade ei apud iat bi etur 14 870701 1410 CODIIOITal dst dante dais respice obuia emos Ee 15 2 6 Safety Devices and Intel oGKS od istumist rettet tee Ere ei ete dede tite El podus 15 CHAPTER 3 INSTALLATION eeeeeeeeeeeee nnne 17 941 Uneraung the EquipiTiehilss te erect ec Pu o Be bar ui ee ie eee EE 17 3 2 Rigging and Placing the TOL ocio pecori seiklustest kaminaahi linale taeda 17 Installation Location Considerations eise 17 3 3 Electrica Connections eor Deep Ne Gate buddies Rat 18 3 4 Setup Ne tuc rr 19 CODDOCIIng PIDIFIg EE 19 Connecting Process Piping c uer aote ee o dupl oon BRE roe aken 20 3 50 dMrntial SSDS EE 22 Starting the Hot OW TOU uei rt a E E eq A MN 22 CHAPTER 4 OPERATION eeeee eere nnn 24
46. pecification information for the heat transfer fluid you select Generally most heat transfer fluids expand at the rate of 2 5 for every increase of 50 F C from temperatures above 60 F 16 C Upright Portable Hot Oil TCUs Chapter 3 Installation 20 Figure 1 Upright Unit Piping Setup Vent solenoid Fill port must be plugged except Cooling water supply E 3 4 NPT 19 1 mm when filling 1 NPT 25 4 mm Q Cooling water drain 3 4 NPT 19 1 mm Sight glass reservoir level gauge From Process oil AW 1 NPT 25 4 mm Manual bypass valve SS i a A Oil reservoir drain 2 CD In To Process oil 1 2 NPT 12 7 mm SOYA 1 NPT 25 4 mm w DD CH otf Um I Connect the TO PROCESS hookup to the entrance of the process and the FROM PROCESS hookup to the exit of the process Connect the COOLING WATER SUPPLY to your plant water supply Connect the COOLING WATER DRAIN line to an open drain or to the return line of your central water system If returning to a central water system use a condensate return tank to avoid a standing water column on the heat exchanger drain line Caution If you are routing the drain line to an open drain make sure that the line is directed away from personnel to avoid scalding Carefully select connecting line
47. procedures necessary for configuring your portable hot oil temperature control unit Configuration of your TCU includes connecting cooling process and vent piping We recommend that you carry out these procedures in the order given here Note Before carrying out these procedures install all equipment as described in this section Connecting Piping Make sure that all external piping is properly sized to reduce external pressure drop as much as possible Do not install process or water supply drain piping smaller than the fittings on the unit If the water supply piping is larger than unit fittings reduce the pipe size at the unit The following table lists recommended Upright TCU pipe sizes Connection To Process From Process Cooling Water Supply Cooling Water Drain Oil Drain Fill Port O Customer is responsible for converting to metric Note Always use a backup wrench to support Upright unit piping when making connections Make sure all external piping is supported independently of the Upright unit The manufacturer recommends that you have strainers installed on the cooling water inlets and customer supplied shut off valves on all piping connections Use common black welded pipe for permanent installations The Upright is designed to operate with an open unrestricted drain line Steam rapidly expands within the heat exchanger so any overpressure condition from backpressure or standing columns of water against the drain
48. ric standards The manufacturer stocks many lengths of flexible metal hose the part number is 572 16969 State the length of hose you want when ordering WARNING Component failure may result in high temperature oil spray causing serious injury or death Make sure hoses valves and other components installed in your process can withstand maximum temperature and pressure of the Upright unit check unit nameplate for specific capacities All components must be carefully inspected for condition before installing Make sure you have factory components if you have any doubt Electrical System Controls The electrical controls of your Upright unit are specially engineered for reliability safety and simplicity of operation Switch functions are clearly labeled Your Upright unit has a system status board so you can evaluate the status and performance of the unit at a glance Pilot lights are provided to indicate key unit functions An audible alarm is standard with your unit The alarm will sound in the event of the following conditions e motor overload e safety thermostat trip over temperature e low fluid pressure e low fluid level e high fluid level optional Push the ALARM SILENCE button to silence the alarm See Section 4 2 on Page 25 for more information on control functions Electrical Panel and System Components The pump motor and immersion heater operate on three phase 50 60 cycle nominal voltage with the control cir
49. rings in clean solvent Blow out bearings with compressed air Do not allow bearings to spin turn them slowly by hand Spinning bearings will damage race and balls Make sure bearings are clean then lubricate with non detergent SAE 30 weight oil and check for roughness Roughness can be determined by turning outer race by hand Casing can be checked for wear or damage while mounted on bracket Upright Portable Hot Oil TCUs Chapter 5 Maintenance 33 Pump Assembly The seal used in this pump is simple to install If you take care during installation good performance will result The principle of the mechanical seal is to make contact between the rotary and stationary members These parts are lapped to a high finish and their sealing effectiveness depends on complete contact When requesting special seal information make sure that you give the pump model number and serial number 1 10 11 12 13 Install bracket bushing if required If bracket bushing has a lubrication groove install bushing with groove at 6 00 o clock position in bracket If carbon graphite Refer to Installation of Carbon Graphite Bushings page 43 Coat shaft of rotor shaft assembly with non detergent SAE 30 weight oil Start end of shaft in bracket bushing turning from right to left slowly pushing rotor in casing Coat idler pin with non detergent SAE 30 weight oil and place idler and bushing on idler pin in head If replacing with carbon graphite bu
50. s 4 F to 120 F 20 C to 49 C Refer to the M2B Owner s Manual supplied with your unit for specific operation instructions Upright Portable Hot Oil TCUs Chapter 4 Operation 24 Identifying Control Panel Switches This section lists the descriptions and functions of the control panel switches These switches control the operation of the unit Figure 4 Control Panel Switches Pump Start Press the START button to start the pump in the normal forward direction Pump Stop Press the STOP button to stop the pump and de energize the controller Caution Always press the Pump Stop button and allow the pump to come to a complete stop before pressing the Pump Reverse button Failure to let the pump stop before reversing may damage the pump and drive Pump Reverse Press the REVERSE button to start the pump in the reverse direction Use this feature to purge oil from the mold Vent Cycle Start Press the VENT button to start the vent cycle timer Use this feature to purge air and water from the unit and process Upright Portable Hot Oil TCUs Chapter 4 Operation 25 Mode Select With the pump running you can select the AUTO position or the Maintained manual cooling position with the Mode Select switch Select AUTO mode to energize the controller permitting it to monitor and control the process The switch automatically returns to the Center Default position when in AUTO mode The switch stays in the Maintained position in Ma
51. s and connectors between the Upright unit and the process to best meet the needs and requirements of your application Make sure lines and connectors have a service rating of at least 100 psig 689 5 kPa 6 9 bars and a temperature rating at least equal to the maximum operating temperature of your Upright unit Note To prevent debris from fouling reservoir fluid the Upright unit is equipped with an internal vent on the reservoir tank Use the plug provided to close off the external fill port after filling the unit with heat transfer fluid Upright Portable Hot Oil TCUs Chapter 3 Installation 21 3 5 Initial Start up Starting the Hot Oil TCU Before you begin your heating process perform the following startup procedures Doing so ensures that all air is vented from the system to prevent fluid degradation and damage to the heater 1 Add recommended heat transfer fluid to the reservoir tank until the level is near the top of the sight glass 2 If so equipped open the manual vent valve on the back of the unit 3 Pushthe PUMP START button to start the pump then check motor rotation by observing the pressure gauge If the gauge indicates positive pressure rotation is correct If not disconnect power and reverse the incoming power leads 4 Asfluid is drawn out of the reservoir tank to fill the process the fluid level falls in the tank Continue to add fluid to maintain the level about four inches 4 10 cm from the bottom o
52. serial numbers when ordering parts Prices are subject to change without notice Description Pressure Gauge 037 00119 00 GAUGE PRESSURE 0 100 PSI Optional Heat Exchangers Tube Bundle Only Ass y part no Tube bundle only part no 106 00267 00 162 00047 10 3 9 SQ FT Upright 550 F 106 00268 00 162 00047 11 6 7 SQ FT Upright 550 F Pilot Lights 715 10074 00 PILOT LED 120 V RED N 12 36 LEAD 715 10075 00 PILOT LED 120 V AMBER N 12 36 LEAD 715 10076 00 PILOT LED 120 V GREEN N 12 36 LEAD Casters 042 00016 00 CASTER SWIVEL 3 042 00017 00 CASTER STATIONARY 3 Upright Portable Hot Oil TCUs Chapter 7 Appendix 45 Manual Reset Safety Thermostat 724 00041 00 THERMOSTAT 200 F 550 F Sight Glass Assembly 037 00046 00 GLASS SIGHT 1524 Note Please give model and serial numbers when ordering parts Prices are subject to change without notice Controllers 601 00521 06 CONTROLLER M2B 550 F 724 00589 01 CONTROLLER STERLCO 4000 Selector Switches and Push Buttons ALARM SILENCE VENT Pressure Switches 733 00029 00 SWITCH PRESSURE D 5 Description co Pump Part number Description 075 00370 01 MECH SEAL VIKING HL4125 0 30 GPM lt e a 720 09240 00 MOTOR 1 HP 3 60 208 230 460 V 720 09242 00 MOTOR 1 2 HP 3 60 208 230 460 V 720 09218 00 MOTOR 2 HP 3 60 208 230 460 V Note Please give model
53. shing Refer to Installation of Carbon Graphite Bushings page 43 Using a 010 to 015 inch head gasket install head and idler assembly on pump Pump head and casing were marked before disassembly to insure proper reassembly If not be sure idler pin which is offset in pump head is positioned toward and equal distance between port connections to allow for proper flow of liquid through pump Tighten head capscrews evenly Place the mechanical seal installation tapered half rings over the shaft and apply P 80 oil supplied with the replacement seal grease is not recommended on the sleeve and rotor shaft Slide the rotating portion of the mechanical seal on the shaft until it bottoms on the shaft step See FIGURE 7 in Appendix Remove the seal installation tapered half rings It is important when using the rings to make sure the thin edge is facing the direction of the shaft end and that the thick end is facing the rotor Apply lubricant to the seal seat o ring and push it in the bracket Note the shinny side of the seat goes towards the carbon graphite seal face Apply Dow Corning 44 high temperature silicon grease to the lip seal area in the seal gland and install on the shaft Install the seal gland plate and secure with two nuts Pack ball bearing with Dow Corning 44 high temperature silicon grease and install in the thrust bearing housing Place bearing spacer collars inside the lip seals Thread the end cap into the bearing housing and
54. stic features with indicator and warning status lights e System status graphic display e Low level alarm for reservoir e Audible alarm e 5 year warranty on controller Options Options marked with indicate options that can be factory installed or retrofitted in the field e Drain valve e Hour meter measures total pump run time hours e General fault visual alarm e Autovent sequence deducts available e Low level alarm deducts available e High level indicator light e Manual bypass deducts available e M2B microprocessor controller options include e 4 20 mA remote set point and retransmission e SPI protocol RS 485 e General protocols types RS 232 485 e Remote sensor 10 Ft 3m Heat exchanger options of 3 9 sq ft 0 3627 sq m and 6 7 sq ft 0 6231 sq m e Remote controller e Lexan cover e Optional operating voltages of 208 3 60 230 3 60 575 3 60 380 3 50 and 415 3 50 Upright Portable Hot Oil TCUs Chapter 2 Functional Description 11 2 5 Feature Descriptions Immersion Heaters The fluid is heated by the specially designed three phase low watt density electrical immersion heater and regulated by the controller The standard heater has a steel sheath for low watt density and good heat transfer These models can be supplied with 6 12 18 or 24 kW low watt density immersion heaters depending upon the heating needs of the process The 18 and 24 kW models are built to provide full or partial heat as req
55. t has a defect that could cause injury you should immediately discontinue its use and inform the manufacturer The principle factors that can result in injury are failure to follow proper operating procedures i e lockout tagout or failure to maintain a clean and safe working environment Upright Portable Hot Oil TCUs Chapter 1 Safety 9 Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for portable hot oil temperature control units Model numbers are listed on the serial tag Make sure you know the model and serial number of your equipment before contacting the manufacturer for parts or service Your portable hot oil temperature control unit circulates thermal transfer type oil through your process and precisely automatically and reliably maintains it at a temperature you can select Portable hot oil temperature control units are sized to meet the specific requirements stated by the Customer at the time of purchase 2 2 General Description The operating range of your temperature control unit is from 100 F to 550 F 38 C to 288 C The unit is best suited for use with a specially formulated Heat Transfer Fluid A recommended list of commercially available heat transfer fluids can be obtained through Customer Service Rapid recirculation of the relatively small amount of fluid provides a close and uniform temperature relationship between
56. that is not within the manufacturer s warranty period and or in new and unused condition suitable for resale Warranty Returns Prior to the return of any material authorization must be given by the manufacturer A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied After inspecting the material a replacement or credit will be given at the manufacturer s discretion If the item is found to be defective in materials or workmanship and it was manufactured by our company purchased components are covered under their specific warranty terms 7 6 Safety Tag Information TCU Safety Tags Hot Read Operation and Installation Manual High Voltage Earth Ground Inside Enclosure Protected Earth Lifting Point Ground Upright Portable Hot Oil TCUs Chapter 7 Appendix 48 7 7 TCU Identification Serial Number Tag Located on back of TCU Company Logo C XXX Series TCU Model Number XXX 030 Max Heating Cooling Capacity HR 460V Serial Number 060701R 16 Date of Manufacture 06 2003 4 5A Over current Protection Device s 4 5A Total Frequency 50 60Hz Compressed air supply None TCU Mass 400 Ibs 180 KG Electrical Diagrams amp Street Address City State Zip Code Telephone Number 7 8 Technical Assistance Parts Department Call
57. the TO PROCESS and FROM PROCESS lines This does of course depend on the configuration of your process and any restrictions within the mold This recirculation combined with the immersion heater and optional cooling capability gives fast and accurate response to bring the fluid up to temperature or to changes in the settings when needed Performance is assured through matching the unique controllers to the high temperature system The two systems are fully integrated to achieve accurate control along with efficient use of water and electricity 2 3 Standard Features Mechanical Features e Dual stage immersion heater with IEC contactors e 550 F 288 C maximum operating temperature 400 F 244 C maximum operating temperature for 6 kW heaters e Manual bypass e Pressure switch for low pump pressure shut down e To Process pressure gauge e Independent safety thermostat e Y strainer on From Process line e Automatic venting sequence e Positive displacement pumps capable of reversing to evacuate the process e Easily removable panels for quick access to internal components e year warranty on parts and labor Labor at factory Upright Portable Hot Oil TCUs Chapter 2 Functional Description 10 Electrical Features e Non fused lockable rotary disconnect Branch circuit fusing NEMA 12 electrical enclosure e UL listed subpanel Controller Features e M2B microprocessor controller with fuzzy logic includes diagno
58. the pump Do not allow the idler to fall from the idler pin To prevent this from happening tilt the top of the head back when removing Avoid damaging the head gasket Remove the idler and the bushing assembly Insert a length of hardwood or brass through the port opening between the rotor teeth to keep the shaft from turning Bend up the lockwasher tang with a spanner wrench Remove the locknut and lockwasher from the shaft Loosen Allen head setscrews in the face of the thrust bearing assembly Remove the thrust bearing assembly by threading out of the bracket Loosen the radial setscrews in the thrust bearing assembly and remove the end cap using the spanner wrench Remove the bearing spacer collars and the ball bearing Using snap ring pliers remove snap ring from shaft Remove two nuts holding seal gland plate and seal gland in place Slide seal gland off of the shaft being careful not to damage the lip seal Using a soft headed hammer gently tap on the end of the rotor shaft until the rotor and shaft assembly can be completely removed from the pump Note the mechanical seal may stick to the shaft causing initial resistance when the shaft is removed Remove the mechanical seal parts from the bracket Clean all parts thoroughly and examine for wear and damage Check lip seals ball bearing bushings and idler pin and replace if necessary Check all other parts for nicks burrs excessive wear and replace if necessary Wash bea
59. to protect If the switch fails it will go to the open condition tripping out the safety circuit At no time should the safety device fail and allow the operation to continue For example if a safety switch is guarding a motor and the safety switch fails the motor should not be able to run Safety Device Lock Outs Some safety devices disconnect electrical energy from a circuit The safety devices that are used on these temperature control units are primarily concerned with electrical power disconnection and the disabling of moving parts that may need to be accessed during the normal operation of the machine Some of the safety devices utilize a manual activator This is the method of initiating the safety lock out This may be in the form of a plug lever or a handle Within this lockable handle there may be a location for a padlock Personnel servicing the equipment should place a padlock in the lockout handle In addition to the safety devices listed above these temperature control units are equipped with a line cord plug This allows the operator or maintenance personnel to unplug the tcu from its power source and tag it out The plug can then be tagged with any number of approved electrical lockout tags available at most electrical supply stores WARNING Always disconnect and lockout all electrical power and pneumatic i e compressed air sources prior to servicing or cleaning the temperature control unit Failure to do so may resu
60. u need to perform maintenance or repair work on equipment above floor level use a solid platform or a hydraulic elevator If there is a permanently installed catwalk on your equipment use it The work platform should have secure footing and a place for tools and parts DO NOT climb on equipment machines or work from ladders If you need to repair a large component use appropriate handling equipment Before you use handling equipment portable A frames electric boom trucks fork trucks overhead cranes be sure the load does not exceed the capacity of the handling equipment or cause it to become unstable Carefully test the condition of lifting cables chains ropes slings and hooks before using them to lift a load Be sure that all non current carrying parts are correctly connected to earth ground with an electrical conductor that complies with current codes Install in accordance with national and local codes When you have completed the repair or maintenance procedure check your work and remove your tools rigging and handling equipment Do not restore power to the equipment until all persons are clear of the area DO NOT start and run the machine until you are sure all parts are functioning correctly BEFORE you turn the machine over to the operator for production verify all equipment enclosure panels guards and safety devices are in place and functioning properly Reporting a Safety Defect If you believe that your equipmen
61. uired by the process and determined by the controller to provide more precise control Heater Tank The Upright features a single pass heater tank The tank is designed to maintain an optimum balance of fluid velocity versus watt density and turbulence for excellent heat transfer and minimal pressure drop The high fluid velocity will greatly prolong the life of the heater and fluid Pump The pump is a mechanical seal positive displacement pump It features a nearly maintenance free design and was selected after extensive testing to provide superior performance flexibility and low maintenance It is well suited for use with a variety of commercially available heat transfer fluids The pump has only two internal moving parts and a specially designed seal to give years of trouble free service even at high temperatures The only routine maintenance required is the monthly greasing and occasional head space adjustment see Section 5 3 on Page 40 for more information The pump is capable of running in either direction Thus the pump reverse feature can be used to draw fluids back from the process It is not necessary to install a service air line to purge lines before changing molds Since the pump is capable of achieving extremely high pressures it is necessary to regulate the pressure through use of a regulating bypass line Ful Flo valve Because the pump is a positive displacement pump it will supply the process with rated flow at or
62. uu x ipid a perdu duse imu need atus ds 48 7 6 Safety Tag Information eeu eR ebur p I 48 IOU Safety V GE i ose eite salo eb uiis E cs uM timet La 48 7 7 TCU Identification Serial Number Tag 49 7 8 gt Technical ASSISIamCO ie etos Eier kt ive aaa Sade Ld do taadu 49 Parts Department aie e Eegeregie 49 Service EE 49 Sales JOD OF eege e e See 49 Contract Department TEE 49 Upright Portable Hot Oil TCUs Chapter 1 Safety iv Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your portable hot oil temperature control unit TCU The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the portable hot oil TCU We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be fol

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