Sterling 682.88107.00 User manual

Brand: Sterling

Model: 682.88107.00

Type: User manual

Upright Hot Oil

Temperature Control Units

Part Number: 682.88107.00

Bulletin Number: SC1-660.3

Effective: 10/22/2009

Write Down Your Serial Numbers Here For Future Reference:

_________________________ _________________________

We are committed to a continuing program of product improvement.

Specifications, appearance, and dimensions described in this manual are subject to change without notice.

DCN No. ____________

Upright Portable Hot Oil TCUs Chapter 1: Safety ii

Shipping Info

Unpacking and Inspection

You should inspect your portable hot oil tcu for possible shipping damage.

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 the Event of Shipping Damage

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 before the transportation company’s inspection and authorization.

File a claim with 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 customer service regarding your wish for assistance and to obtain an RMA (return

material authorization) number.

If the Shipment is Not Complete

Check the packing list as back-ordered items are noted on the packing list. You should have:

; Portable Hot Oil TCU

; 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.

If the Shipment is Not Correct

If the shipment is not what you ordered please contact the parts and service department

immediately at (262) 641-8610. Have the order number and item number available. Hold the

items until you receive shipping instructions.

Returns

Do not return any damaged or incorrect items until you receive shipping instructions from the

shipping department.

Upright Portable Hot Oil TCUs Chapter 1: Safety iii

Table of Contents

CHAPTER 1: SAFETY ................................................................ 5

1-1 How to Use This Manual.............................................................................................5

Safety Symbols Used in this Manual.....................................................................5

1-2 Warnings and Precautions..........................................................................................6

1-3 Responsibility..............................................................................................................7

General Responsibility...........................................................................................7

Operator Responsibility.........................................................................................8

Maintenance Responsibility...................................................................................9

Reporting a Safety Defect .....................................................................................9

CHAPTER 2: FUNCTIONAL DESCRIPTION............................ 10

2-1 Models Covered in This Manual................................................................................10

2-2 General Description...................................................................................................10

2-3 Standard Features.....................................................................................................10

Mechanical Features...........................................................................................10

Electrical Features...............................................................................................11

Controller Features..............................................................................................11

2-4 Options......................................................................................................................11

2-5 Feature Descriptions.................................................................................................12

Immersion Heaters..............................................................................................12

Heater Tank.........................................................................................................12

Pump...................................................................................................................12

Ful-Flo Valve .......................................................................................................12

Connection Lines.................................................................................................13

Electrical System Controls...................................................................................13

Electrical Panel and System Components ..........................................................13

Air Purge .............................................................................................................14

Pressure Switch ..................................................................................................14

Safety Thermostat...............................................................................................14

Reservoir Tank....................................................................................................14

Cooling (Optional) ...............................................................................................15

2-6 Safety Devices and Interlocks...................................................................................15

CHAPTER 3: INSTALLATION ................................................... 17

3-1 Uncrating the Equipment...........................................................................................17

3-2 Rigging and Placing the TCU....................................................................................17

Installation Location Considerations....................................................................17

3-3 Electrical Connections...............................................................................................18

3-4 Setup Procedures......................................................................................................19

Connecting Piping ...............................................................................................19

Connecting Process Piping .................................................................................20

3-5 Initial Start-up............................................................................................................22

Starting the Hot Oil TCU......................................................................................22

CHAPTER 4: OPERATION ....................................................... 24

Upright Portable Hot Oil TCUs Chapter 1: Safety iv

4-1

Start-up......................................................................................................................24

4-2 Controller Description & Operation............................................................................24

Identifying Control Panel Switches......................................................................25

Identifying System Status Board Indicators.........................................................26

Status Indicator Lights.........................................................................................27

Mode Indicator Lights..........................................................................................27

Fault Indicator Lights...........................................................................................27

4-3 Returning Fluid to the Tank.......................................................................................28

4-4 Shutting Down the Hot Oil TCU.................................................................................28

CHAPTER 5: MAINTENANCE .................................................. 30

5-1 Maintenance Schedule..............................................................................................30

5-2 Preventative Maintenance.........................................................................................31

Routine Servicing................................................................................................31

Draining the Unit for Storage...............................................................................31

Preventative Pump Maintenance.........................................................................31

5-3 Corrective Maintenance ............................................................................................32

Pumps and Seals ................................................................................................32

Maintaining the Pump..........................................................................................33

Thrust Bearing Adjustment..................................................................................35

Installation of Carbon Graphite Bushings............................................................35

CHAPTER 6: TROUBLESHOOTING ......................................... 36

6-1 Introduction................................................................................................................36

CHAPTER 7: APPENDIX .......................................................... 39

7-1 Optional Components................................................................................................39

7-2 Technical Specifications............................................................................................40

Annex B Information............................................................................................40

7-3 Drawings and Diagrams............................................................................................42

7-4 Spare Parts List.........................................................................................................45

7-5 Returned Material Policy...........................................................................................48

Credit Returns .....................................................................................................48

Warranty Returns ................................................................................................48

7-6 Safety Tag Information..............................................................................................48

TCU Safety Tags.................................................................................................48

7-7 TCU Identification (Serial Number) Tag....................................................................49

7-8 Technical Assistance.................................................................................................49

Parts Department ................................................................................................49

Service Department.............................................................................................49

Sales Department................................................................................................49

Contract Department...........................................................................................49

Upright Portable Hot Oil TCUs Chapter 1: Safety 5

Chapter 1: Safety

1-1 How to Use This Manual

Use this manual as a guide and reference for installing, operating, and maintaining your

portable hot oil temperature control unit (TCU). The purpose is to assist you in applying

efficient, proven techniques that enhance equipment productivity.

This manual covers only light corrective maintenance. No other maintenance should be

undertaken without first contacting a service engineer.

The Functional Description section outlines models covered, standard features, and safety

features. Additional sections within the manual provide instructions for installation, pre-

operational procedures, operation, preventive maintenance, and corrective maintenance.

The Installation chapter includes required data for receiving, unpacking, inspecting, and setup

of the portable hot oil TCU. We can also provide the assistance of a factory-trained

technician to help train your operator(s) for a nominal charge. This section includes

instructions, checks, and adjustments that should be followed before commencing with

operation of the portable hot oil TCU. These instructions are intended to supplement

standard shop procedures performed at shift, daily, and weekly intervals.

The Operation chapter includes a description of electrical and mechanical controls, in

addition to information for operating the portable hot oil TCU safely and efficiently.

The Maintenance chapter is intended to serve as a source of detailed assembly and

disassembly instructions for those areas of the equipment requiring service. Preventive

maintenance sections are included to ensure that your portable hot oil TCU provides

excellent, long service.

The Troubleshooting chapter serves as a guide for identification of most common problems.

Potential problems are listed, along with possible causes and related solutions.

The Appendix contains technical specifications, drawings, schematics, parts lists, and

available options. A spare parts list with part numbers specific to your machine is provided

with your shipping paperwork package. Refer to this section for a listing of spare parts for

purchase. Have your serial number and model number ready when ordering.

Safety Symbols Used in this Manual

The following safety alert symbols are used to alert you to potential personal injury hazards.

Obey all safety messages that follow these symbols to avoid possible injury or death.

DANGER! DANGER indicates an imminently hazardous situation that, if not avoided,

will result in death or serious injury.

WARNING! WARNING indicates a potentially hazardous situation or practice that, if

not avoided, could result in death or serious injury.

Caution! CAUTION indicates a potentially hazardous situation or practice that, if

not avoided, may result in minor or moderate injury or in property damage.

Upright Portable Hot Oil TCUs Chapter 1: Safety 6

1-2 Warnings and Precautions

Our equipment is designed to provide safe and reliable operation when installed and operated

within design specifications, following national and local safety codes. This may include, but

is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international

regulations.

To avoid possible personal injury or equipment damage when installing, operating, or

maintaining this equipment, use good judgment and follow these safe practices:

; Read and follow these operation and installation instructions when installing,

operating, and maintaining this equipment. If these instructions become damaged or

unreadable, additional copies are available from the manufacturer.

; Follow all SAFETY CODES.

; Wear SAFETY GLASSES and WORK GLOVES.

; Work only with approved tools and devices.

; Disconnect and/or lock out power before servicing or maintaining the equipment.

; 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 equipment and components are properly GROUNDED before you

switch on power.

; When welding or brazing in or around this equipment, make sure VENTILATION is

ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with

sheet metal. An approved FIRE EXTINGUISHER should be close at hand and

ready for use if needed.

; Do not restore power until you remove all tools, test equipment, etc., and the

equipment and related components are fully reassembled.

; Only PROPERLY TRAINED personnel familiar with the information in this

manual should work on this equipment.

We have long recognized the importance of safety and have designed and manufactured our

equipment with operator safety as a prime consideration. We expect you, as a user, to abide

by the foregoing recommendations in order to make operator safety a reality.

Upright Portable Hot Oil TCUs Chapter 1: Safety 7

1-3 Responsibility

These machines are constructed for maximum operator safety when used under standard

operating conditions and when recommended instructions are followed in the maintenance

and operation of the machine.

All personnel engaged in the use of the machine should become familiar with its operation as

described in this manual.

Proper operation of the machine promotes safety for the operator and all workers in its

vicinity.

Each individual must take responsibility for observing the prescribed safety rules as outlined.

All warning and danger signs must be observed and obeyed. All actual or potential danger

areas must be reported to your immediate supervisor.

General Responsibility

No mater who you are, safety is important. Owners, operators and maintenance personnel

must realize that every day, safety is a vital part of their jobs.

If your main concern is loss of productivity, remember that production is always affected in a

negative way following an accident. The following are some of the ways that accidents can

affect your production:

• Loss of a skilled operator (temporarily or permanently)

• Breakdown of shop morale

• Costly damage to equipment

• Downtime

An effective safety program is responsible and economically sound.

Organize a safety committee or group, and hold regular meetings. Promote this group from

the management level. Through this group, the safety program can be continually reviewed,

maintained, and improved. Keep minutes or a record of the meetings.

Hold daily equipment inspections in addition to regular maintenance checks. You will keep

your equipment safe for production and exhibit your commitment to safety.

Please read and use this manual as a guide to equipment safety. This manual contains safety

warnings throughout, specific to each function and point of operation.

Upright Portable Hot Oil TCUs Chapter 1: Safety 8

Operator Responsibility

The operator’s responsibility does not end with efficient production. The operator usually has

the most daily contact with the equipment and intimately knows its capabilities and

limitations.

Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates, or

through a casual attitude toward machinery formed over a period of months or years. Your

employer probably has established a set of safety rules in your workplace. Those rules, this

manual, or any other safety information will not keep you from being injured while operating

your equipment.

Learn and always use safe operation procedures. Cooperate with co-workers to promote safe

practices. Immediately report any potentially dangerous situation to your supervisor or

appropriate person.

REMEMBER:

• NEVER place your hands or any part of your body in any dangerous location.

• NEVER operate, service, or adjust the temperature control unit without appropriate

training and first reading and understanding this manual.

• Before you start the temperature control unit check the following:

• Remove all tools from the tcu;

• Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the

TCUs operating area;

• If your TCU has been inoperative or unattended, check all settings before starting the

unit.

• At the beginning of your shift and after breaks, verify that the controls and other

auxiliary equipment are functioning properly.

• Keep all safety guards in place and in good repair. NEVER attempt to bypass, modify,

or remove safety guards. Such alteration is not only unsafe, but will void the warranty

on your equipment.

• When changing control settings to perform a different mode of operation, be sure

selector switches are correctly positioned. Locking selector switches should only be

adjusted by authorized personnel and the keys removed after setting.

• Report the following occurrences IMMEDIATELY:

• unsafe operation or condition

• unusual temperature control unit action

• leakage

• improper maintenance

• NEVER stand or sit where you could slip or stumble into the

temperature control unit while working on it.

• DO NOT wear loose clothing or jewelry, which can be caught while working on a tcu.

In addition, cover or tie back long hair.

Upright Portable Hot Oil TCUs Chapter 1: Safety 9

• Clean the tcu and surrounding area DAILY, and inspect the machine for loose, missing

or broken parts.

• Shut off power to the tcu when it is not in use. Turn the switch to the OFF position, or

unplug it from the power source.

Maintenance Responsibility

Proper maintenance is essential to safety. If you are a maintenance worker, you must make

safety a priority to effectively repair and maintain equipment.

Before removing, adjusting, or replacing parts on a machine, remember to turn off all electric

supplies and all accessory equipment at the machine, and disconnect and lockout electrical

power. Attach warning tags to the disconnect switch.

When you need to perform maintenance or repair work on equipment above floor level, use a

solid platform or a hydraulic elevator. If there is a permanently installed catwalk on your

equipment, use it. The work platform should have secure footing and a place for tools and

parts. DO NOT climb on equipment, machines, or work from ladders.

If you need to repair a large component, use appropriate handling equipment. Before you use

handling equipment (portable “A” frames, electric boom trucks, fork trucks, overhead cranes)

be sure the load does not exceed the capacity of the handling equipment or cause it to become

unstable.

Carefully test the condition of lifting cables, chains, ropes, slings, and hooks before using

them to lift a load.

Be sure that all non-current carrying parts are correctly connected to earth ground with an

electrical conductor that complies with current codes. Install in accordance with national and

local codes.

When you have completed the repair or maintenance procedure, check your work and remove

your tools, rigging, and handling equipment.

Do not restore power to the equipment until all persons are clear of the area. DO NOT start

and run the machine until you are sure all parts are functioning correctly.

BEFORE you turn the machine over to the operator for production, verify all equipment

enclosure panels, guards and safety devices are in place and functioning properly.

Reporting a Safety Defect

If you believe that your equipment has a defect that could cause injury, you should

immediately discontinue its use and inform the manufacturer.

The principle factors that can result in injury are failure to follow proper operating procedures

(i.e. lockout/tagout), or failure to maintain a clean and safe working environment.

Upright Portable Hot Oil TCUs Chapter 2: Functional Description 10

Chapter 2: Functional Description

2-1 Models Covered in This Manual

This manual provides operation, installation, and maintenance instructions for portable hot oil

temperature control units. Model numbers are listed on the serial tag. Make sure you know

the model and serial number of your equipment before contacting the manufacturer for parts

or service.

Your portable hot oil temperature control unit circulates thermal transfer-type oil through

your process and precisely, automatically, and reliably maintains it at a temperature you can

select. Portable hot oil temperature control units are sized to meet the specific requirements

stated by the Customer at the time of purchase.

2-2 General Description

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 a specially formulated Heat Transfer Fluid. A

recommended list of commercially available heat transfer fluids can be obtained through

Customer Service.

Rapid recirculation of the relatively small amount of fluid provides a close and uniform

temperature relationship between the TO PROCESS and FROM PROCESS lines. This does,

of course, depend on 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 controllers to the high temperature

system. The two systems are fully integrated to achieve accurate control, along with efficient

use of water and electricity.

2-3 Standard Features

Mechanical Features

• Dual stage immersion heater with IEC contactors

• 550°F (288ºC) maximum operating temperature {400°F (244°C) maximum operating

temperature for 6 kW heaters}

• Manual bypass

• Pressure switch for low pump pressure shut-down

• To Process pressure gauge

• Independent safety thermostat

• Y strainer on From Process line

• Automatic venting sequence

• Positive displacement pumps capable of reversing to evacuate the process

• Easily removable panels for quick access to internal components

• 1 year warranty on parts and labor (Labor at factory)

Upright Portable Hot Oil TCUs Chapter 2: Functional Description 11

Electrical Features

• Non-fused lockable rotary disconnect

• Branch circuit fusing

• NEMA 12 electrical enclosure

• UL listed subpanel

Controller Features

• M2B+ microprocessor controller with fuzzy logic; includes diagnostic features with

indicator and warning status lights

• System status graphic display

• Low level alarm for reservoir

• Audible alarm

• 5 year warranty on controller

2-4 Options

Options marked with “*” indicate options that can be factory installed or retrofitted in the

field.

• Drain valve

• Hour meter; measures total pump run time hours

• General fault visual alarm

• Autovent sequence; deducts available

• Low level alarm; deducts available

• High level indicator light

• Manual bypass; deducts available

• 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; 10 Ft. (3m)

• Heat exchanger options of 3.9 sq. ft. (0.3627 sq. m) and 6.7 sq. ft. (0.6231 sq. m)

• Remote controller

• Lexan cover

• Optional operating voltages of 208/3/60, 230/3/60, 575/3/60, 380/3/50, and 415/3/50

Upright Portable Hot Oil TCUs Chapter 2: Functional Description 12

2-5 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 6, 12, 18, or 24 kW low watt density immersion heaters,

depending upon the heating needs of the process. The 18 and 24 kW models are built to

provide full or partial heat as required by the process and determined by the controller, to

provide more precise control.

Heater Tank

The Upright 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.

Pump

The pump is a mechanical seal, positive displacement pump. It features a nearly maintenance

free design, and was selected after extensive testing to provide superior performance,

flexibility, and low maintenance. 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 the monthly greasing and occasional head space adjustment;

see Section 5-3 on Page 40 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 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 bypass line (Ful-

Flo 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 pressure

requirements exceed the rated pressure, the Ful-Flow valve will open and bypass the

necessary fluid to prevent high pressures.

Ful-Flo Valve

A regulating bypass line featuring a Ful-Flo 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

Ful-Flo valve is factory preset to limit system pressure as specified by the customer. It must

not be tampered with in any way.

In the event of an obstruction in the line, the Ful-Flo valve 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.

Upright Portable Hot Oil TCUs Chapter 2: Functional Description 13

Connection Lines

Connections for TO PROCESS and FROM PROCESS lines are 1" NPT (25.4 mm). Water

connections for COOLING WATER SUPPLY and COOLING WATER DRAIN are ¾” NPT

(19.1 mm); see Section 3-4 on Page 20 for more information. The customer is responsible for

conversions to metric standards.

The manufacturer 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 Upright 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 Upright unit are specially engineered for reliability, safety, and

simplicity of operation. Switch functions are clearly labeled. Your Upright 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

• high fluid level (optional)

Push the ALARM SILENCE button to silence the alarm. See Section 4-2 on Page 25 for

more information on control functions.

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 for ease of service. The electrical panel is

UL listed and complies with N.F.P.A. 79 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.

Upright Portable Hot Oil TCUs Chapter 2: Functional Description 14

Air Purge

Upon initial start-up and mold/process change-out, you’ll need to purge all air and water from

the system. The Upright unit has appropriate valving to ensure complete purging. Procedures

are covered in Section 3-5 on Page 23.

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.

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 shuts down if the fluid pressure is not re-established.

The pressure switch is preset at the factory; do not tamper with it.

Safety Thermostat

The safety thermostat is a J-thermocouple sensing, adjustable fail-safe device located in the

heater tank. This is to guard against the unlikely event of “runaway” heating. If over-heating

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.

All controller functions are locked out until the main supply power is disconnected. Resetting

the alarm condition is initiated by depressing the red pump stop button. The reset button is

located inside the electrical enclosure, mounted on the left wall of the enclosure. It is

imperative that a qualified maintenance technician determine and correct the cause of the

fault before resuming operation.

Reservoir Tank

A reservoir tank with sight gauge is standard; usable capacity is seven (7) gallons (26.5

liters). The tank permits thermal expansion of the heat transfer fluid, and provides makeup

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.

The reservoir tank drain is extended beyond the base of the unit for ease of draining. Optional

ball valves are available to further simplify draining

Upright Portable Hot Oil TCUs Chapter 2: Functional Description 15

Cooling (Optional)

The manufacturer-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 our 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 cooling water to pass through the tubes of the heat

exchanger and out the drain. A water supply of 75 psi (517.1 kPa/5.2 bars) maximum is

required for connection to the heat exchanger.

2-6 Safety Devices and Interlocks

This section includes information on safety devices and procedures that are inherent to the

portable hot oil tcu. This manual is not intended to supersede or alter safety standards

established by the user of this equipment. Instead, the material contained in this section is

recommended to supplement these procedures in order to provide a safer working

environment.

At the completion of this section, the operator and maintenance personnel will be able to do

the following:

• Identify and locate specific safety devices.

• Understand the proper use of the safety devices provided.

• Describe the function of the safety device.

Safety Circuit Standards

Safety circuits used in industrial systems protect the operator and maintenance personnel

from dangerous energy. They also provide a means of locking out or isolating the energy for

servicing equipment.

Various agencies have contributed to the establishment of safety standards that apply to the

design and manufacture of automated equipment. The Occupational Safety and Health

Administration (OSHA) and the Joint Industrial council (JIC) are just a few of the

organizations that have joined with the plastics industry to develop safety standards.

Every effort has been made to incorporate these standards into the design of the portable hot

oil tcu; however, it is the responsibility of the personnel operating and maintaining the

equipment to familiarize themselves with the safety procedures and the proper use of any

safety devices.

Upright Portable Hot Oil TCUs Chapter 2: Functional Description 16

Fail Safe Operation

If a safety device or circuit should fail, the design must be such that the failure causes a

“Safe” condition. As an example, a safety switch must be a normally open switch. The switch

must be held closed with the device it is to protect. If the switch fails, it will go to the open

condition, tripping out the safety circuit.

At no time should the safety device fail and allow the operation to continue. For example, if

a safety switch is guarding a motor, and the safety switch fails, the motor should not be able

to run.

Safety Device Lock-Outs

Some safety devices disconnect electrical energy from a circuit. The safety devices that are

used on these temperature control units are primarily concerned with electrical power

disconnection and the disabling of moving parts that may need to be accessed during the

normal operation of the machine.

Some of the safety devices utilize a manual activator. This is the method of initiating the

safety lock out. This may be in the form of a plug, lever or a handle. Within this lockable

handle, there may be a location for a padlock. Personnel servicing the equipment should

place a padlock in the lockout handle.

In addition to the safety devices listed above, these temperature control units are equipped

with a line cord plug. This allows the operator or maintenance personnel to unplug the tcu

from its power source and tag it out. The plug can then be tagged with any number of

approved electrical lockout tags available at most electrical supply stores.

WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)

sources prior to servicing or cleaning the temperature control unit. Failure to do so

may result in serious injury. No one but the person who installed the lockout may

remove it.

Upright Portable Hot Oil TCUs Chapter 3: Installation 17

Chapter 3: Installation

3-1 Uncrating the Equipment

Portable hot oil temperature control units are shipped mounted on a skid, enclosed in a plastic

wrapper, and contained in a cardboard box.

1. Pry the crating away from the skid.

Note: Remove the nails holding the box to the skid and lift the box off carefully;

avoiding staples in the 1’ x 4’ wood supports. Cut the steel banding.

2. Use a pry bar to remove the blocks securing the unit to the skid.

3. Lift unit from sides. Use a pry bar if necessary to carefully remove the

skid from the unit.

4. Lower slowly.

3-2 Rigging and Placing the TCU

Make sure that you meet the following requirements when installing and operating your

Upright hot oil temperature control unit.

Installation Location Considerations

Locate the Upright unit as close as possible to the process for proper circulation and

temperature control. Take care when selecting a location. The area surrounding the unit must

be free of obstructions to ensure proper ventilation of internal components. Allow a minimum

clearance of at least 30 inches (76 cm).

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 the reservoir tank during high

temperature operation.

Caution! Harmful vapors may be generated from thermal fluid during high

temperature operation. Prolonged or repeated exposure of these heat-

generated vapors may result in eye and respiratory tract irritation.

Avoid contact or inhaling harmful amounts or material. Consult the

Material Safety Data Sheet (MSDS) for precautions and instructions for

the thermal fluid you are using.

Note: Before storing your Upright temperature control unit, make sure you remove

all residual water with compressed air to avoid a potential freezing hazard.

See Section 5-2 on Page 39 for more information.

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 to 120ºF -20ºC to 49ºC

You should preheat the process heat transfer fluid first if you want to start the unit below an

ambient temperature of 30ºF (-1ºC).

Upright Portable Hot Oil TCUs Chapter 3: Installation 18

3-3 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 for correct voltage and amperage before making electrical

connections!

Caution!

1. Provide a correctly sized and protected power supply to the unit.

2. If an electrical supply disconnect is not installed as a factory option, the 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 and disconnect the

electricity when service calls are needed.

• Locate disconnects in an easily accessible location. Operators should

not have to squeeze around the Upright unit to reach disconnects,

especially in case of emergency.

• When running conduit whips to the Upright unit, make sure that whips

are routed away from hot piping.

DANGER! Improper electrical connections can cause damage to the unit and

cause serious 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 backwards if not

wired properly.

Upright Portable Hot Oil TCUs Chapter 3: Installation 19

3-4 Setup Procedures

This section provides the procedures necessary for configuring your portable hot oil

temperature control unit.

Configuration of your TCU includes connecting cooling, process and vent piping. We

recommend that you carry out these procedures in the order given here.

Note: Before carrying out these procedures, install all equipment as described in

this section.

Connecting Piping

Make sure that all external piping is properly sized to reduce external pressure drop as much

as possible. Do not install process or water supply/drain piping smaller than the fittings on the

unit. If the water supply piping is larger than unit fittings, reduce the pipe size at the unit.

The following table lists recommended Upright TCU pipe sizes.

Size diameter

Connection inches NPT mm (approx.) c

To Process 1” 25.4

From Process 1” 25.4

Cooling Water Supply ¾” 19.1

Cooling Water Drain ¾” 19.1

Oil Drain ½” 12.7

Fill Port 1” 25.4

c Customer is responsible for converting to metric.

Note: Always use a backup wrench to support Upright unit piping when making

connections. Make sure all external piping is supported independently of the

Upright unit.

The manufacturer recommends that you have strainers installed on the

cooling water inlets and customer-supplied shut-off valves on all piping

connections. Use common black welded pipe for permanent installations.

The Upright 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 withstand the high

temperatures and pressures of your Upright unit. Always insulate all piping to prevent burn

hazards and to retain heat. Make sure insulation is properly rated for maximum operating

temperatures of your Upright unit.

Piping Considerations for Mobile Installations

Because your Upright unit is fitted with casters, its portability is well suited for multiple

applications. You can purchase high-quality flexible metal hose from the manufacturer to

enhance the mobility of your Upright unit; state the length you want when ordering.

Although they cause a drop in pressure, you can also install quick disconnects to your

Upright unit. However, do not install check valves with quick disconnects unless absolutely

necessary!

Upright Portable Hot Oil TCUs Chapter 3: Installation 20

Connecting Process Piping

When connecting process piping, ensure that the Cautions listed below are observed and

followed:

Caution!

• Hoses, valves and other components in your process must be able to withstand

Upright unit maximum temperatures and pressures.

• Maximum temperatures and pressures are listed on the unit nameplate.

• Carefully inspect all components before installation.

• If in doubt about component suitability, obtain factory components.

• Fix all leaks! Fluid can be a potential fire and slip hazard.

Connecting Cooling Water Piping

You must provide cooling water at 25 psi to 75 psi (172.4 kPa to 517.1 kPa/1.7 bars to 5.2

bars) for proper operation. Untreated water can foul or corrode the heat transfer surfaces,

slowing water flow and causing fluid temperature control problems. The manufacturer 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 Upright unit. If

external piping is larger than Upright unit connections, reduce the size of the piping at the

unit.

Connecting Vent Piping

You must leave the vent connection open to the atmosphere at all times. The vent connection

is located on top of the reservoir. On systems with piping above the reservoir level, you must

run vent piping to a minimum height of one foot (1’ / 31 cm) above the highest point in the

system. Run the piping down into an auxiliary vented overflow chamber, such as a vented,

covered 55-gallon (208-liter) drum. This practice ensures that overflow will not create a

hazard to personnel.

Note: All external piping must be supported independently of the Upright unit.

Caution! The reservoir tank must be vented to prevent pressurization. A pressurized

reservoir could rupture, allowing hot fluid to escape and become a

potential fire and slip hazard.

Note: Heat transfer fluids expand when heated. Expansion rates vary, depending

on fluid types and temperatures. For more information on expansion rates,

refer to specification information for the heat transfer fluid you select.

Generally, most heat transfer fluids expand at the rate of 2.5% for every

increase of 50°F/°C from temperatures above 60°F (16°C).

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Sterling 682.88107.00 User manual

Sterling 682.88107.00 User manual

Sterling 682.88107.00 User manual

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