Sterling 6017 User Manual
$30.00
Operation and Installation Manual
6017 Series
Large Hot Oil
Temperature Control Units
Important! Read Carefully Before Attempting to Install or Operate Equipment
Part No. 682.91540.00 Revision 3 Bulletin No. SC1-655-3
Write down your unit serial number(s) ________________ ________________
here for future reference ________________ ________________
________________ ________________
________________ ________________
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. 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
1 General Information .................................................7
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
2-1 Unpacking and Inspection.............................................................17
2-2 In the Event of Shipping Damages................................................17
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
3-1 Work Rules ................................................................................... 19
3-2 Installation Requirements.............................................................. 19
3-3 Connecting Piping......................................................................... 20
3-4 Making Electrical Connections...................................................... 26
Page 4 6017 Series Hot Oil Large Temperature Control Units
Table of Contents
4 Startup Preparations .............................................. 29
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
5-1 The Microprocessor Controller...................................................... 34
5-2 Identifying M2B Controller Panel Components..............................35
5-3 Using M2B Controller Keys...........................................................37
5-4 Identifying Control Panel Switches................................................39
5-5 Identifying System Status Board Indicators................................... 41
6 Preventive Maintenance.........................................46
6-1 Periodic Checks............................................................................ 46
6-2 Routine Servicing.......................................................................... 47
6-3 Draining the Unit for Storage......................................................... 50
6-4 Corrective Maintenance................................................................ 50
6-5 Maintaining the Pump ...............................................See Addendum
7 Troubleshooting ..................................................... 52
6017 Series Hot Oil Large Temperature Control Units Page 5
Charts and Figures
6017 Series Hot Oil Large Temperature Control Unit and
1
2
3
4
5
6
Specifications 16
6017 Unit Piping Setup 16
Typical Flow Schematic 24
Typical M2B Graphic and Button Control Panel 34
Control Panel Switches 39
System Status Board Indicators 41
Page 6 6017 Series Hot Oil Large Temperature Control Units
1 General Information
1-1 Introduction
Your Sterling/Sterlco 6017 Series hot oil temperature control unit
circulates thermal transfer-type oil through your process and to
precisely, automatically, and reliably maintain it at a 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
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.
lines. This does, of course, depend on the configuration
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
Pump
Ful-Flo Valve
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.
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.
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
Cooling
Optional
Connection Lines
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.
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.
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 DRAIN are:
COOLING WATER SUPPLY and
• 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
Safety Thermostat
Reservoir Tank
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.
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.
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
Page 14 6017 Series Hot Oil Large Temperature Control Units
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.
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 Heaters Pump Dimensions Shipping
Number Available capacities Available capacities H W D Weight♠
460 / 230 50 kW 100 kW 150 kW 200 kW 90 gpm 150 gpm 200 gpm in. cm in. cm in. cm lbs. Kg
6017-L
6017-M
6017-P
6017-V
♠ 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.
9 9
9 9
9 9 9 9 9 9 9
9 9 9 9 9 9 9
n/a n/a
n/a n/a
Page 16 6017 Series Hot Oil Large Temperature Control Units
9 9
9
n/a n/a 62” 158 30” 76 60” 153 1,900 862
n/a 62” 158 30” 76 60" 153 1,900 862
62” 158 46” 117 60” 153 3,200 1,452
62” 158 46” 117 60” 153 3,200 1,452
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
2-5 Returns
Do not return any damaged or incorrect items
until you receive shipping instructions from Sterling, Inc.
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.
Important!
Page 18 6017 Series Hot Oil Large Temperature Control Units
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