Page 2 - here for future reference
Page 2 6017 Series Hot Oil Large Temperature Control Units Write down your unit serial number(s) ________________ ________________ here for future reference ________________ ________________ ________________ ________________ ________________ ________________ Sterling/Sterlco is committed to a contin...
Page 3 - Safety Considerations
6017 Series Hot Oil Large Temperature Control Units Page 3 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 code...
Page 4 - Table of Contents; General
Page 4 6017 Series Hot Oil Large Temperature Control Units Table of Contents 1 General Information ................................................. 7 1-1 Introduction ..................................................................................... 7 1-2 Necessary Documents .......................
Page 5 - Startup; Fluid; Preventive
6017 Series Hot Oil Large Temperature Control Units Page 5 Table of Contents 4 Startup Preparations .............................................. 29 4-1 Starting the Unit ............................................................................ 29 4-2 Shutting Down the Unit ........................
Page 6 - Charts and Figures
Page 6 6017 Series Hot Oil Large Temperature Control Units Charts 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 Stat...
Page 7 - and; of your process, and any restrictions within the mold.; Documents; The manuals for accessories and options you’ve selected.
6017 Series Hot Oil Large Temperature Control Units Page 7 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 yo...
Page 8 - Covered
Page 8 6017 Series Hot Oil Large Temperature Control Units 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 spec...
Page 9 - Options; Immersion Heaters
6017 Series Hot Oil Large Temperature Control Units Page 9 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: ...
Page 10 - Heater Tank
Page 10 6017 Series Hot Oil Large Temperature Control Units 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 veloci...
Page 11 - line to the return; Cooling; Optional; Connection Lines; Connections for
6017 Series Hot Oil Large Temperature Control Units Page 11 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 hea...
Page 12 - WARNING; Electrical System Controls
Page 12 6017 Series Hot Oil Large Temperature Control Units 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 ...
Page 13 - Electrical Panel and System Components; unit has; Make sure you properly purge the system of air; before; starting the heater cycle.
6017 Series Hot Oil Large Temperature Control Units Page 13 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 machin...
Page 14 - Pressure Switch; do; Safety Thermostat; resuming operation.; Reservoir Tank; A reservoir tank with sight gauge is standard usable capacity is
Page 14 6017 Series Hot Oil Large Temperature Control Units 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 sh...
Page 16 - Figure 1
Page 16 6017 Series Hot Oil Large Temperature Control Units 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 ...
Page 17 - Shipping; -1 Unpacking and Inspection; According to the contract terms and conditions of the Carrier,
6017 Series Hot Oil Large Temperature Control Units Page 17 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,...
Page 18 - -3 If the Shipment is Not Complete; contact the parts and; Hold the items until you receive shipping; Do not return any damaged or incorrect items
Page 18 6017 Series Hot Oil Large Temperature Control Units 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 ;...
Page 19 - Installation; Rules; Work with approved tools and devices.; maintenance or service.; Requirements; Installation Location Considerations; Allow
6017 Series Hot Oil Large Temperature Control Units Page 19 3 Installation 3-1 Work Rules The installation, operation, and maintenance of this equipment must be conducted in accordance with all applicable work and safety codes for the installation location. This may include, but is not limited to OS...
Page 20 - CAUTION; Before storing your 6017 temperature control unit, make; Piping
Page 20 6017 Series Hot Oil Large Temperature Control Units Make sure that the unit location is not in a confined space to ensure proper air circulation. Special air circulation/ventilation is required for units operating at temperatures exceeding 500ºF (260ºC). Vapors can escape from areas such as ...
Page 21 - The customer is responsible for conversions to metric standards.; independently; Piping Considerations for Mobile Installations
6017 Series Hot Oil Large Temperature Control Units Page 21 The following table lists 6017 TCU pipe sizes. 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) Wat...
Page 22 - Connecting Process Piping; Carefully inspect all components before installation.; Connecting Cooling Water Piping; must; covered
Page 22 6017 Series Hot Oil Large Temperature Control Units Connecting Process Piping ! CAUTION • Hoses, valves and other components in your process must be able to withstand the 6017 unit's maximum temperatures and pressures. • Maximum temperatures and pressures are listed on the unit nameplate. • ...
Page 24 - Figure 3
Page 24 6017 Series Hot Oil Large Temperature Control Units Figure 3 Typical Flow Schematic Note: The heat 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 fo...
Page 25 - Figure 4
6017 Series Hot Oil Large Temperature Control Units Page 25 Figure 4 Custom Process Piping The optimum location for venting is on the top of the overhead return piping above the unit. The customer is encouraged to add an extra vent (Blow-Off) valve at this point. With this new Blow-Off Valve locatio...
Page 26 - Making Electrical Connections; Provide a correctly sized and protected power supply to the unit.; Locate disconnects in an; easily accessible location.
Page 26 6017 Series Hot Oil Large Temperature Control Units 3-4 Making Electrical Connections These units are designed for three-phase voltage operation. Refer to the unit nameplate for proper voltage and amperage requirements, and make sure your electrical service conforms. Check the unit nameplate...
Page 27 - DANGER; The pump runs
6017 Series Hot Oil Large Temperature Control Units Page 27 Check the unit nameplate for correct voltage and amperage before making electrical connections! ! DANGER IMPROPER ELECTRICAL CONNECTIONS CAN DAMAGE THE UNIT AND CAUSE SERIOUS OPERATOR INJURY OR DEATH! MAKE SURE THAT ALL ELECTRICAL CONNECTIO...
Page 29 - -1 Starting the Unit; Close the Return Valve inside the unit.; You must purge the system of air before the heating cycle.
6017 Series Hot Oil Large Temperature Control Units Page 29 4 Startup Preparations 4-1 Starting the Unit UNIT START-UP (WITH MANUAL BLOW-OFF VALVE) The highly engineered controls and controller make this unit almost self operating. Before you can begin heating, it will be necessary to perform the fo...
Page 32 - -2 Shutting Down the Unit; The reservoir tank may not have adequate volume
Page 32 6017 Series Hot Oil Large Temperature Control Units 4-2 Shutting Down the Unit UNIT SHUT DOWN (WITH AUTOVENT SOLENOID OR MANUAL VENT VALVE) Cool the unit down by switching the Mode switch to the "Manual Cool" position. This will disable the heaters ( i.e. prevent the controller from ...
Page 34 - Using Controls and Indicators; -1 The Microprocessor Controller; STATUS; SET POINT; DISPLAY
Page 34 6017 Series Hot Oil Large Temperature Control Units 5 Using Controls and Indicators 5-1 The Microprocessor Controller The M2B controller is an easy-to-operate microprocessor-based PID control device. When the process reaches the set point, the PID control cycles the cooling valve and/or imme...
Page 35 - -2 Identifying M2B Controller Panel Components; Screen Displays
6017 Series Hot Oil Large Temperature Control Units Page 35 5-2 Identifying M2B Controller Panel Components Screen Displays SET POINT Numeric LED During normal operation, the SET POINT LED on the controller displays the process set point you want the unit to maintain. It also displays parameter and ...
Page 36 - Alarm Indicators; fatal fault condition; DEL
Page 36 6017 Series Hot Oil Large Temperature Control Units FROM PROCESS Indicator The FROM PROCESS indicator is on when the PROCESS LED screen on the controller displays the temperature of the incoming fluid. U T Indicator The U T indicator is on when the PROCESS LED screen on the controller displa...
Page 37 - -3 Using M2B Controller Keys; The Sterling, Inc. warranty does not cover TCU failures
6017 Series Hot Oil Large Temperature Control Units Page 37 MOTOR FAIL Indicator The MOTOR FAIL indicator is on during improper pump rotation, motor out of phase, or thermal motor overload conditions. This is a fatal fault condition , requiring that main power be disconnected to reset the M2B contro...
Page 38 - ENTER Key
Page 38 6017 Series Hot Oil Large Temperature Control Units ENTER ENTER Key The ENTER ENTER key is used with the INDEX INDEX key menu to store the value or the item that was changed. If this key is not pressed, the previously-stored value or item is retained. INDEX INDEX Key Each press of the INDEX ...
Page 39 - DISPLAY Key; Press the; key to advance through the display; Digital Flow Screen; -4 Identifying Control Panel Switches; Figure 5
6017 Series Hot Oil Large Temperature Control Units Page 39 DISPLAY DISPLAY Key Press the DISPLAY DISPLAY key to advance through the display menu. Each key press increments to the next available function. The screen returns to delivery temperature after thirty (30) seconds of inactivity. Refer to yo...
Page 40 - Pump Start; Pump Reverse
Page 40 6017 Series Hot Oil Large Temperature Control Units Pump Start Press the START button to start the pump in the normal forward direction. Pump Stop Press the STOP button to stop the pump and de-energize the controller. ! CAUTION Always press the Pump Stop button and allow the pump to come to ...
Page 41 - Alarm Silence; button to silence the audible alarm; After you silence the alarm, make sure you; locate and; the alarm condition before continuing with unit; -5 Identifying System Status Board Indicators; Figure 6; ON
6017 Series Hot Oil Large Temperature Control Units Page 41 Alarm Silence Press the ALARM SILENCE button to silence the audible alarm on the console. ! CAUTION After you silence the alarm, make sure you locate and correct the alarm condition before continuing with unit operation. 5-5 Identifying Sys...
Page 42 - Status Indicator Lights; selection switch
Page 42 6017 Series Hot Oil Large Temperature Control Units Use the status board to optimize unit performance. For example, if you observe a rapid cycling of the Heater and Cool Solenoid indicators, the unit is operating with a process inefficiency; see the Troubleshooting chapter for more informati...
Page 43 - Auto Mode Indicator Light; Fault Indicator Lights; Pump Overload Indicator Light; Low Pressure Indicator Light; This is an alarm condition; Safety Thermo Indicator Light; This is an alarm condition
6017 Series Hot Oil Large Temperature Control Units Page 43 Auto Mode Indicator Light The Auto mode indicator light indicates that the Auto mode is active and the controller is monitoring the system and controlling the process. If the Auto light is off and the Cool Solenoid indicator light is illumi...
Page 44 - High Level Indicator Light; The high fluid level alarm is an available option. The; too high; . Carefully remove just enough fluid so; Low Level Indicator Light; The low fluid level alarm is an available option .The
Page 44 6017 Series Hot Oil Large Temperature Control Units Always correct this alarm condition before returning to normal operation! High Level Indicator Light The high fluid level alarm is an available option. The High Level indicator light illuminates when the heat transfer fluid level in the res...
Page 46 - Before you begin servicing this unit; Checks; Making Daily Checks; add fluid as needed; Making Monthly Checks; Check the pump drive V belt for any wear.
Page 46 6017 Series Hot Oil Large Temperature Control Units 6 Preventive Maintenance ! WARNING Make sure that your maintenance technicians comply with lock-out/tag-out procedures during any servicing or maintenance of this unit and related equipment, per OSHA article ART 1910.147. Before you begin s...
Page 47 - Making Quarterly Checks; Servicing
6017 Series Hot Oil Large Temperature Control Units Page 47 Making Quarterly Checks • Check the heat transfer fluid for deterioration. If the fluid is noticeably darker, or it seems significantly thicker, drain the system and replace the fluid with fresh, new recommended heat transfer fluid. Do a ro...
Page 48 - Servicing the Unit Monthly or Every 500 Hours; Lubricate the pump; at the grease fittings with a high-; Adjust; the pump drive; belt tension; . Use the belt tensioning; Servicing the Unit Every Three Months
Page 48 6017 Series Hot Oil Large Temperature Control Units Servicing the Unit Monthly or Every 500 Hours • Lubricate the pump at the grease fittings with a high- quality polyurea grease rated at 320ºF or higher. Recommended: Chevron Black Pearl; do not over-lubricate . • Adjust the pump drive belt ...
Page 49 - Motor Lubrication Procedure; With Grease Outlet Plug; Clean all grease fittings.; Without Grease Outlet Plug
6017 Series Hot Oil Large Temperature Control Units Page 49 Motor Lubrication Procedure Be sure that the grease you are adding to the motor is compatible with the grease already in the motor. Consult your Baldor distributor or an authorized service center if a grease other than the recommended type ...
Page 50 - Draining the Unit for Storage; Maintenance; Pumps and Seals; you may need to tighten the bolts to stop the leak.; If the pump motor wiring is disconnected for removal from; you must check the actual direction of rotation; when the motor is rewired to the unit.
Page 50 6017 Series Hot Oil Large Temperature Control Units 6-3 Draining the Unit for Storage You should thoroughly flush and drain the 6017 unit if you need to take it out of service for a long time, or if you expect it to become exposed to freezing temperatures. Sterling, Inc. recommends SterlFlus...
Page 52 - Troubleshooting
Page 52 6017 Series Hot Oil Large Temperature Control Units 7 Troubleshooting Condition Possible cause Solution Undersized connectors/lines. Increase size of connectors/ water lines. Long connecting lines between unit and mold. Move the unit closer to the mold and shorten connecting lines. Serpentin...
Page 54 - Service Notes
Page 54 6017 Series Hot Oil Large Temperature Control Units Service Notes
Page 57 - Technical Assistance; Street
6017 Series Hot Oil Large Temperature Control Units Page 57 Technical Assistance Parts Department Call toll-free 7am–5pm CST or call [800] 423-3183, [262] 641-8610, or fax to [262] 641-8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engine...
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