$30.00 Operation and Installation Manual 6017 Series Large Hot Oil Temperature Control Units Important! Read Carefully Before Attempting to Install or Operate Equipment Part No. 682.91540.00 Revision 3 Bulletin No.
Write down your unit serial number(s) ________________ ________________ here for future reference ________________ ________________ ________________ ________________ ________________ ________________ Sterling/Sterlco is committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice. © Copyright Sterling/Sterlco and Sterling, Inc. 2008 All rights reserved. Effective 4/29/2008 Part No. 682.91540.
Safety Considerations Sterling/Sterlco 6017 Series large hot oil temperature control units are designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. To avoid possible personnel injury or equipment damage when installing, operating, or maintaining this equipment, use good judgment and follow these safe practices: ; Follow all SAFETY CODES. ; Wear SAFETY GLASSES and WORK GLOVES.
Table of Contents 1 General Information ................................................. 7 1-1 1-2 1-3 1-4 1-5 1-6 2 Shipping Information.............................................. 17 2-1 2-2 2-3 2-4 2-5 3 Unpacking and Inspection ............................................................. 17 In the Event of Shipping Damages................................................ 17 If the Shipment is Not Complete.................................................... 18 If the Shipment is Not Correct .....
Table of Contents 4 Startup Preparations .............................................. 29 4-1 4-2 4-3 5 Using Controls and Indicators .............................. 34 5-1 5-2 5-3 5-4 5-5 6 The Microprocessor Controller ...................................................... 34 Identifying M2B Controller Panel Components.............................. 35 Using M2B Controller Keys ........................................................... 37 Identifying Control Panel Switches............................
Charts and Figures 1 2 3 4 5 6 Page 6 6017 Series Hot Oil Large Temperature Control Unit and Specifications 16 6017 Unit Piping Setup 16 Typical Flow Schematic 24 Typical M2B Graphic and Button Control Panel 34 Control Panel Switches 39 System Status Board Indicators 41 6017 Series Hot Oil Large Temperature Control Units
1 1-1 General Information Introduction Your Sterling/Sterlco 6017 Series hot oil temperature control unit circulates thermal transfer-type oil through your process and to precisely, automatically, and reliably maintain it at a temperature you can select. The operating range of your temperature control unit is from 100°F to 550°F (38°C to 288°C). The unit is best suited for use with SterlTherm™ Heat Transfer Fluid.
1-3 Models Covered This manual lists installation, operation, and maintenance instructions for the 6017 Series hot oil large temperature control unit. Model numbers are listed on the serial tag. A model number followed by -Q indicates a specially constructed unit, and not all information in this manual may apply. Make sure that you know the model number, serial number, and operating voltage of your unit if you contact Sterling, Inc.
1-5 1-6 Available Options • Drain valve • Manual bypass • Hour meter; measures total pump run time hours • General fault visual alarm • Automatic venting sequence • Low level alarm for reservoir • M2B microprocessor controller options include: • 4-20 mA remote set point and retransmission SPI protocol, RS-485 General protocols, types RS-232, -485 Remote sensor Heat exchanger options of • • 3.9 sq. ft. (0.3627 sq. m) • 6.7 sq. ft. (0.6231 sq. m) • 13 sq. ft. (1.21 sq. m) • 21 sq.
Heater Tank The 6017 features a single pass heater tank. The tank is designed to maintain an optimum balance of fluid velocity versus watt density, and turbulence for excellent heat transfer, and minimal pressure drop. The high fluid velocity will greatly prolong the life of the heater and fluid. Pump The pump is a packed, positive displacement pump. It features a nearly failure free design, and has proven itself after years of dependable service.
In the event of an obstruction in the line, the Fulflo will open and divert fluid from the delivery TO PROCESS line to the return From Process line. A constant flow of fluid is maintained through the heater tank to prevent damage to the heating elements and fluid. Cooling Optional The Sterlco-designed shell and tube heat 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.
Sterling stocks many lengths of flexible metal hose; the part number is 572-16969. State the length of hose you want when ordering. ! WARNING Component failure may result in high-temperature oil spray, causing serious injury or death. Make sure hoses, valves, and other components installed in your process can withstand maximum temperature and pressure of the 6017 unit; check unit nameplate for specific capacities. All components must be carefully inspected for condition before installing.
Electrical Panel and System Components The pump motor and immersion heater operate on three-phase, 50/60 cycle, nominal voltage with the control circuit at 115 V single phase. The control circuit voltage is provided by a single phase machine tool transformer with primary fuse protection and a grounded secondary. A main power disconnect is included as for ease of service. The electrical panel is UL listed and complies with NEC provisions. All components are IEC rated for long life and reduced maintenance.
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 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 mounted on the side of the heater tank. This is to guard against the unlikely event of “runaway” heating.
! WARNING The reservoir tank may cause serious injury if it ruptures from not being properly vented. Make sure that the reservoir tank is always properly vented to prevent tank rupture.
Figure 1 6017 Series Hot Oil Large Temperature Control Unit. The unit shown below is a 6017P Model. 6017 Series Temperature Control Unit Specifications Model Heaters Pump Dimensions Shipping Number Available capacities Available capacities H W D Weight♠ 460 / 230 50 kW 100 kW 150 kW 200 kW 90 gpm 150 gpm 200 gpm in. cm in. cm in. cm lbs.
2 2-1 Shipping Information Unpacking and Inspection You should inspect your Sterling/Sterlco 6017 Series hot oil large temperature control unit for possible shipping damage. If the container and packing materials are in re-usable condition, save them for reshipment if necessary. Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc.
2-3 If the Shipment is Not Complete Check the packing list. The apparent shortage may be intentional. Back-ordered items are noted on the packing list. You should have: ; 6017 Series hot oil large temperature control unit ; Bill of lading ; Packing list ; Operating and Installation packet ; Electrical schematic and panel layout drawings ; Component instruction manuals Re-inspect the container and packing material to see if you missed any smaller items during unpacking.
3 3-1 Installation Work Rules The installation, operation, and maintenance of this equipment must be conducted in accordance with all applicable work and safety codes for the installation location. This may include, but is not limited to OSHA, NEC, CSA, and any other local, national, and international regulations. 3-2 • Read and follow these instructions when installing, operating, and maintaining this equipment.
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 500ºF (260ºC). Vapors can escape from areas such as the reservoir tank during high temperature operation. ! CAUTION Harmful vapors may be generated from thermal fluid during high temperature operation. Prolonged or repeated exposure of these hot-generated vapors may result in eye and respiratory tract irritation.
The following table lists 6017 TCU pipe sizes. Connections for TO PROCESS and FROM PROCESS lines are: • 2" NPT (50.8 mm) at 90 gpm (341 lpm) • 2-1/2" NPT (63.5 mm) at 150 gpm (568 lpm) • 3" NPT (76.2 mm) at 200 gpm (757 lpm) Water connections for COOLING WATER SUPPLY and COOLING WATER DRAIN are: • ¾” NPT (19.1 mm) for 3.9 & 6.7 sq. ft. heat exchangers. • 1" NPT (25.4 mm) for 13, 21, & 27 sq. ft. heat exchangers. The customer is responsible for conversions to metric standards.
Connecting Process Piping ! CAUTION • Hoses, valves and other components in your process must be able to withstand the 6017 unit's maximum temperatures and pressures. • Maximum temperatures and pressures are listed on the unit nameplate. • Carefully inspect all components before installation. • If in doubt about component suitability, obtain factory components. • • Fix all leaks! Fluid can be a potential fire and slip hazard.
! 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 specification information for the heat transfer fluid you select. Generally, most heat transfer fluids expand at the rate of 2.
Figure 3 Typical Flow Schematic Note: The heat exchanger is optional, and the "Vent Valve" is also known as the "Blow-Off Valve." • Vent Valve - open for purge/closed for run/open for pump reverse. • Return Valve - closed for purge/ open for run/ closed for pump reverse. • Reservoir Tank - Open to atmosphere at all times, unless nitrogen blanket provisions are present.
Figure 4 Custom Process Piping The optimum location for venting is on the top of the overhead return piping above the unit. The customer is encouraged to add an extra vent (Blow-Off) valve at this point. With this new BlowOff Valve location the return valve and internal blow-off valve should be closed completely during venting. Otherwise air could be pulled into the piping by gravity instead of being removed.
3-4 Making Electrical Connections These units are designed for three-phase voltage operation. Refer to the unit nameplate for proper voltage and amperage requirements, and make sure your electrical service conforms. Check the unit nameplate for correct voltage and amperage before making electrical connections! ! CAUTION 1. Provide a correctly sized and protected power supply to the unit. 2.
Check the unit nameplate for correct voltage and amperage before making electrical connections! ! DANGER IMPROPER ELECTRICAL CONNECTIONS CAN DAMAGE THE UNIT AND CAUSE SERIOUS OPERATOR INJURY OR DEATH! MAKE SURE THAT ALL ELECTRICAL CONNECTIONS ARE MADE BY A QUALIFIED ELECTRICIAN, AND THAT ALL CONNECTIONS ARE TIGHT. Make all electrical supply connections at the front of the unit. An access panel covers all electrical connections.
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4 Startup Preparations 4-1 Starting the Unit UNIT START-UP (WITH MANUAL BLOW-OFF VALVE) The highly engineered controls and controller make this unit almost self operating. Before you can begin heating, it will be necessary to perform the following start up procedures. This will ensure that all air is vented from the system to prevent fluid degradation and damage to the heater. 1. Open the Return Valve and the Blow-Off Valve. Make sure the drain valves are closed and plugged. 2.
10. If any water is present in the system, it must be boiled off before continuing operation. Select a setpoint of 215°F (102ºC) and observe the reservoir tank vent for any signs of escaping steam. Continue to run at 215ºF (102ºC) until no more steam appears and pressure has stabilized. 11. When fluid level has stabilized and air and water are purged from the system, open the Return Valve all the way. And select a setpoint of 250°F (121°C). 12.
! CAUTION You must purge the system of air before the heating cycle. Personal injury and system damage can occur from a pressurized system. 6. Air and Oil will be vented through the automatic Blow-Off Valve and into the reservoir tank. 7. After the unit stops requiring more oil and has at least 5 psi of pressure, open the Return Valve half way. If the Blow-Off cycle times out, start the sequence again. The timer is factory set at 5 minutes. A longer time can be set if required.
4-2 Shutting Down the Unit UNIT SHUT DOWN (WITH AUTOVENT SOLENOID OR MANUAL VENT VALVE) Cool the unit down by switching the Mode switch to the "Manual Cool" position. This will disable the heaters ( i.e. prevent the controller from turning them on) and open the cool solenoid. Fluid temperature can be monitored on the controller display during cool down. When fluid temperature is below 120ºF, depress the PUMP STOP button to turn the unit off.
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5 5-1 Using Controls and Indicators The Microprocessor Controller The M2B controller is an easy-to-operate microprocessor-based PID control device. When the process reaches the set point, the PID control cycles the cooling valve and/or immersion heater to maintain the proper leaving fluid temperature. The controller is fully factory tested. Set the process temperature set point you want and the controller does the rest. Built-in range of operation on the controller is 0°F to 550°F (-18ºC to 288ºC).
5-2 Identifying M2B Controller Panel Components Screen Displays SET POINT Numeric LED During normal operation, the SET POINT LED on the controller displays the process set point you want the unit to maintain. It also displays parameter and pre-set function values during setup. PROCESS Numeric LED During normal operation, the PROCESS LED on the controller displays the actual process temperature at the To Process thermocouple.
FROM PROCESS Indicator The FROM PROCESS indicator is on when the PROCESS LED screen on the controller displays the temperature of the incoming fluid. UT Indicator The UT indicator is on when the PROCESS LED screen on the controller displays the difference in temperature between outgoing Delivery fluid and incoming Return fluid.
MOTOR FAIL Indicator The MOTOR FAIL indicator is on during improper pump rotation, motor out of phase, or thermal motor overload conditions. This is a fatal fault condition, requiring that main power be disconnected to reset the M2B controller.
ENTER ENTER Key ENTER INDEX The ENTER key is used with the INDEX key menu to store the value or the item that was changed. If this key is not pressed, the previously-stored value or item is retained. INDEX INDEX Key INDEX INDEX key advances the screen to the Each press of the next menu item. Refer to your Sterling/Sterlco M2B Temperature Control Owner’s Manual for a list of functions available using this key.
DISPLAY DISPLAY Key DISPLAY Press the DISPLAY key to advance through the display menu. Each key press increments to the next available function. The screen returns to delivery temperature after thirty (30) seconds of inactivity. Refer to your Sterling/Sterlco M2B Temperature Control Owner’s Manual for a list of menus available using this key. Digital Flow Screen Optional The optional digital flow screen displays process flow in gallons per minute (gpm). No customer-usable control is necessary.
Pump Start Press the START direction. button to start the pump in the normal forward Pump Stop Press the STOP controller. button to stop the pump and de-energize the ! 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.
Alarm Silence Press the ALARM SILENCE on the console. button to silence the audible alarm ! CAUTION After you silence the alarm, make sure you locate and correct the alarm condition before continuing with unit operation. 5-5 Identifying System Status Board Indicators The system status board is located next to the controller panel. It displays indicator lights to show current operation status, letting you analyze system performance.
Use the status board to optimize unit performance. For example, if you observe a rapid cycling of the Heater and Cool Solenoid indicators, the unit is operating with a process inefficiency; see the Troubleshooting chapter for more information. What follows is a description of system status board indicators. Status Indicator Lights Pump Reverse Indicator Light The Pump Reverse indicator light illuminates when the unit pump runs in reverse.
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.
Always correct this alarm condition before returning to normal operation! High Level Indicator Light The high fluid level alarm is an available option. The High Level indicator light illuminates when the heat transfer fluid level in the reservoir tank is too high. Carefully remove just enough fluid so this indicator light shuts off and an adequate volume is maintained in the reservoir. Low Level Indicator Light The low fluid level alarm is an available option .
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6 Preventive Maintenance ! WARNING Make sure that your maintenance technicians comply with lock-out/tag-out procedures 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 the unit, let the unit cool down completely, and turn off the water.
Making Quarterly Checks • Check the heat transfer fluid for deterioration. If the fluid is noticeably darker, or it seems significantly thicker, drain the system and replace the fluid with fresh, new recommended heat transfer fluid. Do a routine check of the fluid every 1,000 hours of operation or every three (3) months, whichever comes first. Contact Sterling, Inc. Service for information on fluid testing.
Servicing the Unit Monthly or Every 500 Hours • Lubricate the pump at the grease fittings with a highquality polyurea grease rated at 320ºF or higher. Recommended: Chevron Black Pearl; do not over-lubricate. • Adjust the pump drive belt tension. Use the belt tensioning specifications listed in this chapter on Page 51. Make sure that the motor pulley is properly aligned with the pump pulley; use a straightedge to check. Tighten motor mounting bolts after realignment.
Motor Lubrication Procedure Be sure that the grease you are adding to the motor is compatible with the grease already in the motor. Consult your Baldor distributor or an authorized service center if a grease other than the recommended type is to be used. A high grade ball or roller bearing grease should be used. Recommended grease for standard service conditions is Polyrex EM (Exxon Mobil). Equivalent and compatible greases include: Texaco Polystar, Rykon Premium #2, Pennzoil Pen 2 Lube and Chevron SRI.
6-3 Draining the Unit for Storage You should thoroughly flush and drain the 6017 unit if you need to take it out of service for a long time, or if you expect it to become exposed to freezing temperatures. Sterling, Inc. recommends SterlFlush™ flushing fluid or equivalent for flushing your 6017 unit; follow unit flushing instructions that comes with SterlFlush™ flushing fluid. Drain plugs are provided at the base of the heater tank, reservoir tank, and on the pump.
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7 Troubleshooting Condition Possible cause Undersized connectors/lines. Long connecting lines between unit and mold. Serpentine flow through mold. Blocked line in mold. Temperature fluctuations/rapid cycling from hot to cold. Quick disconnect fitting with check valve. Carbon build-up in unit piping or fittings. Faulty Sterlco TCU. Reversed probes. Loss of fluid in process. Vent valve open. Unit does not heat properly/can not achieve set point.
Condition Unit does not heat. (cont’d.) Unit overheats/unable to cool. Possible cause Controller heater output open. Clogged Y strainer. Water supply to unit is turned OFF. Water drain is plugged or excessive back pressure in drain line. Heat exchanger tubes plugged by lime deposits. Faulty solenoid valve. Leaks in connecting lines. Air in circulating lines. Low fluid. Defective Ful-Flo valve. Rapid drop in pressure/no pressure. Water in fluid. Vent solenoid open. Pump running in reverse.
Service Notes Page 54 6017 Series Hot Oil Large Temperature Control Units
Service Notes 6017 Series Hot Oil Large Temperature Control Units Page 55
Service Notes Page 56 6017 Series Hot Oil Large Temperature Control Units
Technical Assistance Parts Department Call toll-free 7am–5pm CST or call [800] 423-3183, [262] 641-8610, or fax to [262] 641-8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone or fax order, please have the model and serial number of your unit when you contact us.
