Sterlco 2016C User Manual

Operation and Installation Manual

2016-C Series

Portable Hot Oil

Temperature Control Units

Important! Read Carefully Before Attempting to Install or Operate Equipment

Part No. 682.94404.00 Revision 1 Bulletin No. SC1-645.1

Write down your unit serial number(s) ________________ ________________

© Copyright Sterling, Inc. 2012
All rights reserved. Effective 4/27/2012
Part No. 682.94404.00 Revision 1 Bulletin No. SC1-645.1

here for future reference ________________ ________________
________________ ________________
________________ ________________

Sterling is committed

to a continuing program of product improvement.

Specifications, appearance, and dimensions described in this manual

are subject to change without notice.

Page 2 2016-C Series Hot Oil Portable Temperature Control Units

Safety Considerations

STERLING 2016-C Series portable 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.
 Disconnect and/or lock out power before servicing or

maintaining the hot oil temperature control unit.

 Use care when LOADING, UNLOADING, RIGGING, or

MOVING this equipment.

 Operate this equipment within design specifications.
 OPEN, TAG, and LOCK ALL DISCONNECTS before

working on equipment. You should remove the fuses and carry
them with you.

 Make sure the hot oil temperature control unit and components

are properly GROUNDED before you switch on power.

 Do not jump or bypass any electrical safety control.
 Do not restore power until you remove all tools, test

equipment, etc., and the hot oil temperature control unit and
related equipment are fully reassembled.

 Only PROPERLY TRAINED personnel familiar with the

information in this manual should work on this equipment.

COT-C Series Hot Oil Portable Temperature Control Units Page 3

Table of Contents

1 General Information ................................................. 6

1-1 Introduction ..................................................................................... 6

1-2 Necessary Documents .................................................................... 6

1-3 Models Covered .............................................................................. 7

1-4 Standard Features .......................................................................... 7

1-5 Available Options ............................................................................ 7

1-6 Feature Descriptions ....................................................................... 8

2 Shipping Information ............................................ 15

2-1 Unpacking and Inspection ............................................................. 15

2-2 In the Event of Shipping Damages ................................................ 15

2-3 If the Shipment is Not Complete.................................................... 16

2-4 If the Shipment is Not Correct ....................................................... 16

2-5 Returns ......................................................................................... 16

3 Installation .............................................................. 17

3-1 Work Rules ................................................................................... 17

3-2 Installation Requirements .............................................................. 17

3-3 Connecting Piping ......................................................................... 18

3-4 Making Electrical Connections ...................................................... 22

4 Startup Preparations .............................................. 25

4-1 Starting the Unit ............................................................................ 25

4-2 Shutting Down the Unit ................................................................. 27

4-3 Returning Fluid to the Tank ........................................................... 28

5 Using Controls and Indicators ............................. 31

5-1 The Microprocessor Controller ...................................................... 31

5-2 Controller Display .......................................................................... 31

5-3 Using Controller Keys ................................................................... 32

5-4 Identifying Control Panel Switches ................................................ 32

6 Preventive Maintenance ........................................ 35

6-1 Periodic Checks ............................................................................ 35

6-2 Routine Servicing .......................................................................... 36

6-3 Draining the Unit for Storage ......................................................... 37

6-4 Corrective Maintenance ................................................................ 37

6-5 Maintaining the Pump ................................................................... 38

7 Troubleshooting ..................................................... 52

Page 4 2016-C Series Hot Oil Portable Temperature Control Units

Charts and Figures

Figure 1 2016-C Series Hot Oil Portable Temperature Control Unit and Specifications 14

Figure 2 2016-C Unit Piping Setup ................................................................................ 21

Figure 3 Typical E5CK Microprocessor Controller ........................................................ 31

Figure 4 Control Panel Switches ................................................................................... 33

Figure 5 18-24 GPM Pump Contrustion 075-00370-02 ................................................. 39

Figure 6 Thrust Bearing Assembly ................................................................................ 40

Figure 7 Mechanical Seal Assembly ............................................................................. 41

Figure 8 Customer-Recommended Spare Parts ........................................................... 48

COT-C Series Hot Oil Portable Temperature Control Units Page 5

1 General Information

1-1 Introduction

Your STERLING 2016-C 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 400°F (38°C to 205°C). The unit is best

suited for use with TrueTherm™ Heat Transfer Fluid. A

recommended list of commercially available heat transfer fluids
can be obtained through STERLING Customer Service.

Rapid recirculation of the relatively small amount of fluid provides
a close and uniform temperature relationship between 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 STERLING
controllers to the STERLING high temperature system. The two
systems are fully integrated to achieve accurate control, along with
efficient use of water and electricity.

1-2 Necessary Documents

The following documents are necessary for the safe installation,
operation, and maintenance of your STERLING 2016-C Series hot
oil portable temperature control unit. You can obtain additional
copies from STERLING, Inc. Make sure that appropriate personnel
are familiar with these documents:

 This manual.
 The electrical schematic and connection diagram in the control

enclosure.

 The manuals for accessories and options you’ve selected.
 The customer parts list in the control enclosure.

Page 6 2016-C Series Hot Oil Portable Temperature Control Units

1-3 Models Covered

This manual lists installation, operation, and maintenance
instructions for the 2016-C Series hot oil portable 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.

1-4 Standard Features

 Off-the-shelf microprocessor-based PID temperature

controller with Process and Set Point LED readouts

 Non-fused lockable rotary disconnect
 Dual stage immersion heater with IEC contactors
 400ºF (205ºC) maximum operating temperature
 Branch fusing
 System status graphic display
 Pressure switch for low pump pressure shut-down
 NEMA 12 electrical enclosure
 UL listed subpanel
 To Process pressure gauge
 Independent safety thermostat
 Automatic venting sequence
 Positive displacement pumps capable of reversing to

evacuate the process

 Low level alarm for reservoir
 Easily removable panels for quick access to internal

components

 Audible alarm

1-5 Available Options

 Drain valve

COT-C Series Hot Oil Portable Temperature Control Units Page 7

 Hour meter; measures total pump run time hours
 General fault visual alarm
 Auto-vent sequence; deducts available
 Low level alarm; deducts available
 High level indicator light
 Manual bypass
 DIN controller with:

 4-20 mA current control output
 RS-232 or RS-485 communications
 Remote sensor; 10 ft. (3 m)

 Y-strainer on From Process line (external to unit)
 Remote controller
 Lexan cover
 Optional operating voltages of 208/3/60, 230/3/60, 575/3/60,

380/3/50, and 415/3/50

1-6 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 are supplied with a 6 kW low watt density
immersion heater.

Heater Tank

The 2016-C 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

Page 8 2016-C Series Hot Oil Portable Temperature Control Units

Ful-Flo Valve

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 6-5 on Page 38 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 the 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 by-pass line (Ful-Flo valve). Because the pump is a
positive displacement pump, it will supply the process with rated
flow at or 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 to which it is attached. 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 the pressure requirements exceed
the rated pressure, the Ful-Flo valve will open and bypass the
necessary fluid to prevent high pressures.

Cooling

A regulating by-pass 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 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 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.

The STERLING-designed shell and tube heat exchanger is
provided as optional equipment in this unit. The design features
straight-tube construction and copper-nickel tubes for durability
and optimal heat transfer.

The modular construction (unique to STERLING 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.

COT-C Series Hot Oil Portable Temperature Control Units Page 9

! 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 2016-C 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.

Connection Lines

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.

Connections for TO PROCESS and FROM PROCESS lines are
½” NPT (12.5 mm). Water connections for COOLING WATER

SUPPLY and COOLING WATER DRAIN are ½” NPT (12.5 mm).

(see Section 3.) The customer is responsible for conversions to
metric standards.

STERLING stocks many lengths of flexible metal hose; the part
number is 572-16969. State the length of hose you want when
ordering.

Electrical System Controls

The electrical controls of your 2016-C unit are specially
engineered for reliability, safety and simplicity of operation. The
switches are clearly labeled as to their function. Your 2016-C 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

Page 10 2016-C Series Hot Oil Portable Temperature Control Units

in the event of the following conditions:

 motor overload
 safety thermostat trip (over temperature)

 low fluid pressure
 low fluid level
 high fluid level (optional)

Push the ALARM SILENCE button to silence the alarm. See
Section 5 on page 31 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 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
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.

COT-C Series Hot Oil Portable Temperature Control Units Page 11

! 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 starting the heater cycle.

Air Purge

Pressure Switch

Upon initial start-up and mold/process change-out, you’ll need to
purge all air and water from the system. The 2016-C unit has
appropriate valving to ensure complete purging; procedures are
covered in Section 4 on Page 25.

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 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 overheating 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.

All 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

Page 12 2016-C Series Hot Oil Portable Temperature Control Units

determine and correct the cause of the fault before resuming
operation.

Reservoir Tank

! 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.

A reservoir tank with sight gauge is standard; usable capacity is
one (2) gallon (7.6 liters). The tank permits thermal expansion of
the heat transfer fluid, and provides make-up fluid.

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.

COT-C Series Hot Oil Portable Temperature Control Units Page 13

Figure 1

Model

Pump

Dimensions

Shipping

Number

Heater

Power

Pressure

Flow H W

D

Weight

460 / 230

6 kW

hp

kW

PSI

Bar

gpm

lpm

in.

cm

in.

cm

in.

cm

lbs.

Kg

2016-C

Std.

0.75

0.56

50

3.45

6

22.8

28

71

13

33

31

79

265

120

2016-C Series Hot Oil Portable Temperature Control Unit

2016-C Series Temperature Control Unit Specifications

Page 14 2016-C Series Hot Oil Portable Temperature Control Units

2 Shipping Information

Important!

According to the contract terms and conditions of the Carrier,

the responsibility of the Shipper ends at the time and place of shipment.

2-1 Unpacking and Inspection

You should inspect your STERLING 2016-C Series hot oil
portable 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. In case of
breakage, damage, shortage, or incorrect shipment, refer to the
following sections.

2-2 In the Event of Shipping Damages

 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 to

STERLING, Inc. before the transportation company
inspection and authorization.

 File a claim against 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 STERLING, Inc. regarding your wish for assistance

and to obtain an RMA (return material authorization) number.

COT-C Series Hot Oil Portable Temperature Control Units Page 15

2-3 If the Shipment is Not Complete

Important!

Do not return any damaged or incorrect items

until you receive shipping instructions from STERLING, Inc.

Check the packing list. The apparent shortage may be intentional.
Back-ordered items are noted on the packing list. You should have:

 2016-C Series hot oil portable 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. Determine that the item was
not inadvertently taken from the area before you checked in the
shipment. Notify STERLING, Inc. immediately of the shortage.

2-4 If the Shipment is Not Correct

2-5 Returns

If the shipment is not what you ordered, contact STERLING, Inc.
immediately. For shipments in the United States and Canada,

call 1 [phone]; for all other countries, call 001 (847)
273-7700. Include the order number and item.
Hold the items until you receive shipping instructions.

Page 16 2016-C Series Hot Oil Portable Temperature Control Units

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
international regulations.

 Read and follow these instructions when installing, operating

and maintaining this equipment. If the instructions become
damaged or unreadable, obtain additional copies from
STERLING.

 Only qualified personnel familiar with this equipment should

work on or with this hot oil temperature control unit.

 Work with approved tools and devices.
 Disconnect the electricity before maintenance or service.

If the unit is installed with a power cord that can be un­plugged, unplug it. If the unit is permanently wired to a
power main, make sure that a fused power disconnect is
installed to allow the disconnect to be locked in the OFF
position. Open and lock out the disconnect installed in the
control enclosure.

3-2 Installation Requirements

Make sure that you meet the following requirements when
installing and operating your 2016-C hot oil temperature control
unit.

Installation Location Considerations

Locate the 2016-C 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).

COT-C Series Hot Oil Portable Temperature Control Units Page 17

Make sure that the unit location is not in a confined space to ensure

! 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.

Avoid contact or inhaling harmful amounts of material.
Consult the Material Safety Data Sheet (MSDS) for
precautions and instructions for the thermal fluid you
are using.

Ambient storage range

Ambient operation range

ºF

ºC

ºF

ºC

-40ºF to 185ºF

-40ºC to 85ºC

-4ºF to 120ºF

-20ºC to 49ºC

proper air circulation. Vapors can escape from areas such as the
reservoir tank during high temperature operation.

Note: Before storing your 2016-C temperature control unit, make

sure you remove all residual water with compressed air to
avoid a potential freezing hazard. See Section 6-3 on Page
37 for more information.

Note the following table of ambient temperature ranges permitted
for storage and operation:

You should preheat the process heat transfer fluid first if you want
to start the unit below an ambient temperature of 30ºF (-1ºC).

3-3 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.

Page 18 2016-C Series Hot Oil Portable Temperature Control Units

The following table lists TCO/TCU pipe sizes.

Size diameter

Connection

inches NPT

mm (approx.) 

To Process

0.5” NPT

12.5 mm

From Process

0.5” NPT

12.5 mm

Cooling Water Supply

0.5” NPT

12.5 mm

Cooling Water Drain

0.5” NPT

12.5 mm

Oil Drain

0.5” NPT

12.5 mm

Fill Port

0.5” NPT

12.5 mm

 Customer is responsible for converting to metric.

Notes: Always use a backup wrench to support 2016-C unit piping

when making connections. Make sure all external piping is
supported independently of the 2016-C unit.

STERLING, Inc. 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 2016-C 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
must be avoided.

If you must use a pipe joint compound, use a compound that can
withstand the high temperatures and pressures of your 2016-C 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 2016-C unit.

Piping Considerations for Mobile Installations

COT-C Series Hot Oil Portable Temperature Control Units Page 19

Because your 2016-C unit is fitted with casters, its portability is
well suited for multiple applications. You can purchase high­quality flexible metal hose from STERLING to enhance the
mobility of your 2016-C unit; state the length you want when
ordering.

Although they cause a drop in pressure, you can also install quick
disconnects to your 2016-C unit. However, do not install check
valves with quick disconnects unless absolutely necessary!

Connecting Process Piping

! CAUTION

 Hoses, valves and other components in your process must be able to

withstand 2016-C unit 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.

Connecting Cooling Water Piping

You must provide cooling 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. STERLING,
Inc. sells a complete line of water treatment equipment that can
reduce downtime and maintenance costs.

Install properly-sized cooling water lines – never smaller than the
outlets on the 2016-C unit. If external piping is larger than 2016-C
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

and on the back of the unit. 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.

Remember: All external piping must be supported independently
of the 2016-C unit.

Page 20 2016-C Series Hot Oil Portable Temperature Control Units

! 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

2.5% for every increase of 50°F/°C from temperatures
above 60°F (16°C).

Figure 2

2016-C 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 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.

COT-C Series Hot Oil Portable Temperature Control Units Page 21

! 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 lines and connectors between the 2016-C 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 ratingat least equal to the maximum operating

temperature of your 2016-C unit.

! CAUTION

1. Provide a correctly sized and protected power supply to the unit.

2. If an 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.

Note: To prevent debris from fouling reservoir fluid, the 2016-C

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.

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.

 Locate disconnects in an easily accessible location.

Operators should not have to squeeze around the 2016-C unit

Page 22 2016-C Series Hot Oil Portable Temperature Control Units

to reach disconnects, especially in case of emergency.

 When running conduit whips to the 2016-C unit, make sure

! 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.

that whips are routed away from hot piping.

Check the unit nameplate for correct voltage and amperage
before making electrical connections!

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.

COT-C Series Hot Oil Portable Temperature Control Units Page 23

- Notes -

Page 24 2016-C Series Hot Oil Portable Temperature Control Units

4 Startup Preparations

! CAUTION

You must purge the system of air before the heating cycle.

Personal injury and system damage can occur from a pressurized system.

4-1 Starting the Unit

Unit Start-up (With Autovent Solenoid)

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. Add fluid to the reservoir tank until the level is near the top of
the sight glass.

2. Turn the Pump Rev|Off|Fwd switch to Fwd to start the pump.
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.

3. As fluid is drawn out of the reservoir tank to fill the process, the
fluid level will fall in the tank. Continue to add fluid to
maintain the level about 4 inches from the bottom of the sight
glass.

4. Air and Oil will be vented through the Vent Solenoid and into
the reservoir tank.

5. Two minutes after the unit has built at least 5psi of pressure,
select a set point of 100°F and switch unit into the "Auto" mode.
As the oil warms up, viscosity will decrease, and the pressure
will fall.

6. With 2 minute intervals increase the setpoint to 150 and 200°F.

COT-C Series Hot Oil Portable Temperature Control Units Page 25

7. If any water is present in the system, it must be boiled off before

! CAUTION

You must purge the system of air before the heating cycle.

Personal injury and system damage can occur from a pressurized system.

continuing operation. Select a setpoint of 215ºF (102ºC) and
observe the reservoir tank vent for any signs of escaping steam.
Continue to run at 215ºF until no more steam appears and
pressure has stabilized.

8. When fluid level has stabilized and air and water is purged from
the system, allow the vent timer to run out.

Unit Start-up (With Manual Vent 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. Add fluid to the reservoir tank until the level is near the top of
the sight glass.

2. Open the Vent Valve on the back of the unit.

3. Turn the Pump Rev|Off|Fwd switch to Fwd to start the pump.
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. As fluid is drawn out of the reservoir tank to fill the process, the
fluid level will fall in the tank. Continue to add fluid to
maintain the level about 4 inches from the bottom of the sight
glass.

5. Air and Oil will be vented through the Vent Valve and into the
reservoir tank.

6. Two minutes after the unit has built at least 5psi of pressure,
select a set point of 100°F and switch unit into the "Auto" mode.
As the oil warms up, viscosity will decrease, and the pressure
will fall.

7. With 2 minute intervals, increase the setpoint to 150 and 200 °F.

Page 26 2016-C Series Hot Oil Portable Temperature Control Units

8. If any water is present in the system, it must be boiled off before
continuing operation. Select a setpoint of 215ºF (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.

9. When fluid level has stabilized and air and water is purged from
the system, close the Vent Valve. Do not open the Vent Valve
above 250°F.

With the system properly purged, only 4 - 6" of fluid should be
visible in the sight glass. This will allow for expansion of the fluid
as it heats, as well as capacity for process fluid when the pump is
reversed and fluid withdrawn from the mold.

The Model 2016-C is now ready for use. All that is required is to
select a process set point on the controller as described in the
controller manual.

Note: If all traces of water are not removed from the system,

severe cavitation may occur at elevated temperatures.

Indications are a “gravely” sounding pump, fluctuating or

dropping pressure, or rapidly rising fluid level in the
expansion tank. Repeat Step #7 if any of this occurs.

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, if
equipped with optional heat exchanger. Fluid temperature can be
monitored on the controller display during cool down. When fluid
temperature is below 120ºF, Turn the Pump Rev|Off|Fwd switch
to Off to turn the unit off.

COT-C Series Hot Oil Portable Temperature Control Units Page 27

! 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).

4-3 Returning Fluid to the Tank

Returning Fluid to Tank (With Autovent Solenoid)

If the unit is to be moved from one process to another (i.e. mold
changes, etc.), the following steps must be taken to drain the mold
and process lines. Note that this is just the opposite of unit start
up/air purge:

1. Cool fluid to 100 degrees °F maximum.

2. Turn the Pump Rev|Off|Fwd switch to Off.

3. Turn the Pump Rev|Off|Fwd switch to Rev. The pump

will then run in reverse, drawing fluid from the mold and
lines, and into the reservoir tank.

4. Watch the sight glass to prevent overflow of the
reservoir tank.

If it appears that the tank may overfill, connect a line from the

FILL port of the reservoir tank to a clean auxiliary container.

Page 28 2016-C Series Hot Oil Portable Temperature Control Units

Returning Fluid To Tank (With Manual Vent Valve)

If the unit is to be moved from one process to another (i.e. mold
changes, etc.), the following steps must be taken to drain the mold
and process lines. Note that this is just the opposite of unit start
up/air purge:

1. Cool fluid to 100 degrees °F maximum.

2. Open the Vent Valve to allow in fresh air into the pipes.

3. Turn the Pump Rev|Off|Fwd switch to Off.

4. Turn the Pump Rev|Off|Fwd switch to Rev. The pump
will then run in reverse, drawing fluid from the mold and
lines, and into the reservoir tank.

5. Watch the sight glass to prevent overflow of the
reservoir tank.

If it appears that the tank may overfill, connect a line from the

FILL port of the reservoir tank to a clean auxiliary container.

COT-C Series Hot Oil Portable Temperature Control Units Page 29

- Notes -

Page 30 2016-C Series Hot Oil Portable Temperature Control Units

5 Using Controls and Indicators

5-1 The Microprocessor Controller

The controller is an easy-to-operate microprocessor-based PID
control device. When the process reaches the set point, the
controller cycles the cooling valve or the immersion heater to
maintain the proper To Process temperature.

The controller has been fully factory tested. Set the desired process
temperature set point and the control does the rest.

Built-in range of operation on the controller is 0°F to 400°F (-18ºC
to 205ºC).

5-2 Controller Display

Figure 3

Typical 3216

Microprocessor Controller

See Figure 3

Measured Temperature Value Numeric LED

During normal operation, the large green PV Process Value LED
on the controller displays the actual process temperature at the To
Process thermocouple. It also lists parameter symbols during setup
and error messages if an error occurs.

Required Temperature Numeric LED

During normal operation, the smaller green SP Set Value LED on
the controller displays the process set point you want the chiller to
maintain. It also displays parameter and pre-set function values
during setup.

COT-C Series Hot Oil Portable Temperature Control Units Page 31

5-3 Using Controller Keys

Important!

Do not change any of the control settings without

consulting the STERLING Service Department.

The STERLING, Inc. warranty does not cover temperature control unit failures

from tampering with controller settings!

See Figure 3

Page Key

From any display – press to return to the HOME display.

Scroll Key

Press to select a new parameter. If held down it will continuously
scroll through the parameters.

Down Key

Up Key

Each press of the Down Arrow key decrements or reduces the
values or settings on the SV Set Value display.

Each press of the Up Arrow key increments or advances the
values or settings on the SV Set Value display.

5-4 Identifying Control Panel Switches

This section lists the descriptions and functions of the control panel
switches. These switches control the operation of the unit.

Page 32 2016-C Series Hot Oil Portable Temperature Control Units

Pump Rev|Off|Fwd

! CAUTION

Always turn to Pump Off and allow the pump to come
to a complete stop before turning to Pump Reverse.

Failure to let the pump stop before reversing may
damage the pump and drive.

Figure 4

Control Panel Switches

Turn the Pump Rev|Off|Fwd switch to Fwd to start the pump in
the normal forward direction.

Turn the Pump Rev|Off|Fwd switch to Off to stop the pump and
de-energize the controller.

Turn the Pump Rev|Off|Fwd switch to Rev to start the pump in
the reverse direction. Use this feature to purge oil from the mold.

Vent Cycle Start

Press the VENTbutton to start the vent cycle timer. Use this feature
to purge air and water from the unit and process.

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

COT-C Series Hot Oil Portable Temperature Control Units Page 33

! 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 chapter.
Improper switching can seriously damage the heater,
as it could become energized with air in the system.

! CAUTION

After you silence the alarm, make sure you locate and
correct the alarm condition before continuing with unit

operation.

Alarm Silence

returns to the Center Default position when in AUTO mode. The
switch stays in the Maintained position in Manual Cooling mode.

Press the ALARM SILENCE button to silence the audible alarm
on the console.

Page 34 2016-C Series Hot Oil Portable 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 unit, let the unit
cool down completely, and turn off the
water.

Failure to follow these directives can result
in serious injury or death!

6-1 Periodic Checks

Making Daily Checks

 Check fluid level; add fluid as needed.
 Check all connecting lines, hoses, and connectors for wear or

damage.

Making Monthly Checks

 Check for leaks developing at the pump seal, gaskets, and

other similar locations.

 Check the pump drive V belt for any wear.
 Check the reservoir tank vent for any obstructions.

COT-C Series Hot Oil Portable Temperature Control Units Page 35

Making Quarterly Checks

 Check the heat transfer fluid for deterioration. If the fluid is

Making Six-Month Checks

 Inspect electrical connections for secure, tight electrical

 Check the mounting bolts on the pump, the motor, and the

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.

terminations and ground connections. Inspect the power
cable, especially at the entrance point to the electrical
enclosure. Have a qualified electrician perform this
inspection.

heater flange for tightness.

 Remove the heat exchanger tube bundle and check it for lime

and mineral deposits. Carefully clean the bundle as needed.

6-2 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.

Page 36 2016-C Series Hot Oil Portable Temperature Control Units

Servicing the Unit Monthly or Every 500 Hours

 Lubricate the pump at the grease fittings with Dow-Corning

#44 or a high-quality lithium grease rated at 400ºF (204ºC) 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.

6-3 Draining the Unit for Storage

You should thoroughly flush and drain the 2016-C 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 TrueFlush™ flushing fluid or equivalent for flushing

your 2016-C unit; follow unit flushing instructions that comes with
TrueFlush™ 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.

6-4 Corrective Maintenance

Pumps and Seals

Each 2016-C unit is completely tested and calibrated before
leaving the factory. The unit is then cooled, drained, and packed
for shipment.

COT-C Series Hot Oil Portable Temperature Control Units Page 37

If the unit stands idle for a long time before being installed in your

! WARNING

Before opening the pump chamber:

 Make sure that any pressure in the 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 result in serious injury
or death!

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 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
Diagram provided in unit for more information.

6-5 Maintaining the Pump

Disassembly

Page 38 2016-C Series Hot Oil Portable Temperature Control Units

Figure 5

18-24 GPM Pump Construction 075-00370-02

COT-C Series Hot Oil Portable Temperature Control Units Page 39

Disassembling the Pump

1. Mark 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 pump.

Remove head from pump. Do not allow idler to fall from idler
pin. To prevent this tilt top of head back when removing.
Avoid damaging head gasket.

2. Remove idler and bushing assembly.

3. Insert length of hardwood or brass through port opening
between rotor teeth to keep shaft from turning. Bend up tang of
lockwasher and with a spanner wrench remove locknut and
lockwasher from shaft.

4. Loosen Allen head setscrews in the face of the thrust bearing
assembly. Remove the thrust bearing assembly by threading
out of the bracket.

Figure 6

Thrust Bearing Assembly

5. Loosen the radial setscrews in the thrust bearing assembly and
remove the end cap using the spanner wrench.

6. Remove the bearing spacer collars and the ball bearing.

7. Using snap ring pliers, remove snap ring from shaft.

8. Remove two nuts holding seal gland plate and seal gland in
place. Slide seal gland off of shaft being careful not to damage
the lip seal.

9. Using a soft headed hammer, gently tap on the end of the rotor
shaft until the rotor and shaft assembly can be completely

Page 40 2016-C Series Hot Oil Portable Temperature Control Units

removed from the pump. Note the mechanical seal may stick
to the shaft causing initial resistance when the shaft is
removed.

10. Remove the mechanical seal parts from the bracket.

11. 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 bearings 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.

12. Casing can be checked for wear or damage while mounted on
bracket.

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. 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 45.

2. 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.

Figure 7

Mechanical Seal Assembly

COT-C Series Hot Oil Portable Temperature Control Units Page 41

3. 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 bushing, Refer to Installation of Carbon Graphite
Bushings, page 50.

4. 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.

5. 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 5. 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.

6. 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.

7. 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.

Page 42 2016-C Series Hot Oil Portable Temperature Control Units

8. 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 tighten with a spanner wrench.
Tighten the radial set screws that lock the end cap in place.

9. Using the snap ring pliers, install the snap ring onto the shaft.

10 Thread the thrust bearing assembly into the bracket. Turn until

hand tight. This forces the rotor against the head.

11. Put lock-washer 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.-lbs.
torque and bend one tang of lock-washer into slot.

12. Adjust pump end clearance. Refer to section on Thrust Bearing
Adjustment.

13. Lubricate all grease fittings with Dow Corning #44 high
temperature silicon grease.

COT-C Series Hot Oil Portable Temperature Control Units Page 43

Thrust Bearing Adjustment

! WARNING

Before starting the pump, make sure that all
drive equipment guards are in place!

Failure to properly install the guards may result
in serious injury or death!

PUMP

SIZE

Turn Outer End Cap C.C.W.

No. of Notches*

or Length on O.D., Inches

G

- 0.75"

HL, HV 6 1"

KK 10 1.38"

1. Loosen axial setscrews in face of end cap on the thrust bearing

2. Make a mark on the OD of the bearing housing and a

3. Tighten the axial setscrews in the face of the thrust bearing

*Each small notch on outer end cap represents .001 inch end clearance.

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.

corresponding mark on the bracket. Back off thrust bearing
housing the required number of marks or distance on the OD
as shown below.

assembly. Make sure the rotor shaft turns freely. If it does
not, repeat steps 1 and 2.

Page 44 2016-C Series Hot Oil Portable Temperature Control Units

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. A press must be used for installation.

2. Be certain bushing is started straight.

3. Do not stop pressing operation until bushing is in proper
position. Starting and stopping will result in a cracked bushing.

4. Check bushing for cracks after installation.

Carbon graphite bushings with extra interference fits are
frequently furnished for high temperature operation. These
bushings must be installed by a shrink fit.

1. Heat bracket or idler to 750°F.

2. Install cool bushings with a press.

3. If facilities are not available to reach 750°F. temperature, it is
possible to install with 450°F. temperature; however, the lower
the temperature, the greater the possibility of cracking the
bushing.

COT-C Series Hot Oil Portable Temperature Control Units Page 45

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

Lubricating the Pump

Adjusting End Clearance

Examining Internal Parts

procedures.

Using #2 ball bearing grease and a hand-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.

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.

Cleaning the Pump

Storing Your 2016-C Unit

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.

A clean pump is easier to inspect, lubricate and adjust; it runs
better and looks better!

If you anticipate that your unit will be out of service or stored for a
long time, flush and drain the pump and circulating system to
protect it from freeze-ups or rusting. See Section 6-3 on Page 37
for more information.

Page 46 2016-C Series Hot Oil Portable Temperature Control Units

COT-C Series Hot Oil Portable Temperature Control Units Page 47

Part number

Description

722-00138-01

HTR, IMM, 6 KW, 208 V, 3”, 6 ELE

722-00138-02

HTR, IMM, 6 KW, 240 V, 3”, 6 ELE

722-00138-03

HTR, IMM, 6 KW, 380 V, 3”, 6 ELE

722-00138-04

HTR, IMM, 6 KW, 415 V, 3”, 6 ELE

722-00138-05

HTR, IMM, 6 KW, 480 V, 3”, 6 ELE

722-00138-06

HTR, IMM, 6 KW, 600 V, 3”, 6 ELE

Part number

Description

542-00007-08

GASKET, FLANGE, 3

Part number

Description

572-92405-00

TANK, HEATER, TCO, 3½

Part number

Description

724-00041-00

THERMOSTAT, 200ºF — 550ºF

Figure 8

Customer Recommended Spare Parts

Immersion Heaters

Note: 6 kW heaters are modified 12 kW heaters; jumpers are

remove from one leg.

Heater Gasket

Heater Tank

Manual Reset Safety Thermostat

Note: Please give model and serial numbers when ordering parts.

Prices are subject to change without notice.

Page 48 2016-C Series Hot Oil Portable Temperature Control Units

Figure 8

Part number

Description

037-00158-00

GAUGE, PRESSURE, 0 — 100 PSI

Ass’y. part no.

Description

106-00024-00

1.5 SQ. FT. 2016-C 400°F

Part number

Description

042-00016-00

CASTER, SWIVEL, 3”

042-00017-00

CASTER, STATIONARY, 3”

Part number

Description

037-00047-00

GLASS, SIGHT, 27”

Customer Recommended Spare Parts Cont’d.

Pressure Gauge

Heat Exchanger

Casters

Sight Glass Assembly

Note: Please give model and serial numbers when ordering parts.

Prices are subject to change without notice.

COT-C Series Hot Oil Portable Temperature Control Units Page 49

Figure 8

Part number

Description

724-00671-01

LTR, MPB, 1/16, 2, T/C Omron E5CK

Part number

Description

721-01028-00

PUMP STOP

721-01027-00

PUMP START

721-01026-00

ALARM SILENCE

717-01016-00

MODE SELECT

721-01026-00

VENT

721-01029-00

PUMP REVERSE

717-10055-00

HALF-FULL HEAT, LOCAL-REMOTE (OPTIONAL)

Part number

Description

733-00029-00

SWITCH, PRESSURE

Part number

Description

075-00381-02

MECH. SEAL, VIKING G4125 (0-10 GPM)

Part number

Description

720-09217-00

MOTOR, ¾ HP 3/60/208, 230, 460 V

720-09024-00

MOTOR, ¾ HP 3/60/575 V

Part number

Description

100-00309-00

BELT, 4L, 27-1/2LG

Customer Recommended Spare Parts Cont’d.

Controller

Selector Switches and Push Buttons

Pressure Switches

Pump

Motors

Replacement Belts

Note: Please give model and serial numbers when ordering parts.

Prices are subject to change without notice.

Page 50 2016-C Series Hot Oil Portable Temperature Control Units

Figure 8

Part number

Description

732-00007-03

¼” VENT VALVE, 115 V COIL (0-125 PSI, 300°F)

732-00012-02

½” VENT VALVE, 115 V COIL (0-125 PSI, 300°F)

Part number

Description

701-00036-00

SENSOR, TC, TYPE “K”

692.07369.28

SENSOR, RTD, 1000 OHM

Part number

Description

728-00153-00

SWITCH, DISCONNECT, 45 AMP

728-00168-00

SWITCH, DISCONNECT, 100 AMP

Part number

Description

542-08133-00

INSULATION, TANK, HEATER

Part number

Description

044-00304-00

VALVE, RELIEF, FUL-FLO, ½”

Customer Recommended Spare Parts Cont’d.

Solenoid Valves

Sensing Probe Equipment

Disconnect Switches

Heater Tank Insulation

Ful-Flo Relief Valves

Note: Please give model and serial numbers when ordering parts.

Prices are subject to change without notice.

COT-C Series Hot Oil Portable Temperature Control Units Page 51

7 Troubleshooting

Condition

Possible cause

Solution

Temperature fluctuations/rapid
cycling from hot to cold.

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 flow
instead of series flow.

Blocked line in mold.

Check mold for metal chips or
deposits. Clean mold.

Quick disconnect fitting with
check valve.

Remove and replace fitting or
valve.

Carbon build-up in unit piping or
fittings.

Clean or replace affected piping.
Replace fluid.

Faulty TCU.

Check unit by opening the
manual bypass to determine if
the TCU contols the set point
temperature.

Reversed probes.

Switch Return and Delivery
probes.

Unit does not heat properly/can
not achieve set point.

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 stream or trickle of water
out of the drain line.

Switch to Manual Cool mode
several times to flush valve. If
the leak continues, disconnect
the power to the unit, turn off the
water supply, and clean or
replace the solenoid.

Degraded fluid.

Drain and replace fluid.

Unit does not heat.

Defective heater contactor.

Visual inspection of coil and
contacts. Repair/replace
defective contactors.

Defective immersion heater.

Check resistance on all three (3)
legs of heater with an
ohmmeter. If not all equal,
contact factory for replacement
heater.

Heater burnout.

Check heater tank for scorched/
discolored paint. Check
resistance on all three (3) legs of
heater with an ohmmeter.
Replace heater as needed.

Page 52 2016-C Series Hot Oil Portable Temperature Control Units

Condition

Possible cause

Solution

Unit does not heat.
(cont’d.)

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.

Clogged Y strainer.

Clean Y strainer.

Unit overheats/unable to cool.

Water supply to unit is turned

OFF.

Open water supply.

Water drain is plugged or
excessive back pressure in drain
line.

Clear drain line or eliminate
back pressure condition.

Heat exchanger tubes plugged
by lime deposits.

Remove tube bundles; clean/
replace as required.

Faulty solenoid valve.

Test solenoid valve by switching
to Manual Cool mode and listen
for valve operation. Replace if
faulty.

Rapid drop in pressure/no
pressure.

Leaks in connecting lines.

Inspect/replace faulty line or
connection.

Air in circulating lines.

Perform venting sequence in
Section 4-1 on Pages 27-29.

Low fluid.

Check fluid level in sight glass.
Add fluid if required.

Defective Ful-Flo valve.

Replace Ful-Flo valve.

Water in fluid.

Drain water from low point in
piping (Section 4-1 on Pages
27-29), or boil water off.

Vent solenoid open.

Allow vent timer to run out; or,
check valve operation when unit
is cold by opening the fill port.

Pump running in reverse.

Check motor; rewire if
necessary. (See electrical
diagrams)

Pump repair/adjustment needed.

Adjust head spacing or replace
worn pump components.

V belt broken/worn.

Replace as required.

Noisy pump.
Water in fluid.

Drain water from low point in
piping (Section 4-1 on Pages
27-29), or boil water off.

Severely degraded fluid.

Drain and flush system. Replace
fluid.

Troubleshooting Cont’d.

COT-C Series Hot Oil Portable Temperature Control Units Page 53

DIAGRAMS

FLOW &

ELEMENTARY ELECTRICAL

Please refer to Electrical Drawings Provided in Packet with Unit

Page 54 2016-C Series Hot Oil Portable Temperature Control Units

Service Notes

COT-C Series Hot Oil Portable Temperature Control Units Page 55

Service Notes

Page 56 2016-C Series Hot Oil Portable Temperature Control Units

Service Notes

COT-C Series Hot Oil Portable Temperature Control Units Page 57

Service Notes

Page 58 2016-C Series Hot Oil Portable Temperature Control Units

Service Notes

COT-C Series Hot Oil Portable Temperature Control Units Page 59

Index I

Adjusting End Clearance, 46
Air Purge, 12
Alarm Silence, 34
Alarm Silence, 12, 11
Available Options, 7
Charts and Figures, 5
Connecting Cooling Water

Piping, 20
Connecting Piping, 18
Connecting Process Piping, 20
Connecting Vent Piping, 20
Connection Lines, 10
Control Unit Specifications, 14
Controller display, 31
Corrective Maintenance, 37

Pumps and Seals, 37
Down key, 32
Draing Unit for Storage, 37
Electrical Connections, 22
Electrical Panel and System

Components, 11
Electrical System Controls, 10
Feature Descriptions, 8
Ful-Flo Valve, 9
General Information, 6
Heater Tank, 8
Identifying Control Panel

Switches, 32

Pump Start, 32

Identifying controls and

features

Controller display, 31

Microprocessor controller,

31
Immersion Heaters, 8
Incomplete Shipment, 16
Incorrect Shipment, 16
Installation, 17

INSTALLATION OF CARBON

GRAPHITE BUSHINGS, 45

Installation Requirements, 17
Introduction, 6
Location Considerations, 17

Lock-out/tag-out, Error! Not a

valid bookmark in entry on
page 35

Lubricating the Pump, 46
Maintaing the Pump, 38
Maintaining the Pump

Disassembly, 38

Measured LED, 31
Microprocessor controller, 31

Mobile Installations, 19
Mode Select, 33
Models Covered, 7
Necessary Documents, 6
Page key, 32
Piping Setup (Drawing), 21
Pressure Switch, 12
Preventative Maintenance

Making Daily Checks, 35
Making Monthly Checks, 35

Preventative Pump

Maintenance, 46

Preventive Maintenance, 35

Periodic Checks, 35
Pump, 8
Pump Assembly, 41
Pump Maintenance

Cleaning the Pump, 46

Examining Internal Parts, 46
Pump Rev|Off|Fwd, 33
Reservoir Tank, 13
Returning fluid to the tank, 28
Returning Fluid to the Tank

(With Autovent Solenoid), 28

With Manual Vent Valve, 28
Returns, 16
RMA number, 15
Safety Considerations, 3
Safety Thermostat, 12
Scrol key, 32
Shipping Damages, 15
Shipping Information, 18, 15
Shutting down the unit, 27
Shutting Down the Unit

Unit Shut Down (With

Autovent Solenoid or

Manual Vent Valve), 27
SP LED, 31
Spare Parts, 48
Standard Features, 7
Starting the Unit, 25
Startup Preparations

Unit Start-up (With Autovent

Solenoid), 25

Unit Start-up (With Manual

Vent Valve), 30, 25
Start-up Preparations

Unit Start-up (With Manual

Vent Valve), 26
Startup Preparations., 29, 25
Storing Your 2016-C Unit, 46
Table of Contents, 4
THRUST BEARING

ADJUSTMENT, 44
Troubleshooting, 52
Unpacking and Inspection, 15
Up key, 32
Using Controller Keys, 32
Using Controls and Indicators,

31
Vent Cycle Start, 33
Work Rules, 17

Page 60 2016-C Series Hot Oil Portable Temperature Control Units

Parts Department

Call toll-free 7am–6pm 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 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 including 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.
www.sterling.com

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.

Sterling, Inc

2900 S. 160th Street

New Berlin, WI 53151

[262] 641-8610  Fax [262] 641-8653

COT-C Series Hot Oil Portable Temperature Control Units Page 61