Sterling 6017 series manual

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. SC1-655-3 $30. 00[...]

Page 2 6017 Series Hot Oil Large Temperature Control Units Write down your unit serial number(s) ________________ ________________ here for future reference ________________ ________________ ________________ ________________ ________________ ________________ Sterling/Sterlco is committed to a cont inuing program of product improvement. Specificatio[...]

6017 Series Hot Oil Large Temperature Control Units Page 3 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[...]

Page 4 6017 Series Hot Oil Large Temperature Control Units Table of Contents 1 General Information ................................................. 7 1-1 Introduc tion ..................................................................................... 7 1-2 Necessary Document s ....................................................................[...]

6017 Series Hot Oil Large Temperature Control Units Page 5 Table of Contents 4 Startup Preparations .............................................. 29 4-1 Starting t he Unit ............................................................................ 29 4-2 Shutting Down the Un it ................................................................. 32 [...]

Page 6 6017 Series Hot Oil Large Temperature Control Units Charts and Figures 1 6017 Series Hot Oil Large Temperature Control Unit and Specifications 16 2 6017 Unit Piping Setup 16 3 Typical Flow Schematic 24 4 Typical M2B Graphic and Button Control Panel 34 5 Control Panel Switches 39 6 System Status Board Indicators 41[...]

6017 Series Hot Oil Large Temperature Control Units Page 7 1 General Information 1-1 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 tem perature you can select. The operating range of your tempera[...]

Page 8 6017 Series Hot Oil Large Temperature Control Units 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 num ber followed by -Q indicates a specially constructed unit, and not all information i[...]

6017 Series Hot Oil Large Temperature Control Units Page 9 1-5 Available Options • Drain valve • Manual bypass • Hour meter; measures total pum p run time hours • General fault visual alarm • Automatic venting sequence • Low level alarm for reservoir • M2B microprocessor controller options include:  4-20 mA rem ote set point and re[...]

Page 10 6017 Series Hot Oil Large Temperature Control Units 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[...]

6017 Series Hot Oil Large Temperature Control Units Page 11 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 Ster[...]

Page 12 6017 Series Hot Oil Large Temperature Control Units 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[...]

6017 Series Hot Oil Large Temperature Control Units Page 13 Electrical Panel and System Component s The pump motor and im mersion 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 prim ary fuse protection[...]

Page 14 6017 Series Hot Oil Large Temperature Control Units 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-establish[...]

6017 Series Hot Oil Large Temperature Control Units Page 15 ! 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.[...]

Page 16 6017 Series Hot Oil Large Temperature Control Units Figure 1 6017 Series Hot Oil Large Temperature Control Unit. The unit shown below is a 6017P Model. 6017 Series Temperature Cont rol Unit Specifications Model Heaters Pump Dimensions Shipping Number Av ailable capacities Av ailable capacities H W D Weight ♠ 460 / 230 50 kW 100 kW 150 kW [...]

6017 Series Hot Oil Large Temperature Control Units Page 17 2 Shipping Information 2-1 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[...]

Page 18 6017 Series Hot Oil Large Temperature Control Units 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 [...]

6017 Series Hot Oil Large Temperature Control Units Page 19 3 Installation 3-1 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 i[...]

Page 20 6017 Series Hot Oil Large Temperature Control Units 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 opera[...]

6017 Series Hot Oil Large Temperature Control Units Page 21 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 a[...]

Page 22 6017 Series Hot Oil Large Temperature Control Units 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[...]

6017 Series Hot Oil Large Temperature Control Units Page 23 ! 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 temperat[...]

Page 24 6017 Series Hot Oil Large Temperature Control Units 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 rev[...]

6017 Series Hot Oil Large Temperature Control Units Page 25 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 (Blo w-Off) valve at this point. With this new Blow- Off Valve location the return valve and internal blow-off valve s[...]

Page 26 6017 Series Hot Oil Large Temperature Control Units 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 conform s. Check the unit nameplate for correct voltage and amperage before making e[...]

6017 Series Hot Oil Large Temperature Control Units Page 27 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 A[...]

Page 28 6017 Series Hot Oil Large Temperature Control Units - Notes -[...]

6017 Series Hot Oil Large Temperature Control Units Page 29 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[...]

Page 30 6017 Series Hot Oil Large Temperature Control Units 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[...]

6017 Series Hot Oil Large Temperature Control Units Page 31 ! CAUTION You must purge the system of air before the heating cy cle. Personal injury and sy stem 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 a[...]

Page 32 6017 Series Hot Oil Large Temperature Control Units 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 fr om turning them on) and open the cool solenoid. Fl[...]

6017 Series Hot Oil Large Temperature Control Units Page 33 - Notes -[...]

Page 34 6017 Series Hot Oil Large Temperature Control Units 5 Using Controls and Indicators 5-1 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 [...]

6017 Series Hot Oil Large Temperature Control Units Page 35 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 Nume[...]

Page 36 6017 Series Hot Oil Large Temperature Control Units FROM PROCESS Indicator The FROM PROCESS indicator is on when the PROCESS LED screen on the controller displays the temperature of the incoming fluid. U T Indicator The U T indicator is on when the PROCESS LED screen on the controller displays the difference in temperature between outgoing [...]

6017 Series Hot Oil Large Temperature Control Units Page 37 MOTOR FAIL Indicator The MOTOR FAIL indicator is on during improper pump rotation, motor out of phase, or thermal m otor overload conditions. This is a fatal fault condition , requiring that main power be disconnected to reset the M2B controller . 5-3 Using M2B Controller Keys SET POINT SE[...]

Page 38 6017 Series Hot Oil Large Temperature Control Units ENTER ENTER Key The ENTER ENTER key is used with the INDEX 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 Each press of the INDEX INDEX key advances the screen to the next menu ite[...]

6017 Series Hot Oil Large Temperature Control Units Page 39 DISPLAY DISPLAY Key Press the DISPLAY 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?[...]

Page 40 6017 Series Hot Oil Large Temperature Control Units 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 b[...]

6017 Series Hot Oil Large Temperature Control Units Page 41 Alarm Silence Press the ALARM SILENCE button to silence the audible alarm on the console. ! CAUTION After you silence the alarm, make sure y ou locate and correct the alarm condition before continuing with unit operation. 5-5 Identifying System Status Board Indicators The system status boa[...]

Page 42 6017 Series Hot Oil Large Temperature Control Units Use the status board to optimize unit performance. For exam ple, 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 statu[...]

6017 Series Hot Oil Large Temperature Control Units Page 43 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 [...]

Page 44 6017 Series Hot Oil Large Temperature Control Units 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 en[...]

6017 Series Hot Oil Large Temperature Control Units Page 45 - Notes -[...]

Page 46 6017 Series Hot Oil Large Temperature Control Units 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 u[...]

6017 Series Hot Oil Large Temperature Control Units Page 47 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 recomm ended heat transfer fluid. Do a routine check of the fluid every 1,000 hours of o[...]

Page 48 6017 Series Hot Oil Large Temperature Control Units Servicing the Unit Monthly or Every 500 Hours • Lubricate the pump at the grease fittings with a high- quality 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 specificati[...]

6017 Series Hot Oil Large Temperature Control Units Page 49 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[...]

Page 50 6017 Series Hot Oil Large Temperature Control Units 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. recomm ends SterlFlush™ flushing fluid or equivalent for flushing yo[...]

6017 Series Hot Oil Large Temperature Control Units Page 51[...]

Page 52 6017 Series Hot Oil Large Temperature Control Units 7 Troubleshooting Condition Possible cause Solution Undersized connectors/lines. Increase size of connectors/ water lines. Long connecting lines between unit and mold. Move the unit closer to the mold and shorten connecting lines. Serpentine flow through mold. Connect lines for parallel fl[...]

6017 Series Hot Oil Large Temperature Control Units Page 53 Condition Possible cause Solution Controller heater output open. Check the heater output with an ohmmeter to ground. It should read in the mega-ohm range. Infinite or zero readings indicate a defective output. Unit does not heat. (cont’d.) Clogged Y strainer. Clean Y strainer. Water supp[...]

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 Service Notes[...]

6017 Series Hot Oil Large Temperature Control Units Page 57 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 w ith genuine OEM quality parts manufactured to engineering design s pecifications, which w ill maxim[...]