$30.00
Operation and Installation Manual
6017 Series
Large Hot Oil
Temperature Control Units
Important! Read Carefully Before Attempting to Install or Operate Equipment
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Part No. 682.91540.00 |
Revision 3 |
Bulletin No. SC1-655-3 |
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Write down your unit serial number(s) |
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here for future reference |
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Sterling/Sterlco is committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual
are subject to change without notice.
© Copyright Sterling/Sterlco and Sterling, Inc. 2008
All rights reserved. |
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Effective 4/29/2008 |
Part No. 682.91540.00 |
Revision 3 |
Bulletin No. SC1-655-3 |
Page 2 |
6017 Series Hot Oil Large Temperature Control Units |
Safety Considerations
Sterling/Sterlco 6017 Series large hot oil temperature control units are designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes.
To avoid possible personnel injury or equipment damage when installing, operating, or maintaining this equipment, use good judgment and follow these safe practices:
;Follow all SAFETY CODES.
;Wear SAFETY GLASSES and WORK GLOVES.
;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.
6017 Series Hot Oil Large Temperature Control Units |
Page 3 |
Table of Contents
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.................................................1 General Information |
7 |
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1-1 |
Introduction ..................................................................................... |
7 |
1-2 |
Necessary Documents .................................................................... |
7 |
1-3 |
Models Covered .............................................................................. |
8 |
1-4 |
Standard Features .......................................................................... |
8 |
1-5 |
Available Options ............................................................................ |
9 |
1-6 |
Feature Descriptions ....................................................................... |
9 |
2 Shipping Information.............................................. |
17 |
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2-1 |
Unpacking and Inspection............................................................. |
17 |
2-2 In the Event of Shipping Damages................................................ |
17 |
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2-3 |
If the Shipment is Not Complete.................................................... |
18 |
2-4 |
If the Shipment is Not Correct ....................................................... |
18 |
2-5 |
Returns ......................................................................................... |
18 |
3 |
Installation............................................................... |
19 |
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3-1 |
Work Rules ................................................................................... |
19 |
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3-2 |
Installation Requirements.............................................................. |
19 |
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3-3 |
Connecting Piping ......................................................................... |
20 |
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3-4 |
Making Electrical Connections ...................................................... |
26 |
Page 4 |
6017 Series Hot Oil Large Temperature Control Units |
Table of Contents
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..............................................4 Startup Preparations |
29 |
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4-1 |
Starting the Unit ............................................................................ |
29 |
4-2 |
Shutting Down the Unit ................................................................. |
32 |
4-3 |
Returning Fluid to the Tank........................................................... |
32 |
5 |
Using Controls and Indicators .............................. |
34 |
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5-1 |
The Microprocessor Controller...................................................... |
34 |
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5-2 Identifying M2B Controller Panel Components.............................. |
35 |
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5-3 |
Using M2B Controller Keys ........................................................... |
37 |
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5-4 |
Identifying Control Panel Switches................................................ |
39 |
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5-5 |
Identifying System Status Board Indicators................................... |
41 |
6 |
Preventive Maintenance......................................... |
46 |
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6-1 |
Periodic Checks ............................................................................ |
46 |
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6-2 |
Routine Servicing .......................................................................... |
47 |
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6-3 Draining the Unit for Storage......................................................... |
50 |
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6-4 |
Corrective Maintenance ................................................................ |
50 |
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6-5 |
Maintaining the Pump ............................................... |
See Addendum |
7 |
Troubleshooting ..................................................... |
52 |
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6017 Series Hot Oil Large Temperature Control Units |
Page 5 |
Charts and Figures
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1 |
6017 Series Hot Oil Large Temperature Control Unit and |
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Specifications |
16 |
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2 |
6017 Unit Piping Setup |
16 |
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3 |
Typical Flow Schematic |
24 |
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4 |
Typical M2B Graphic and Button Control Panel |
34 |
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5 |
Control Panel Switches |
39 |
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6 |
System Status Board Indicators |
41 |
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Page 6 |
6017 Series Hot Oil Large Temperature Control Units |
1 |
General Information |
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1-1 Introduction
Your Sterling/Sterlco 6017 Series hot oil temperature control unit circulates thermal transfer-type oil through your process and to precisely, automatically, and reliably maintain it at a temperature you can select. The operating range of your temperature control unit is from 100°F to 550°F (38°C to 288°C). The unit is best suited for use with SterlTherm™ Heat Transfer Fluid. A recommended list of commercially available heat transfer fluids can be obtained through Sterling Customer Service.
Rapid recirculation of the 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 Sterlco controllers to the Sterlco high temperature system. The two systems are fully integrated to achieve accurate control.
1-2 Necessary Documents
The following documents are necessary for the safe installation, operation, and maintenance of your Sterling/Sterlco 6017 Series hot oil large 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.
6017 Series Hot Oil Large Temperature Control Units |
Page 7 |
1-3 Models Covered
This manual lists installation, operation, and maintenance instructions for the 6017 Series hot oil large temperature control unit.
Model numbers are listed on the serial tag. A model number followed by -Q indicates a specially constructed unit, and not all information in this manual may apply. Make sure that you know the model number, serial number, and operating voltage of your unit if you contact Sterling, Inc.
1-4 Standard Features
•M2B microprocessor controller with fuzzy logic; includes diagnostic features with indicator and warning status lights
•Non-fused lockable rotary disconnect
•Dual stage immersion heater with IEC contactors
•550°F (288ºC) 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
•Y strainer on From Process line
•A packed positive displacement pumps capable of reversing to evacuate the process
•Easily removable panels for quick access to internal components
•Audible alarm
Page 8 |
6017 Series Hot Oil Large Temperature Control Units |
1-5 Available Options
•Drain valve
•Manual bypass
•Hour meter; measures total pump run time hours
•General fault visual alarm
•Automatic venting sequence
•Low level alarm for reservoir
•M2B microprocessor controller options include:
4-20 mA remote set point and retransmission
SPI protocol, RS-485
General protocols, types RS-232, -485
Remote sensor
•Heat exchanger options of
•3.9 sq. ft. (0.3627 sq. m)
•6.7 sq. ft. (0.6231 sq. m)
•13 sq. ft. (1.21 sq. m)
•21 sq. ft. (1.96 sq.m)
•27 sq. ft. (2.51 sq. m)
•Remote controller
•Lexan cover
•Mechanical Seal Pump
•Optional operating voltages of 208/3/60, 230/3/60, 575/3/60, 380/3/50, and 415/3/50
•Provisions for a Nitrogen Blanket on the Reservoir can drastically increase fluid life.
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 can be supplied with 50, 60, 75, 100, 120, 150, and 200 kW low watt density immersion heaters, depending upon the heating needs of the process. All models are built to provide full or partial heat as required by the process and determined by the controller, to provide more precise control.
6017 Series Hot Oil Large Temperature Control Units |
Page 9 |
Heater Tank
The 6017 features a single pass heater tank. The tank is designed to maintain an optimum balance of fluid velocity versus watt density, and turbulence for excellent heat transfer, and minimal pressure drop. The high fluid velocity will greatly prolong the life of the heater and fluid.
Pump
The pump is a packed, positive displacement pump. It features a nearly failure free design, and has proven itself after years of dependable service. It is well suited for use with a variety of 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 weekly greasing and occasional packing and headspace adjustment; see Chapter 6 on Page 47 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 (Fulflo 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 that it is attached to. 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 fulflow valve will open and bypass the necessary fluid to prevent high pressures.
Ful-Flo Valve
A regulating by-pass line featuring a Fulflo 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 Fulflo is factory preset to limit system pressure as specified by the customer. It must not be tampered with in any way.
Page 10 |
6017 Series Hot Oil Large Temperature Control Units |
In the event of an obstruction in the line, the Fulflo will open and divert fluid from the delivery TO PROCESS line to the return From Process line. A constant flow of fluid is maintained through the heater tank to prevent damage to the heating elements and fluid.
Cooling
Optional
The Sterlco-designed shell and tube heat exchanger is provided as optional equipment in this unit. The design features U-tube construction and copper-nickel tubes for durability and optimal heat transfer.
The modular construction (unique to Sterlco 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.
The controller automatically regulates cooling by opening and closing the cooling solenoid. This allows the proper amount of oil to pass over the tubes of the heat exchanger. 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:
•2" NPT (50.8 mm) at 90 gpm (341 lpm)
•2-1/2" NPT (63.5 mm) at 150 gpm (568 lpm)
•3" NPT (76.2 mm) at 200 gpm (757 lpm)
Water connections for COOLING WATER SUPPLY and
COOLING WATER DRAIN are:
•¾” NPT (19.1 mm) for 3.9 & 6.7 sq. ft. heat exchangers.
•1" NPT (25.4 mm) for 13, 21, & 27 sq. ft. heat exchangers. (See Chapter 3.) The customer is responsible for conversions to metric standards.
6017 Series Hot Oil Large Temperature Control Units |
Page 11 |
Sterling stocks many lengths of flexible metal hose; the part number is 572-16969. State the length of hose you want when ordering.
! WARNING
Component failure may result in high-temperature oil spray, causing serious injury or death.
Make sure hoses, valves, and other components installed in your process can withstand maximum temperature and pressure of the 6017 unit; check unit nameplate for specific capacities.
All components must be carefully inspected for condition before installing. Make sure you have factory components if you have any doubt.
Electrical System Controls
The electrical controls of your 6017 unit are specially engineered for reliability, safety and simplicity of operation. The switches are clearly labeled as to their function. Your 6017 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 )
•low fluid pressure
•low fluid level (optional)
•high fluid level (optional)
Push the ALARM SILENCE button to silence the alarm. See
Chapter 4 for more information on control functions.
Page 12 |
6017 Series Hot Oil Large Temperature Control Units |
Electrical Panel and System Components
The pump motor and immersion heater operate on three-phase, 50/60 cycle, nominal voltage with the control circuit at 115 V single phase. The control circuit voltage is provided by a single phase machine tool transformer with primary fuse protection and a grounded secondary. A main power disconnect is included as for ease of service. The electrical panel is UL listed and complies with NEC provisions.
All components are IEC rated for long life and reduced maintenance. 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.
Air Purge
Upon initial start-up and mold/process change-out, you’ll need to purge all air and water from the system. The 6017 unit has appropriate valving to ensure complete purging. Procedures are covered in Chapter 3.
! 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.
6017 Series Hot Oil Large Temperature Control Units |
Page 13 |
Pressure Switch
A pressure switch is built into each unit to guard against heater damage. This feature prevents the heater elements from being energized unless the pump is running and fluid is in the system. After a preset time, the pump shuts down if the fluid pressure is not re-established. The pressure switch is preset at the factory; do not tamper with it.
Safety Thermostat
The safety thermostat is mounted on the side of the heater tank. This is to guard against the unlikely event of “runaway” heating. 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.
The safety thermostat is a manual reset type. All controller functions are locked out until the red "STOP" button is pushed. It is imperative that a qualified maintenance technician determine and correct the cause of the fault before resuming operation.
Reservoir Tank
A reservoir tank with sight gauge is standard; usable capacity is
•40 gallons (151 liters) on 6017L & 6017M units
•65 gallons (246 liters) on 6017P & 6017V units.
The tank permits thermal expansion of the heat transfer fluid, and provides make-up fluid.
Page 14 |
6017 Series Hot Oil Large Temperature Control Units |
! 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.
6017 Series Hot Oil Large Temperature Control Units |
Page 15 |
Figure 1
6017 Series Hot Oil Large Temperature Control Unit.
The unit shown below is a 6017P Model.
6017 Series Temperature Control Unit Specifications
Model |
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Heaters |
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Pump |
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Dimensions |
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Shipping |
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Number |
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Available capacities |
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Available capacities |
H |
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W |
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D |
Weight♠ |
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460 / 230 |
50 kW 100 kW 150 kW 200 kW |
90 gpm |
150 gpm |
200 gpm |
in. |
cm |
in. |
cm |
in. |
cm |
lbs. |
Kg |
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6017-L |
9 |
9 |
n/a |
n/a |
9 |
9 |
n/a |
62” |
158 |
30” |
76 |
60" |
153 |
1,900 |
862 |
6017-M |
9 |
9 |
n/a |
n/a |
9 |
n/a |
n/a |
62” |
158 |
30” |
76 |
60” |
153 |
1,900 |
862 |
6017-P |
9 |
9 |
9 |
9 |
9 |
9 |
9 |
62” |
158 |
46” |
117 |
60” |
153 |
3,200 |
1,452 |
6017-V |
9 |
9 |
9 |
9 |
9 |
9 |
9 |
62” |
158 |
46” |
117 |
60” |
153 |
3,200 |
1,452 |
♠ The actual shipping weights may vary based on options selected. The shipping weights listed are the maximum shipping weights for standard units of the listed cabinet size.
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Page 16 |
6017 Series Hot Oil Large Temperature Control Units |
2 Shipping Information
2-1 Unpacking and Inspection
You should inspect your Sterling/Sterlco 6017 Series hot oil large temperature control unit for possible shipping damage. If the container and packing materials are in re-usable condition, save them for reshipment if necessary.
Thoroughly 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 RGA (return goods authorization) number.
6017 Series Hot Oil Large Temperature Control Units |
Page 17 |
2-3 If the Shipment is Not Complete
Check the packing list. The apparent shortage may be intentional.
Back-ordered items are noted on the packing list. You should have:
;6017 Series hot oil large temperature control unit
;Bill of lading
;Packing list
;Operating and Installation packet
;Electrical schematic and panel layout drawings
;Component instruction manuals
Re-inspect the container and packing material to see if you missed any smaller items during unpacking. 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 the parts and services department immediately at [262] 641-8610. Have item and order numbers ready. 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 18 |
6017 Series Hot Oil Large Temperature Control Units |
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