royal series 2016 u series oil temperature control...

Royal Series 2016 U Series Oil Temperature Control Units Reference Manual (PN: 882.12044.00 & 882.12046.00) for

Complete Operation and Installation Instructions (Available online at www.sterlco.com)

Sterling Products, Inc. Part No: 682.98487.11 2900 S. 160th Street • New Berlin, WI 53151 USA Bulletin No: HC2-345 Tel. 262.641.8600 • Fax 262.641.8653

Safety Concerns

Quickstart Installation Checklist (Refer to main manual for complete installation instructions).

1. Connect 3-phase power based on nameplate data. 2. Install properly sized plumbing between temperature control unit

and primary processing equipment (supply and return). 3. Install properly sized plumbing between temperature control unit

and cooling water supply and return. You must provide cooling water at 25 psig to 75 psig (172.4 kPa to 517.1 kPa/1.7 bar to 5.2 bar).

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

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

Start Up 1. Add fluid to the reservoir tank until the level is near the top of the sight glass. 2. Turn disconnect switch to ON position. 3. Depress the "Pump Start" button to start the pump. 4. Maintain the level about 4 inches from the bottom of the sight glass. 5. Air and Oil will be vented through the Vent Solenoid and into the reservoir tank for 10 minutes. 6. 2 minutes after the unit has built at least 5psi of pressure, select a set point of 100°F (PV) by pressing the

Up Arrow or Down Arrow keys, and switch unit into the "Auto" mode. 7. With 2 minute intervals increase the setpoint to 150 and 200°F. 8. Select a setpoint of 215ºF (102ºC) and continue to run until no more steam appears and pressure has

stabilized.

Shut Down 1. Switch the Mode switch to the “Manual Cool” position. 2. Allow temperature to stabilize at 120°F (50°C). 3. Push the Pump Stop button to de-energize the unit.

Advanced Controller




Spare Parts Location (See next page for Spare Parts List)




Spare Parts List (See previous page for Spare Parts Location)

Cooling Heat Exchanger -

Valves Complete Heat

Exchanger Replacement Tube

Bundle

1a 3.9 sq. ft. U-tube 106.00267.00 162.00047.10 6.9 sq. ft U-tube 106.00268.00 162.00047.11 13 sq. ft. U-tube 106.00169.00 162.00047.12 21 sq. ft. U-tube 106.00170.00 162.00047.13

1b ¾ inch (1.9 cm) 732.00013.02

Immersion Heaters 230/3/60 460/3/60 575/3/50

2 12-kW (1 req’d) 722.90603.04 722.90603.13 722.90603.16 12-kW contactor (2 req’d) 726.00270.02 726.00265.02 726.00265.02 18-kW (1 req’d) 722.90603.05 722.90603.14 722.90603.17 18-kW contactor (2 req’d) 726.00271.02 726.00269.02 726.00268.02 24-kW (1 req’d) 722.90603.06 722.90603.15 722.90603.18 24-kW contactor (2-req’d) 726.00272.02 726.00270.02 726.00269.02 36-kW (2 req’d) 722.90603.05 722.90603.14 722.90603.17 36-kW contactor (2 req’d) 726.00273.02 726.00271.02 726.00271.02 48-kW (2 req’d) 722.90603.06 722.90603.15 722.90603.18 48-kW contactor (2 req’d) 726.00346.02 726.00272.02 726.00271.02

Motor Pumps 230/3/60 460/3/60 575/3/50 3 18 to 24 gpm Pump 075.00370.02 075.00370.02 075.00370.02 1-HP (0.75 kW) motor 720.09240.00 720.09240.00 720.09274.00 1-HP (075 kW) MCP 726.00334.00 726.00330.00 726.00330.00 1.5-HP (1.1 kW) motor 720.09242.00 720.09242.00 720.09028.00 1.5-HP (1.1 kW) MCP 726.00336.00 726.00334.00 726.00334.00 2-HP (1.5 kW) motor 720.09218.00 720.09218.00 720.09322.00 2-HP (1.5 kW) MCP 726.00336.00 726.00334.00 726.00334.00 50 gpm Pump 075.00421.02 075.00421.02 075.00421.02 3-HP (2.25 kW) motor 720.09638.00 720.09638.00 720.09247.00 3-HP (2.25 kW) MCP 726.00337.00 726.00336.00 726.00334.00

Pump Seal Kits

4 075.00370.02 Pump 162.00030.144 075.00421.02 Pump 162.00030.161

Common Parts 5 Pressure switch ** 733.00029.00

6 Safety thermostat (1 per heater) 724.00735.00

Safety thermostat probe (1 per heater) 701.00115.00

7 Relief valve 044.00138.00

8 18 to 24 gpm Ful-flo bypass valve 044.00239.00

50 gpm Ful-flo bypass valve 044.00164.00

9 1000 Ohm RTD Probe 692.07369.28

Temperature control module 601.00522.02 AEC

Document # 2005-spares-tcu

** Reference complete manual (PN: 682.88108.00) for proper settings and installation.




Troubleshooting - Quick Guide Problem Possible cause Solution

Unit does not turn on

No power Check main disconnect, fuses, wiring, and power lead to unit. Wrong voltage supplied to unit Voltage must be within plus or minus 10% of nameplate rating Defective START push button Replace Control circuit fuse blown Replace Defective control transformer Check transformer. Replace if necessary.

Unit does not run

Broken or loose wire in pump motor control circuit Locate and repair

Pump motor contactor holding coil is open Repair or replace Pump overload light on Reset and test each leg for balanced amp draws

Temperature fluctuations/rapid cycling from hot to cold.

Undersized connectors/lines. Increase size of connectors/fluid lines.

Long connecting lines between unit and mold. Move the unit closer to the process and shorten connecting lines.

Blocked line in process. Check process for debris or deposits. Clean mold. Carbon build-up in unit piping or fittings. Clean or replace affected piping. Replace fluid.

Unit overheats or does not 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.

Unit does not heat properly/cannot 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.

Clogged Y strainer. Clean Y strainer.

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.

Rapid drop in pressure/no pressure.

Leaks in connecting lines. Inspect/replace faulty line or connection. Air in circulating lines. Preform venting sequence in Chapter 3. Low fluid. Check fluid level in sight glass. Add fluid if required. Defective Ful-Flo valve. See Chapter 3.

Water in fluid. Drain water from low point in piping (see Chapter 3), 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 warn pump components. V belt broken/worn. Replace as required.

Noisy pump. Water in fluid. Drain water from low point in piping ( see Chapter 3), or boil

water off. Severely degraded fluid. Drain and flush system. Replace fluid.

royal series 2016 u series oil temperature control...

Documents