Sterlco 6017 Series Operation And Installation Manual Download Page 1

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Summary of Contents for 6017 Series

Page 1: ...RECENT ADDITIONS INDUSTRY SERVICES JOIN OUR MAILING LIST SELL US YOUR MACHINE If we can be of any assistant or if you have any questions please don t hesitate to contact us at 847 360 9170 You may also visit our website at https www diecastmachinery com Thank you ...

Page 2: ...n 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 2 Bulletin No SC1 655 30 00 ...

Page 3: ... ________________ ________________ ________________ ________________ 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 2003 All rights reserved Effective 10 17 2003 Part No 682 91540 00 Revision 2 Bulletin No SC1 655 ...

Page 4: ...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 GROUNDE...

Page 5: ...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 6: ...tors 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 Addendu...

Page 7: ...harts and Figures 1 6017 Series Hot Oil Large Temperature Control Unit and Specifications 16 2 6017 Unit Piping Setup 16 3 Typical Flow Schematic 24 4 Typical M2B Graphic and Button Control Panel 34 5 Control Panel Switches 39 6 System Status Board Indicators 41 ...

Page 8: ...n 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...

Page 9: ...act 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 enclos...

Page 10: ...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 st...

Page 11: ...rom 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...

Page 12: ...lly 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 maxim...

Page 13: ...ou 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 ke...

Page 14: ...nts 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 ...

Page 15: ...ety 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 but...

Page 16: ...Large Temperature Control Units Page 15 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 ...

Page 17: ...ties 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 n a n a n a 62 158 30 76 60 153 1 900 862 6017 M n a n a n a n a 62 158 30 76 60 153 1 900 862 6017 P 62 158 46 117 60 153 3 200 1 452 6017 V 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 t...

Page 18: ...ng 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 aut...

Page 19: ...iner 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 1 800 783 ...

Page 20: ...pproved tools and devices Disconnect the electricity before maintenance or service If the unit is installed with a power cord that can be un plugged 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 Installati...

Page 21: ...r precautions and instructions for the thermal fluid you are using Note Before storing your 6017 temperature control unit make sure you remove all residual water with compressed air to avoid a potential freezing hazard Note the following table of ambient temperature ranges permitted for storage and operation Ambient storage range Ambient operation range ºF ºC ºF ºC 40ºF to 185ºF 40ºC to 85ºC 4ºF t...

Page 22: ... supplied shut off valves on all piping connections Use common black welded pipe for permanent installations The 6017 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 w...

Page 23: ...sfer surfaces slowing water flow and causing fluid temperature control problems Sterling Inc sells a complete line of water treatment equipment that can reduce downtime and maintenance costs Run properly sized cooling water lines never smaller than the outlets on the 6017 unit If external piping is larger than 6017 unit connections reduce the size of the piping at the unit Connecting Vent Piping Y...

Page 24: ... the process and the FROM PROCESS hookup to the exit of the process Connect the COOLING WATER SUPPLY to your plant water supply Connect the COOLING WATER DRAIN line to an open drain or to the return line of your central water system If returning to a central water system use a condensate return tank to avoid a standing water column on the heat exchanger drain line CAUTION If you are routing the dr...

Page 25: ...eat exchanger is optional and the Vent Valve is also known as the Blow Off Valve Vent Valve open for purge closed for run open for pump reverse Return Valve closed for purge open for run closed for pump reverse Reservoir Tank Open to atmosphere at all times unless nitrogen blanket provisions are present ...

Page 26: ...ocess to be vented without contaminating the rest of the piping and unit to be contaminated with air This is accomplished by the following steps once the process is reconnected to the unit and the isolation valves are still closed Note during this process the internal blow off valve is closed and the return valve can be open 1 Open the external vent valve 2 Open the isolation valve that is deliver...

Page 27: ...e customer is responsible to properly size and install a suitable disconnect 3 Refer to National Electric Code NEC 430 24 26 for proper feed conductor and supply disconnect sizing 4 Voltages must be within plus or minus ten percent 10 of the nameplate rating 5 Maintain a safe ground and disconnect the power supply before servicing the unit A qualified electrician should make electrical connections...

Page 28: ...S OPERATOR INJURY OR DEATH MAKE SURE THAT ALL ELECTRICAL CONNECTIONS ARE MADE BY A QUALIFIED ELECTRICIAN AND THAT ALL CONNECTIONS ARE TIGHT Make all electrical supply connections at the front of the unit An access panel covers all electrical connections Run electrical connections to the supply terminals from either side of the unit Make sure that all three phases are wired correctly The pump runs ...

Page 29: ...Page 28 6017 Series Hot Oil Large Temperature Control Units Notes ...

Page 30: ...gauge If the gauge indicates positive pressure rotation is correct If not disconnect power and reverse the incoming power leads 5 As fluid is drawn out of the reservoir tank to fill the process the fluid level will fall in the tank Continue to add fluid to maintain the level about 4 inches from the bottom of the sight glass CAUTION You must purge the system of air before the heating cycle Personal...

Page 31: ...Repeat Steps 9 12 if this occurs UNIT START UP WITH AUTOVENT SOLENOID The highly engineered controls and controller make this unit almost self operating Before you can begin heating it will be necessary to perform the following start up procedures This will ensure that all air is vented from the system to prevent fluid degradation and damage to the heater The autovent solenoid operates just like t...

Page 32: ...oiled off before continuing operation Select a setpoint of 215 F 102ºC and observe the reservoir tank vent for any signs of escaping steam Continue to run at 215ºF 102ºC until no more steam appears and pressure has stabilized Restart the Blow Off cycle as necessary if it times out 11 When fluid level has stabilized and air and water are purged from the system open the Return Valve all the way And ...

Page 33: ...to drain the mold and process lines Note that this is just the opposite of unit start up air purge 1 Cool fluid to 150 F 66 C maximum 2 Depress the PUMP STOP push button 3 Close the Return Valve 4 Open the Blow Off Valve with autovent the valve will open on its own 5 Depress and hold the PUMP REVERSE push button The pump will then run in reverse drawing fluid from the mold and lines and into the r...

Page 34: ...6017 Series Hot Oil Large Temperature Control Units Page 33 Notes ...

Page 35: ... fluid temperature The controller is fully factory tested Set the process temperature set point you want and the controller does the rest Built in range of operation on the controller is 0 F to 550 F 18ºC to 288ºC Figure 4 Typical M2B Graphic and Button Control Panel SET POINT INDEX HI ALARM UP DISPLAY ENTER ALARM LO DOWN RUN LO HEAT COOL HI HEAT STATUS ALARM HI LO PRESSURE SET POINT FLUID THERMO ...

Page 36: ...t also lists parameter symbols during setup and error messages if an error occurs Status Indicators RUN Indicator The RUN indicator is on during normal operation and flashes during the auto tuning sequence HI HEAT Indicator The HI HEAT indicator is on when fluid heaters are at 100 capacity to rapidly raise fluid temperature LO HEAT Indicator The LO HEAT indicator is on when fluid heaters are at 50...

Page 37: ...CU shuts down and resumes operation only when a proper level of fluid pressure is restored SAFETY THERMO Indicator The SAFETY THERMO indicator is on when an over temperature condition occurs The heater outputs are then disabled the pump continues to operate and the COOL solenoid energizes This is a fatal fault condition requiring that main power be disconnected to reset the M2B controller HI LO AL...

Page 38: ...ey then press the UP UP Arrow key to increase the set point value or press the DOWN DOWN Arrow key to decrease the set point value displayed on the SET POINT LED screen UP UP Arrow Key Press the UP UP Arrow key to increment or advance the values or settings on the LED screens DOWN DOWN Arrow Key Press the DOWN DOWN Arrow key to decrement or reduce the values or settings on the LED screens Importan...

Page 39: ...M Key Press and hold the HI ALARM HI ALARM key then press the UP UP Arrow key to increase the alarm high limit value or press the DOWN DOWN Arrow key to decrease the alarm high limit value on the SET POINT LED screen Refer to your Sterling Sterlco M2B Temperature Control Owner s Manual for a list of functions available using this key ALARM LO LO ALARM Key Press and hold the ALARM LO LO ALARM key t...

Page 40: ...gital Flow Screen Optional The optional digital flow screen displays process flow in gallons per minute gpm No customer usable control is necessary Depending on option level and setup flows can be measured at rates reaching and exceeding 75 gallons per minute 284 lpm 5 4 Identifying Control Panel Switches This section lists the descriptions and functions of the control panel switches These switche...

Page 41: ...he vent cycle timer Use this feature to purge air and water from the unit and process This is used when the Autovent Cycle Option is added to the unit Mode Select With the pump running you can select the AUTO position or the MAN COOL manual cooling position with the Mode Select switch Select AUTO mode to energize the controller permitting it to monitor and control the process The switch automatica...

Page 42: ...ifying System Status Board Indicators The system status board is located next to the controller panel It displays indicator lights to show current operation status letting you analyze system performance Figure 6 System Status Board Indicators PUMP OVERLOAD PUMP REVERSE PUMP FORWARD SYSTEM STATUS MODE POWER ON AUTO HEATER BYPASS RELIEF VALVE ON SAFETY THERMO DELIVERY STRAINER RETURN LOW PRESSURE HE...

Page 43: ...ly during normal operation Heater On Indicator Light The Heater On indicator illuminates when the heater energizes This indicator illuminates intermittently when the controller energizes and de energizes the heater as the heating cycle requires Cool Solenoid Indicator Light The Cool Solenoid indicator illuminates when the cooling solenoid energizes This indicator illuminates intermittently as the ...

Page 44: ...overload fault and the unit shuts down Always correct the alarm condition before returning to normal operation Low Pressure Indicator Light The Low Pressure indicator light illuminates when the unit has low heat transfer fluid pressure This is an alarm condition so the audible alarm activates to notify you of the low pressure fault and disables controller outputs permitting the pump to continue to...

Page 45: ... high Carefully remove just enough fluid so this indicator light shuts off and an adequate volume is maintained in the reservoir Low Level Indicator Light The low fluid level alarm is an available option The Low Level indicator light illuminates when the heat transfer fluid level in the system is too low This is an alarm condition so the audible alarm activates to notify you of the low fluid level...

Page 46: ...6017 Series Hot Oil Large Temperature Control Units Page 45 Notes ...

Page 47: ...is unit disconnect all power to the unit let the unit cool down completely and turn off the water Failure to follow these directives can result in serious injury or death 6 1 Periodic Checks Making Daily Checks Check fluid level add fluid as needed Check all connecting lines hoses and connectors for wear or damage Making Monthly Checks Check for leaks developing at the pump seal gaskets and other ...

Page 48: ...ially at the entrance point to the electrical enclosure Have a qualified electrician perform this inspection Check the mounting bolts on the pump the motor and the heater flange for tightness Remove the heat exchanger tube bundle and check it for lime and mineral deposits Carefully clean the bundle as needed 6 2 Routine Servicing Your hot oil temperature control unit requires little in preventive ...

Page 49: ...ate Adjust the pump drive belt tension Use the belt tensioning specifications listed in this chapter on Page 51 Make sure that the motor pulley is properly aligned with the pump pulley use a straightedge to check Tighten motor mounting bolts after realignment Inspect the screen in the Y strainer for accumulations of debris Clean as needed Servicing the Unit Every Three Months Remove and clean the ...

Page 50: ...000 1 000 0 61 17 0 1 2 25 40 HP 8 000 4 000 750 0 81 23 0 1 5 Caution To avoid damage to motor bearings grease must be kept free of dirt For an extremely dirty environment contact your Baldor distributor or an authorized Baldor Service Center for additional information With Grease Outlet Plug 1 Clean all grease fittings 2 Remove grease outlet plug 3 If motor is stopped add the recommended amount ...

Page 51: ... is then cooled drained and packed for shipment If the unit stands idle for a long time before being installed in your factory gaskets can dry out and possibly leak when you start the unit In most cases these gaskets soon swell and form a tight seal If not you may need to tighten the bolts to stop the leak Similarly rough handling in shipping may sometimes cause minor leaks upon startup you may ne...

Page 52: ...6017 Series Hot Oil Large Temperature Control Units Page 51 ...

Page 53: ...ch Return and Delivery probes 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 d...

Page 54: ...l Cool mode and listen for valve operation Replace if faulty Leaks in connecting lines Inspect replace faulty line or connection Air in circulating lines Perform 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 Al...

Page 55: ...Page 54 6017 Series Hot Oil Large Temperature Control Units Service Notes ...

Page 56: ...6017 Series Hot Oil Large Temperature Control Units Page 55 Service Notes ...

Page 57: ...Page 56 6017 Series Hot Oil Large Temperature Control Units Service Notes ...

Page 58: ...r Parts List included in your information packet for replacement part numbers Service Department Call toll free 8am 5pm CST 800 783 7835 or call 414 354 0970 Sterling Sterlco has a qualified service department ready to help Service contracts are available for most Sterling Sterlco products Sales Department Call 414 354 0970 Monday Friday 8am 5pm CST Sterling Sterlco products are sold by a network ...

Page 59: ...size letters are combined with series number 125 and 4125 indicating both unmounted or mounted pump unit This manual deals only with Series 125 and 4125 Heavy Duty Bracket Mounted Pumps Refer to Figures 1 through 15 for general configuration and nomenclature used in this manual Pump specifications and recommendations are listed in Catalogue Section 141 Series 125 and 4125 Heavy Duty Bracket Mounte...

Page 60: ...tment to control leakage as packing runs in Make initial adjustments carefully and do not over tighten packing gland After initial adjustment inspection will reveal need for packing gland adjustment or packing replacement Refer to instructions under Disassembly page 4 and Assembly page 5 regarding repacking pump CLEANING PUMP Keep pump as clean as possible This will facilitate inspection adjustmen...

Page 61: ...ead Plate 7 Bearing Spacer Collar Inner 20 Casing 33 Capscrew for Head 8 Ring Half Round 21 Nut for Flanges 34 Relief Valve Gasket 9 End Cap Inner 22 Capscrew for Flanges 35 Capscrew for Relief Valve 10 Packing Gland 23 Pipe Flange Gasket 36 Internal Relief Valve 11 Packing Gland Nut 24 Pipe Plug 37 Cover Plate Relief Valve 12 Packing Gland Capscrew 25 Rotor and Shaft 13 Packing 26 Idler and Bushi...

Page 62: ...UTIONS ARE UNDERSTOOD FAILURE TO FOLLOW ABOVE LISTED PRECAUTIONARY MEASURES MAY RESULT IN SERIOUS INJURY OR DEATH SECTION TSM 141 2 ISSUE C PAGE 4 OF 13 1 Mark head and casing before disassembly to insure proper reassembly The idler pin which is offset in pump head must be positioned toward and equal distance between port connections to allow for proper flow of liquid through pump Remove head from...

Page 63: ... with carbon graphite bushing Refer to Installation of Carbon Graphite Bushings page 11 6 Using a 010 to 015 inch head gasket install head and idler assembly on pump Pump head and casing were marked before disassembly to insure proper reassembly If not be sure idler pin which is offset in pump head is positioned toward and equal distance between port connections to allow for proper flow of liquid ...

Page 64: ...l it is tight against bearing Refer to Figure 5 page 5 11 Put Iockwasher and locknut on shaft Insert length of hardwood or brass through port opening between rotor teeth to keep shaft from turning Tighten locknut to 120 150 ft lbs Torque LS or 170 190 ft lbs Torque Q QS M Bend one tang of lockwasher into slot of locknut If tang does not line up with slot tighten locknut until it does Failure to ti...

Page 65: ...DEATH 1 Mark head and casing before disassembly to insure proper reassembly The idler pin which is offset in pump head must be positioned toward and equal distance between port connections to allow for proper flow of liquid through pump Remove head from pump Do not allow idler to fall from idler pin Tilt top of head back when removing to prevent this Avoid damaging head gasket If pump is furnished...

Page 66: ...g screw cap must always point toward suction port Refer to Figures 1 2 and 3 on page 1 For relief valve repair or adjustments Refer to Pressure Relief Valve Instructions page 11 4 Clean rotor shaft and bracket seal housing bore Be sure they are free of dirt grit and scratches Gently radius leading edge of shaft diameter over which seal must be placed 5 Install seal set collar Examine set collar fo...

Page 67: ...h of hardwood or brass from port opening 13 Adjust pump end clearance Refer to Thrust Bearing Adjustment page 10 14 Lubricate all grease fittings with multi purpose grease NLGI 2 SET COLLAR 6 Sealing faces on mechanical seals should not be touched with anything but fingers or a clean cloth A tapered sleeve is available at extra cost for Q QS and M pumps from Viking Pump for seal installation on sh...

Page 68: ... TOTAL END CLEARANCE LS 2 5 005 Q QS AND M 5 010 FIGURE 11 TAPERED INSTALLATION SLEEVE SHAFT SECTION TSM 141 2 ISSUE C SEAL ACCESS HOLE FOR SETSCREWS MECHANICAL SEAL ROTARY MEMBER SEAL SEAT FIGURE 10 OPTIONAL MECHANICAL SEAL SEAL SEAT GASKET LEFT SIDE OF PUMP SEAL HOLDER SEAL HOLDER PLATE MECHANICAL SEAL ROTARY MEMBER LOCKNUT OUTER LIP SEAL INNER LIP SEAL OUTER END CAP NYLON INSERT OUTER SPACER CO...

Page 69: ...e bushings must be installed by a shrink fit 1 Heat bracket or idler to 750 F 2 Install cool bushings with a press 3 If facilities are not available to reach 750 F temperature it is possible to install with 450 F temperature however the lower the temperature the greater the possibility of cracking bushing Consult factory with specific questions on high temperature applications Refer to Engineering...

Page 70: ...overs adjusting screw Loosen locknut which locks adjusting screw so pressure setting will not change during operation of pump 2 Install a pressure gauge in discharge line for actual adjustment operation 3 Turn adjusting screw in to increase pressure and out to decrease pressure 4 With discharge line closed at a point beyond pressure gauge gauge will show maximum pressure valve will allow while pum...

Page 71: ...o be defective in workmanship or material they will be replaced or repaired free of charge FOB Cedar Falls Iowa Viking assumes no liability for consequential damages of any kind and the purchaser by acceptance of delivery assumes all liability for the consequences of the use or misuse of Viking products by the purchaser his employees or others Viking will assume no field expense for service or par...

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