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Sterling 682.88107.00 manual

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Table of contents for the manual

  • Page 1

    Upright Hot Oil Temperature Control Units Part Number: 682.88107.0 0 Bulletin Number: SC1-660.3 Effective: 10/22/2009 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed t[...]

  • Page 2

    Upright Portable Hot Oil TCUs Chapter 1: Safety ii Shipping Info Unpacking and Inspection You should inspect your portable hot oil tcu for p ossible shipping damage. Thoroughly check the equipment for any dam age th at might have occurred in transit, such as broken or loose wiring and components, l oose hardware and mounting screws, etc. In the Eve[...]

  • Page 3

    Upright Portable Hot Oil TCUs Chapter 1: Safety iii Table of Contents CHAPTER 1: SAFETY ................................................................ 5 1-1 How to Use This Manual ............................................................................................. 5 Safety Symbols Used in this Manual .....................................[...]

  • Page 4

    Upright Portable Hot Oil TCUs Chapter 1: Safety iv 4-1 Start-up...................................................................................................................... 2 4 4-2 Controller Description & Operation............................................................................ 24 Identifying Control Panel Switches .......[...]

  • Page 5

    Upright Portable Hot Oil TCUs Chapter 1: Safety 5 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 manu[...]

  • Page 6

    Upright Portable Hot Oil TCUs Chapter 1: Safety 6 1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national a nd local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, national and internati[...]

  • Page 7

    Upright Portable Hot Oil TCUs Chapter 1: Safety 7 1-3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended inst ructions are followed in the maintenance and operation of the machine. All personnel engaged in the use of the machin e should become familiar with it[...]

  • Page 8

    Upright Portable Hot Oil TCUs Chapter 1: Safety 8 Operator Responsibility The operator’s responsibility does not end with e fficient 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[...]

  • Page 9

    Upright Portable Hot Oil TCUs Chapter 1: Safety 9 • Clean the tcu and surrounding area DAILY , and inspect the machine for loose, missing or broken parts. • 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 safet[...]

  • Page 10

    Upright Portable Hot Oil TCUs Chapter 2: Functional Description 10 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and m aintenance 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 [...]

  • Page 11

    Upright Portable Hot Oil TCUs Chapter 2: Functional Description 11 Electrical Features • Non-fused lockable rotary disconnect • Branch circuit fusing • NEMA 12 electrical enclosure • UL listed subpanel Controller Features • M2B+ microprocessor controller with fuzzy logic; includes diagnostic features with indicator and warning status ligh[...]

  • Page 12

    Upright Portable Hot Oil TCUs Chapter 2: Functional Description 12 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 controlle r. The standard heater has a steel sheath for low watt density and good heat transfer. These models can b[...]

  • Page 13

    Upright Portable Hot Oil TCUs Chapter 2: Functional Description 13 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 ¾” NPT (19.1 mm); see Section 3-4 on Page 20 fo r more information. The customer is responsible for conversions to [...]

  • Page 14

    Upright Portable Hot Oil TCUs Chapter 2: Functional Description 14 Air Purge Upon initial start-up and mold/process change-out, yo u’ll need to purge all air and water from the system. The Upright unit has appropriate va lving to ensure complete purging. Procedures are covered in Section 3-5 on Page 23. WARNING! Failure to purge the system of air[...]

  • Page 15

    Upright Portable Hot Oil TCUs Chapter 2: Functional Description 15 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) a llows[...]

  • Page 16

    Upright Portable Hot Oil TCUs Chapter 2: Functional Description 16 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 sw itch must be a normally open switch. The switch must be held closed with the device it is to protect. If the switch fails[...]

  • Page 17

    Upright Portable Hot Oil TCUs Chapter 3: Installation 17 Chapter 3: Inst allation 3-1 Uncrating the Equipment Portable hot oil temperature control units are sh ipped m ounted 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 [...]

  • Page 18

    Upright Portable Hot Oil TCUs Chapter 3: Installation 18 3-3 Electrical Connections These units are designed for three-phase voltage operation. Refer to the unit nameplate for proper voltage and amperage re quirem ents, and make sure your electrical service conforms . Check the unit nameplate for correct voltage and amperage before making electrica[...]

  • Page 19

    Upright Portable Hot Oil TCUs Chapter 3: Installation 19 3-4 Setup Procedures This section provides the procedures necessar y for configuring your portable hot oil temperature control unit. Configuration of your TCU includes connecting cooling, pr ocess and vent piping. We recommend that you carry out these procedures in the order given here. Note:[...]

  • Page 20

    Upright Portable Hot Oil TCUs Chapter 3: Installation 20 Connecting Process Piping When connecting process piping, ensure that the Cautions listed below are observed and followed: Caution! • Hoses, valves and other components in your process must be able to withstand Upright unit maximum temperatures and pressures. • Maximum temperatures and pr[...]

  • Page 21

    Upright Portable Hot Oil TCUs Chapter 3: Installation 21 Figure 1: Upright Unit Piping Setup 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[...]

  • Page 22

    Upright Portable Hot Oil TCUs Chapter 3: Installation 22 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[...]

  • Page 23

    Upright Portable Hot Oil TCUs Chapter 3: Installation 23 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. Indi cations are a rough-sounding pump, fluctuating or dropp[...]

  • Page 24

    Upright Portable Hot Oil TCUs Chapter 4: Operation 24 Chapter 4: Operation 4-1 Start-up 1. 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 (38ºC) and switch the unit into AUTO m ode. As the oil warms up, viscosity decrease[...]

  • Page 25

    Upright Portable Hot Oil TCUs Chapter 4: Operation 25 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. [...]

  • Page 26

    Upright Portable Hot Oil TCUs Chapter 4: Operation 26 Mode Select. With the pump running, you can select the AUTO position or the Maintained (manual cooling) position with the Mod e Select switch. Select AUTO mode to energize the controller, permitting it to m onitor and control the process. The switch automatically returns to the Center Default po[...]

  • Page 27

    Upright Portable Hot Oil TCUs Chapter 4: Operation 27 Status Indicator Lights Pump Reverse Indicator Light. The Pump Reverse indicator light illuminates when the unit pump runs in reverse. Pump Forward Indicator Light. The Pump Forward indicator light illum inates when the unit pump runs in the normal forward direction. This indicator t ypically il[...]

  • Page 28

    Upright Portable Hot Oil TCUs Chapter 4: Operation 28 High Level Indicator Light (Optional). The High Level indicator light illuminates when the heat transfer fluid level in the reservoir tank is too high. Carefu lly remove just enough fluid so this indicator light shuts off. Low Level Indicator Light. The Low Level indicator light illuminates when[...]

  • Page 29

    Upright Portable Hot Oil TCUs Chapter 4: Operation 29 When fluid temperature dips below 120ºF (49ºC), press the PUMP STOP button to turn off the unit.[...]

  • Page 30

    Upright Portable Hot Oil TCUs Chapter 5: Maintenance 30 Chapter 5: Maintenance 5-1 Maintenance Schedule The checklist below contains a list of items wh ich 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. System model # Serial # Every w[...]

  • Page 31

    Upright Portable Hot Oil TCUs Chapter 5: Maintenance 31 5-2 Preventative Maintenance WARNING! Make sure that your maintenance technicians comply with lock-out/tag-out procedures during any servicing or maintenance of th is unit and related equipment, per OSHA article ART 1910.147. Before you begin servicing this unit, disconnect all power to it, le[...]

  • Page 32

    Upright Portable Hot Oil TCUs Chapter 5: Maintenance 32 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 ma y lose some capacity of pressure as a result. If you reset the end clearance, pump performance should improve. Examining Internal Par[...]

  • Page 33

    Upright Portable Hot Oil TCUs Chapter 5: Maintenance 33 Maintaining the Pump Disassembling the Pump WARNING! Before opening the pump chamber: • Make sure that any pressure in th e chamber has been completely vented! • Make sure that the motor cannot be inadvertently started while you work on the pump! Failure to follow these precautions may res[...]

  • Page 34

    Upright Portable Hot Oil TCUs Chapter 5: Maintenance 34 Pump Assembly The seal used in this pump is simple to in stall. 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 effe[...]

  • Page 35

    Upright Portable Hot Oil TCUs Chapter 5: Maintenance 35 Thrust Bearing Adjustment 1. Loosen axial setscrews in face of end cap on the thrust bearing assembly. If rotor shaft cannot be turned by hand, back off th e thrust bearing assem bly until there is a noticeable drag of the shaft. Note mechani cal seal will provide some drag and this is a norma[...]

  • Page 36

    Upright Portable Hot Oil TCUs Chapter 6: Troubleshooting 36 Chapter 6: T roubleshooting 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 m ust be accomplished with the power off, line fuses rem oved, and with the machine[...]

  • Page 37

    Upright Portable Hot Oil TCUs Chapter 6: Troubleshooting 37 Problem Possible cause Corrective action Loss of fluid in process. Check all lines/connections/ fittings. Vent valve open. Allow vent timer to run out; or, check valve operation when unit is cold by opening the fill port. Faulty/dirty solenoid valve; usually detected when there is a steady[...]

  • Page 38

    Upright Portable Hot Oil TCUs Chapter 6: Troubleshooting 38 Problem Possible cause Corrective action Leaks in connecting lines. Inspect/replace faulty line or connection. Air in circulating lines. Perform venting sequence in Chapter 3. Low fluid. Check fluid level in sight glass. Add fluid if required. Defective Ful-Flo valve. See Chapter 3. Water [...]

  • Page 39

    Upright Portable Hot Oil TCUs Chapter 7: Appendix 39 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: • Drain valve • Hour meter; measures total pump run time hours • General fault visual alarm • Autovent sequence; deducts available • Low level alar[...]

  • Page 40

    Upright Portable Hot Oil TCUs Chapter 7: Appendix 40 7-2 Technical Specifications Annex B Information The following design information is provided for your reference: 1. No modifications are allowed to this equi pment that could alter the CE compliance 2. Ambient temperature: 40 degrees Celsius – Maxim um (104 degrees Fahrenheit) 3. Humidity rang[...]

  • Page 41

    Upright Portable Hot Oil TCUs Chapter 7: Appendix 41 Figure 6: Upright Series Hot Oil Portable Temperature Control Unit Upright Series Temperature Control Unit Specifications Upright- Model number 1 1.5 2 3 12 kW heater 17 18 19 20 18 kW heater 25 26 27 28 24 kW heater 32 33 34 35 36 kW heater 47 48 49 50 Full load amps; 460/3/60 VAC 48 kW heater 6[...]

  • Page 42

    Upright Portable Hot Oil TCUs Chapter 7: Appendix 42 7-3 Drawings and Diagrams Figure 7: 18-24 GPM Pump Construction 075-00370-02[...]

  • Page 43

    Upright Portable Hot Oil TCUs Chapter 7: Appendix 43 Figure 8: Thrust Bearing Assembly[...]

  • Page 44

    Upright Portable Hot Oil TCUs Chapter 7: Appendix 44 Figure 9: Belt Tensioning Instructions[...]

  • Page 45

    Upright Portable Hot Oil TCUs Chapter 7: Appendix 45 7-4 Spare Parts List Immersion Heaters Part number Description 722-00138-07 HTR, IMM, 12 KW, 208 V, 3”, 6 ELE 722-00138-08 HTR, IMM, 12 KW, 240 V, 3”, 6 ELE 722-00138-09 HTR, IMM, 12 KW, 380 V, 3”, 6 ELE 722-00138-10 HTR, IMM, 12 KW, 415 V, 3”, 6 ELE 722-00138-11 HTR, IMM, 12 KW, 480 V, 3[...]

  • Page 46

    Upright Portable Hot Oil TCUs Chapter 7: Appendix 46 Manual Reset Safety Thermostat Part number Description 724-00041-00 THERMOSTAT, 200 ºF — 550ºF Sight Glass Assembly Part number Description 037-00046-00 GLASS, SIGHT, 15¾ Note: Please give model and serial numbers when ordering parts. Prices are subject to change without notice. Controllers [...]

  • Page 47

    Upright Portable Hot Oil TCUs Chapter 7: Appendix 47 Solenoid Valves Part number Description 732-00007-03 ¼” VALVE, 115 V COIL (0-125 PSI, 3 00°F) 732-00013-01 ¾” VALVE, 115 V COIL (0-125 PSI, 3 00°F) Sensing Probe Equipment Part number Description 692-07369-05 HEAT & COOL, M2B 701-00003-00 TYPE ‘I’ TH ERMOCOUPLE Disconnect Switches[...]

  • Page 48

    Upright Portable Hot Oil TCUs Chapter 7: Appendix 48 7-5 Returned Material Policy Credit Returns Prior to the return of any material authorization m ust 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 r[...]

  • Page 49

    Upright Portable Hot Oil TCUs Chapter 7: Appendix 49 7-7 TCU Identification (Serial Number) Tag (Located on back of TCU) Company Logo XXX Series TCU Model Number XXX-030 Max Heating/Cooling Capacity HR 460V Serial Number 060701R 1 Ǿ Date of Manufacture 06/2003 4.5A Over-current Protec tion Device (s) 4.5A Total Frequency 50/60Hz Compressed air sup[...]