Sterling Water Heater User Manual

Micro Series Water Temperature Control Units

Reference Manual (PN: 682.89373.00) for

Quickstart Installation Checklist

(Refer to main manual for complete installation instructions).

1. Connect 3-phase power ba sed on nameplate data.

2. Install properly sized pl umbing between temperature control unit
and primary processing equipment (supply and return).

3. Install properly sized pl umbing between temperature control unit
and cooling water supply and return. Cooling water supply must be
at least 16 psi (110 kPa/1.1bar) for a 250˚F (121°C)
and 55 psi (379 kPa/3.8bar) for a 300˚F (149°C) configuration.

4. Ensure proper pump rotation. (The pump should be moving
clockwise while looking at the motor end).

Complete Operation and Installation Instructions

(Available online at www.sterlco.com)

configuration

Unit Operation

(Refer to main manual and controller manual for complete operating instructions).

Start Up

1. Push the ON/OFF rocker switch to the ON ( | ) to energize the unit and begin the temperature control cycle.
The switch will be illuminated whenever the unit is on.

2. The unit will automatically vent for approximately one minute.

3. If needed, press and hold the vent button to purge any additional air from the process loop.

4. Set process temperature (PV) by pressing the Up Arrow or Down Arrow keys.

Shut Down

1. Adjust set point below 150˚ F (66˚ C).
Allow unit to stabilize.

2. Push ON/OFF rocker switch to the OFF
( 0 ) position to de-energize the unit.

Standard Controller

Sterling, Inc. Part No: 682.92594.10
2900 S. 160
Tel. [phone] • Fax [phone]

th

Street · New Berlin, WI 53151 · USA Bulletin No: HC2-320

Micro Series Water Temperature Control Units

Reference Manual (PN: 682.89373.00) for

Complete Operation and Installation Instructions

(Available online at www.sterlco.com)

Spare Parts Location

(See next page for Spare Parts List)

Sterling, Inc. Part No: 682.92594.10
2900 S. 160
Tel. [phone] • Fax [phone]

th

Street · New Berlin, WI 53151 · USA Bulletin No: HC2-320

Micro Series Water Temperature Control Units

Reference Manual (PN: 682.89373.00) for

(See previous page for Spare Parts Location)

Cooling Valves

Immersion

Heaters

2

Motor Pumps

3

Pump Seal

Kits

4

Common Parts

5
6
7
8

AEC

Document #

** Reference complete manual (PN: 682.89374.00) for proper settings and installation.

¼-inch (0.64 cm) x 5/32 orifice 732.00024.02

230/3/60 460/3/60 575/3/50

3-kW (3 req’d)

3-kW contactor

6-kW (3 req’d)

6-kW contactor

9-kW (3 req’d)

9-kW contactor

½-HP (0.37 kW) 075.00915.00 – 250 °F (121°C) 075.00915.00 – 250 °F (121°C)

½-HP MCP 726.00304.02 726.00303.02 726.00302.02

¾-HP (0.56 kW) 075.00856.00 – 250 °F (121°C) 075.00856.00 – 250 °F (121°C)

¾-HP MCP 726.00305.02 726.00303.02 726.00303.02

½-HP (0.37 kW)
¾-HP (0.56 kW)

2005-spares-tcu

Complete Operation and Installation Instructions

(Available online at www.sterlco.com)

Spare Parts List

Standard Solenoid

722.00128.20 722.00128.19 722.00130.04

726.00268.02 726.00267.02 726.00267.02

722.00128.01 722.00128.03 722.00130.01

726.00270.02 726.00267.02 726.00265.02

722.00128.05 722.00128.06 722.00130.02

726.00270.02 726.00268.02 726.00268.02

230/3/60 460/3/60 575/3/50

250 °F (121°C) (SC/C/EPDM)

162.00024.136

250 °F (121°C) pressure switch ** 692.86688.00K

250 °F (121°C) safety thermostat 724.00665.00

Relief valve 044.00138.00

Type “K” thermocouple 701.00124.00

Temperature control module (Cal) less outputs 692.89720.00

N/A

075.00915.02 – 250 °F
(121°C)

075.00856.02 – 250 °F
(121°C)

Sterling, Inc. Part No: 682.92594.10
2900 S. 160

th

Street · New Berlin, WI 53151 · USA Bulletin No: HC2-320

Tel. [phone] • Fax [phone]

Problem Possible cause Solution

Unit does not turn on

Unit does not run

Temperature fluctuations/
rapid cycling from hot to
cold.

Unit overheats or does not
cool

Unit does not heat/cannot
achieve set point

Micro Series Water Temperature Control Units

Reference Manual (PN: 682.89373.00) for

No power.

Wrong voltage supplied to unit.
Defective on/off switch. Replace.

Control circuit fuse blown. Replace.
Defective control transformer. Check transformer.
Broken or loose wire in pump motor control circuit. Locate and repair.
Pump motor contactor holding coil is open. Repair or replace.

Low water pressure light on.

Water supply to unit is turned off. Open water supply.
Pump overload light on.
Undersized connectors/ water lines. Increase size of connectors/ water lines.
Long connecting lines between unit and mold.

Serpentine flow through mold.
Blocked water line in mold.

Quick disconnect fitting with check valve. Remove and replace fitting or valve.
Lime buildup in unit piping. Clean or replace.
Drain is plugged or excessive back pressure is in drain
line.

Faulty solenoid valve.

Controller Cool output relay open. Replace output relay.
Solenoid valve is not operating, but COOL LED is on.

Solenoid coil circuit is open.

Modulating valve is not operating, but OUT2 LED is on.
Insufficient pressure differential between cooling

WATER IN and OUT lines.
Cooling valve is undersize. Replace cooling valve with a larger valve.

Defective heater contactor.

Defective immersion heater.

Heater contactor is not energizing, but HEAT LED is on.

Faulty/dirty solenoid valve.

Complete Operation and Installation Instructions

(Available online at www.sterlco.com)

Troubleshooting - Quick Guide

Check main disconnect, fuses, wiring, and
power lead to unit.

Voltage must be within plus or minus 10% of
nameplate rating.

Check for at least 16 psig (110.32 kPa/1.1
bars) water pressure on WATER IN or CITY
WATER MAKEUP.

Reset and test each leg for balanced amp
draws.

Move the unit closer to the mold and shorten
connecting lines.
Connect lines for parallel flow instead of
series flow.
Check mold for metal chips or lime buildup.
Clean mold.

Clear drain line or eliminate back pressure
condition.

Test solenoid valve by pressing VENT
button and listen for valve operation.
Replace if faulty.

Set process temperature to minimum and
check for magnetism on solenoid coil top.

Check coil resistance. If MΩ range, replace
solenoid coil.

Set process temperature to minimum and
check for complete travel of valve.

Find a means to get less back pressure in
the WATER OUT line.

Visually inspect coil and contacts;
repair/replace defective contactors.

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

Set process temperature to maximum and
check for control voltage at heater contactor.

Press VENT button several times to flush
the valve.

Sterling, Inc. Part No: 682.92594.10
2900 S. 160
Tel. [phone] • Fax [phone]

th

Street · New Berlin, WI 53151 · USA Bulletin No: HC2-320