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) |
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here for future reference |
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Sterling is committed
to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual
are subject to change without notice.
© Copyright Sterling, Inc. 2012
All rights reserved. |
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Effective 4/27/2012 |
Part No. 682.94404.00 |
Revision 1 |
Bulletin No. SC1-645.1 |
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
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1 |
.................................................General Information |
6 |
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1-1 |
Introduction ..................................................................................... |
6 |
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1-2 |
Necessary Documents .................................................................... |
6 |
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1-3 |
Models Covered .............................................................................. |
7 |
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1-4 |
Standard Features .......................................................................... |
7 |
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1-5 |
Available Options ............................................................................ |
7 |
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1-6 |
Feature Descriptions ....................................................................... |
8 |
2 |
Shipping Information ............................................ |
15 |
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2-1 |
Unpacking and Inspection ............................................................. |
15 |
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2-2 In the Event of Shipping Damages................................................ |
15 |
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2-3 If the Shipment is Not Complete.................................................... |
16 |
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2-4 If the Shipment is Not Correct ....................................................... |
16 |
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2-5 |
Returns ......................................................................................... |
16 |
3 |
Installation .............................................................. |
17 |
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3-1 |
Work Rules ................................................................................... |
17 |
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3-2 |
Installation Requirements.............................................................. |
17 |
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3-3 |
Connecting Piping ......................................................................... |
18 |
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3-4 |
Making Electrical Connections ...................................................... |
22 |
4 |
Startup Preparations.............................................. |
25 |
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4-1 |
Starting the Unit ............................................................................ |
25 |
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4-2 Shutting Down the Unit ................................................................. |
27 |
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4-3 Returning Fluid to the Tank ........................................................... |
28 |
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5 |
Using Controls and Indicators ............................. |
31 |
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5-1 |
The Microprocessor Controller ...................................................... |
31 |
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5-2 |
Controller Display.......................................................................... |
31 |
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5-3 |
Using Controller Keys ................................................................... |
32 |
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5-4 Identifying Control Panel Switches................................................ |
32 |
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6 |
Preventive Maintenance ........................................ |
35 |
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6-1 |
Periodic Checks ............................................................................ |
35 |
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6-2 |
Routine Servicing .......................................................................... |
36 |
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6-3 Draining the Unit for Storage......................................................... |
37 |
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6-4 |
Corrective Maintenance ................................................................ |
37 |
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6-5 |
Maintaining the Pump ................................................................... |
38 |
7 |
Troubleshooting ..................................................... |
52 |
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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 |
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Figure 2 2016-C Unit Piping Setup................................................................................ |
21 |
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Figure 3 Typical E5CK Microprocessor Controller ........................................................ |
31 |
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Figure 4 Control Panel Switches ................................................................................... |
33 |
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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 |
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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.
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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 |
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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
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2016-C Series Hot Oil Portable Temperature Control Units |
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.
Ful-Flo Valve
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.
Cooling
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 |
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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.
Connection Lines
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.
! 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.
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 in the event of the following conditions:
motor overload
safety thermostat trip (over temperature)
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2016-C Series Hot Oil Portable Temperature Control Units |
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 |
Air Purge
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.
! 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.
Pressure Switch
A pressure switch is built into each unit to guard against heater damage. This feature prevents the heater elements from being energized unless the pump is running and fluid is in the system. After a preset time, the pump shuts down if the fluid pressure is not re-established. The pressure switch is preset at the factory; do not tamper with it.
Safety Thermostat
The safety thermostat is 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 determine and correct the cause of the fault before resuming operation.
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2016-C Series Hot Oil Portable Temperature Control Units |
Reservoir Tank
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.
! 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.
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 |
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Figure 1
2016-C Series Hot Oil Portable Temperature Control Unit
2016-C Series Temperature Control Unit Specifications
Model |
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Pump |
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Dimensions |
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Shipping |
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Number |
Heater |
Power |
Pressure |
Flow |
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H |
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W |
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D |
Weight |
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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 |
Page 14 |
2016-C Series Hot Oil Portable Temperature Control Units |
2 |
Shipping Information |
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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
Important!
According to the contract terms and conditions of the Carrier,
the responsibility of the Shipper ends at the time and place of shipment.
Notify the transportation company’s local agent if you discover damage.
Hold the damaged goods and packing material for the examining agent’s inspection. Do not return any goods 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 |
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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:
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
If the shipment is not what you ordered, contact STERLING, Inc. immediately. For shipments in the United States and Canada,
call 1 (847) 273-7700; for all other countries, call 001 (847) 273-7700. Include the order number and item.
Hold the items until you receive shipping instructions.
2-5 Returns
Important!
Do not return any damaged or incorrect items
until you receive shipping instructions from STERLING, Inc.
Page 16 |
2016-C Series Hot Oil Portable Temperature Control Units |
3 |
Installation |
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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 |
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Make sure that the unit location is not in a confined space to ensure proper air circulation. Vapors can escape from areas such as the reservoir tank during high temperature operation.
! CAUTION
Harmful vapors may be generated from thermal fluid during high temperature operation.
Prolonged or repeated exposure of these hot-generated vapors may result in eye and respiratory tract irritation.
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.
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:
Ambient storage range |
Ambient operation range |
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ºF |
ºC |
ºF |
ºC |
-40ºF to 185ºF |
-40ºC to 85ºC |
-4ºF to 120ºF |
-20ºC to 49ºC |
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
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!
COT-C Series Hot Oil Portable Temperature Control Units |
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