Operation and Installation Manual 2016M Series Portable Hot ......control, along with efficient use of water and electricity. 1-2 Necessary Documents The following documents are necessary

Operation and Installation Manual

2016M SeriesPortable Hot Oil

Temperature Control UnitsImportant! Read Carefully Before Attempting to Install or Operate Equipment

Part No. 682.88107.00 Revision 2 Bulletin No. SC1-640.2

$30.00

2016M Series Hot Oil Portable Temperature Control Units

Write down your unit serial number(s) ________________ ________________

here for future reference ________________ ________________

________________ ________________

________________ ________________

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. 2002All rights reserved. Effective 8/6/02

Part No. 682.88107.00 Revision 2 Bulletin No. SC1-610.2

2016M Series Hot Oil Portable Temperature Control Units Page 3

Safety Considerations

Sterling/Sterlco 2016M Series portable hot oil temperature controlunits are designed to provide safe and reliable operation wheninstalled and operated within design specifications, followingnational and local safety codes.

To avoid possible personnel injury or equipment damage wheninstalling, operating, or maintaining this equipment, use goodjudgment and follow these safe practices:

Follow all SAFETY CODES. Wear SAFETY GLASSES and WORK GLOVES. Disconnect and/or lock out power before servicing or

maintaining the hot oil temperature control unit.

Use care when LOADING, UNLOADING, RIGGING, orMOVING this equipment.

Operate this equipment within design specifications. OPEN, TAG, and LOCK ALL DISCONNECTS before

working on equipment. You should remove the fuses and carrythem with you.

Make sure the hot oil temperature control unit and componentsare properly GROUNDED before you switch on power.

Do not jump or bypass any electrical safety control. Do not restore power until you remove all tools, test

equipment, etc., and the hot oil temperature control unit andrelated equipment are fully reassembled.

Only PROPERLY TRAINED personnel familiar with theinformation in this manual should work on this equipment.


Table of Contents

1 General Information .................................................7

1-1 Introduction……………………………………………………………….71-2 Necessary Documents………………………………………………….71-3 Models Covered………………………………………………………… 81-4 Standard Features……………………………………………………… 81-5 Available Options………………………………………………………..91-6 Feature Descriptions…………………………………………………….9

2 Shipping Information .............................................16

2-1 Unpacking and Inspection…………………………………………….162-2 In the Event of Shipping Damages…………………………………...162-3 If the Shipment is Not Complete……………………………………...172-4 If the Shipment is Not Correct………………………………………...172-5 Returns………………………………………………………………….17

3 Installation...............................................................18

3-1 Work Rules……………………………………………………………...183-2 Installation Requirements……………………………………………..183-3 Connecting Piping…………………………………………………….. 193-4 Making Electrical Connections………………………………………. 23


Table of Contents

4 Startup Preparations ..............................................27

4-1 Starting the Unit……………………………………………………….. 274-2 Shutting Down the Unit………………………………………………..284-3 Returning Fluid to the Tank…………………………………………...29

5 Using Controls and Indicators ..............................31

5-1 The Microprocessor Controller………………………………………. 315-2 Identifying M2B Controller Panel Components…………………… 325-3 Using M2B Controller Keys…………………………………………...345-4 Identifying Control Panel Switches………………………………….. 365-5 Identifying System Status Board Indicators…………………………38

6 Preventive Maintenance.........................................43

6-1 Periodic Checks………………………………………………………..436-2 Routine Servicing………………………………………………………446-3 Draining the Unit for Storage………………………………………….456-4 Corrective Maintenance……………………………………………….456-5 Maintaining the Pump………………………………………………….46

7 Troubleshooting .....................................................60

I Index ........................................................................64


Charts and Figures

1 2016M Series Hot Oil Portable Temperature Control Unit andSpecifications 152 2016M Unit Piping Setup 223 Typical M2B Graphic and Button Control Panel 314 Control Panel Switches 365 System Status Board Indicators 386 18-24 GPM Pump Construction 075-00370-02 477 Thrust Bearing Assembly 488 Customer-Recommended Spare Parts 56-59


1 General Information

1-1 IntroductionYour Sterling/Sterlco 2016M Series hot oil temperature controlunit circulates thermal transfer-type oil through your process andto precisely, automatically, and reliably maintain it at atemperature you can select. The operating range of yourtemperature control unit is from 100°F to 550°F (38°C to 288°C).The unit is best suited for use with SterlTherm™ Heat TransferFluid. A recommended list of commercially available heat transferfluids can be obtained through Sterling Customer Service.

Rapid recirculation of the relatively small amount of fluid providesa close and uniform temperature relationship between the TOPROCESS and FROM PROCESS lines. This does, of course,depend on the configuration of your process, and any restrictionswithin the mold.

This recirculation, combined with the immersion heater andoptional cooling capability, gives fast and accurate response tobring the fluid up to temperature, or to changes in the settingswhen needed.

Performance is assured through matching the uniqueSterling/Sterlco controllers to the Sterling/Sterlco high temperaturesystem. The two systems are fully integrated to achieve accuratecontrol, along with efficient use of water and electricity.

1-2 Necessary DocumentsThe following documents are necessary for the safe installation,operation, and maintenance of your Sterling/Sterlco 2016M Serieshot oil portable temperature control unit. You can obtain additionalcopies from Sterling, Inc. Make sure that appropriate personnel arefamiliar with these documents:

This manual. The electrical schematic and connection diagram in the control

enclosure.

The manuals for accessories and options you’ve selected. The customer parts list in the control enclosure.


1-3 Models CoveredThis manual lists installation, operation, and maintenanceinstructions for the 2016M Series hot oil portable temperaturecontrol unit.

Model numbers are listed on the serial tag. A model numberfollowed by -Q indicates a specially constructed unit, and not allinformation in this manual may apply. Make sure that you knowthe model number, serial number, and operating voltage of yourunit if you contact 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{400°F (244°C) maximum operating temperature for 6 kWheaters}

• Manual bypass

• Branch fusing

• System status graphic display

• Pressure switch for low pump pressure shut-down

• NEMA 12 electrical enclosure

• UL listed subpanel

• To Process pressure gauge

• Independent safety thermostat

• Y strainer on From Process line

• Automatic venting sequence

• Positive displacement pumps capable of reversing toevacuate the process

• Low level alarm for reservoir

• Easily removable panels for quick access to internalcomponents

• Audible alarm


1-5 Available Options• 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 6.7sq. 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

1-6 Feature DescriptionsImmersion Heaters

The fluid is heated by the specially designed three-phase low wattdensity electrical immersion heater, and regulated by thecontroller. The standard heater has a steel sheath for low wattdensity and good heat transfer.

These models can be supplied with 6, 12, 18, or 24 kW low wattdensity immersion heaters, depending upon the heating needs ofthe process. The 18 and 24 kW models are built to provide full orpartial heat as required by the process and determined by thecontroller, to provide more precise control.


Heater TankThe 2016M features a single pass heater tank. The tank is designedto maintain an optimum balance of fluid velocity versus wattdensity, and turbulence for excellent heat transfer, and minimalpressure drop. The high fluid velocity will greatly prolong the lifeof the heater and fluid.

PumpThe pump is a mechanical seal, positive displacement pump. Itfeatures a nearly maintenance free design, and was selected afterextensive testing to provide superior performance, flexibility, andlow maintenance. It is well suited for use with a variety ofcommercially available heat transfer fluids. The pump has onlytwo internal moving parts, and a specially designed seal to giveyears of trouble free service, even at high temperatures. The onlyroutine maintenance required is the monthly greasing andoccasional head space adjustment; see Section 6 on Page 43 formore information.

The pump is capable of running in either direction. Thus, thepump reverse feature can be used to draw fluids back from theprocess. It is not necessary to install a service air line to purge linesbefore changing molds. Since the pump is capable of achievingextremely high pressures, it is necessary to regulate the pressurethrough use of a regulating bypass line (Ful-Flo valve). Becausethe pump is a positive displacement pump, it will supply theprocess 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 theprocess that it is attached to. Systems with large processconnections, ports, and piping will operate at low pressures. Whilesystems with small process connections, ports, and piping willoperate at higher pressures. Once pressure requirements exceed therated pressure, the Ful-Flow valve will open and bypass thenecessary fluid to prevent high pressures.

Ful-Flo ValveA regulating bypass line featuring a Ful-Flo valve is standard in allunits. This is a safety device to prevent excessive pressure in theevent that the delivery line is obstructed. Each Ful-Flo valve isfactory preset to limit system pressure as specified by thecustomer. It must not be tampered with in any way.In the event of an obstruction in the line, the Ful-Flo valve willopen and divert fluid from the delivery TO PROCESS line to thereturn FROM PROCESS line. A constant flow of fluid is


maintained through the heater tank to prevent damage to theheating elements and fluid.

CoolingOptional

The Sterling/Sterlco-designed shell and tube heat exchanger isprovided as optional equipment in this unit. The design features U-tube construction and copper-nickel tubes for durability andoptimal heat transfer.

The modular construction (unique to Sterling/Sterlco units) allowsthe tube bundle to be easily removed for periodic cleaning.Additionally, check valves are installed on the water supply anddrain lines to prevent water from back flowing into the heatexchanger from a closed drain or into the water supply piping.

The controller automatically regulates cooling by opening andclosing the cooling solenoid. This allows the proper amount ofcooling water to pass through the tubes of the heat exchanger andout the drain. A water supply of 75 psi (517.1 kPa/5.2 bars)maximum is required for connection to the heat exchanger.

Connection Lines

Connections for TO PROCESS and FROM PROCESS lines are 1"NPT (25.4 mm). Water connections for COOLING WATERSUPPLY and COOLING WATER DRAIN are ¾” NPT (19.1 mm);see Section 3 on Page 18 for more information. The customer isresponsible for conversions to metric standards.

Sterling stocks many lengths of flexible metal hose; the partnumber is 572-16969. State the length of hose you want whenordering.

! WARNINGComponent failure may result in high-temperatureoil spray, causing serious injury or death.Make sure hoses, valves, and other componentsinstalled in your process can withstand maximumtemperature and pressure of the 2016M unit; checkunit nameplate for specific capacities.All components must be carefully inspected forcondition before installing. Make sure you havefactory components if you have any doubt.


Electrical System Controls

The electrical controls of your 2016M unit are specially engineeredfor reliability, safety, and simplicity of operation. Switch functionsare clearly labeled. Your 2016M unit has a system status board soyou 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 soundin 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. SeeSection 5 on Page 31 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 Vsingle phase. The control circuit voltage is provided by a singlephase machine tool transformer with primary fuse protection and agrounded secondary. A main power disconnect is included for easeof service. The electrical panel is UL listed and complies withN.F.P.A. 79 provisions.

All components are IEC rated for long life and reducedmaintenance. The heater elements are branch fused, and protectedfrom contactor welding by a separate primary voltage contactor.The pump motor is controlled by a full voltage magnetic reversingstarter, with fused branch circuit overcurrent and thermal overloadprotection. Many additional features are available as options.

A NEMA 12 enclosure is standard, with NEMA 4 available as anoption.


Air Purge

Upon initial start-up and mold/process change-out, you’ll need topurge all air and water from the system. The 2016M unit hasappropriate valving to ensure complete purging. Procedures arecovered in Chapter 3 on Page 18.

! WARNINGFailure to purge the system of air before heatingmay result in serious injury or critical system andequipment damage.Make sure you properly purge the system of airbefore starting the heater cycle.

Pressure Switch

A pressure switch is built into each unit to guard against heaterdamage. This feature prevents the heater elements from beingenergized unless the pump is running and fluid is in the system.After a preset time, the pump shuts down if the fluid pressure is notre-established. The pressure switch is preset at the factory; do nottamper with it.

Safety Thermostat

The safety thermostat is a J-thermocouple sensing, adjustable fail-safe device located in of the heater tank. This is to guard againstthe unlikely event of “runaway” heating. If over-heating doesoccur, the safety thermostat shuts down the heater outputs andsounds an audible alarm. A red pilot light on the status board alsoilluminates. The unit continues to pump fluid through the system toprevent heater damage. Auxiliary factory installed alarms such asbeacons and klaxons are available as options.

All controller functions are locked out until the main supply poweris disconnected. Resetting the alarm condition is initiated bydepressing the red pump stop button. The reset button is locatedinside the electrical enclosure, mounted on the left wall of theenclosure. It is imperative that a qualified maintenancetechnician determine and correct the cause of the fault beforeresuming operation.


Reservoir Tank

A reservoir tank with sight gauge is standard; usable capacity isseven (7) gallons (26.5 liters). The tank permits thermal expansionof the heat transfer fluid, and provides makeup fluid.

! WARNING

The reservoir tank may cause serious injury if itruptures from not being properly vented.Make sure that the reservoir tank is alwaysproperly vented to prevent tank rupture.

The reservoir tank drain is extended beyond the base of the unit forease of draining. Optional ball valves are available to furthersimplify draining.


Figure 12016M Series Hot Oil Portable Temperature Control Unit

2016M Series Temperature Control Unit Specifications2016M-Model number

1 1.5 2 6 kW heater; 400ºF (204ºC) only 9 10 1112 kW heater 16 17 1818 kW heater 24 25 26

Full load amps; 460/3/60

24 kW heater 31 32 33Reservoir capacity in gallons / liters 7 gallons / 26.5 liters

hp / kW 1 / 0.746 1.5 / 1.12 2 / 1.49gpm 18 gpm 24 gpmFlowlpm 68.1 lpm 90.8 lpmpsig 30 psig 50 psig 30/50 psigkPa 206.8 kPa 377.8 kPa 206.8/377.8

Pressure

bars 2.1 bars 3.8 bars 2.1/3.8 bars

TEFC pump

Connection size 1” NPT (approx. 25.4 mm)Height 46” / 116.8 cmWidth 18¼” / 46.4 cm

Dimensions in inches / cm

Depth 42” / 106.7 cmShipping weight in lbs. / Kg 600 lbs. / 273 Kg

2016M units require ten (10) gallons (37.9 liters) minimum to run properly.


2 Shipping Information

2-1 Unpacking and InspectionYou should inspect your Sterling/Sterlco 2016M Series hot oilportable temperature control unit for possible shipping damage. Ifthe container and packing materials are in re-usable condition, savethem for reshipment if necessary.

Thoroughly check the equipment for any damage that might haveoccurred in transit, such as broken or loose wiring andcomponents, loose hardware and mounting screws, etc. In case ofbreakage, damage, shortage, or incorrect shipment, refer to thefollowing sections.

2-2 In the Event of Shipping DamagesImportant!

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 discoverdamage.

Hold the damaged goods and packing material for theexamining agent’s inspection. Do not return any goods toSterling, Inc. before the transportation company inspectionand authorization.

File a claim against the transportation company. Substantiatethe claim by referring to the agent’s report. A certified copy ofour invoice is available upon request. The original Bill ofLading is attached to our original invoice. If the shipment wasprepaid, write us for a receipted transportation bill.

Advise Sterling, Inc. regarding your wish for assistance and toobtain an RGA (return goods authorization) number.


2-3 If the Shipment is Not CompleteCheck the packing list. The apparent shortage may be intentional.Back-ordered items are noted on the packing list. You should have:

2016M Series hot oil portable temperature control unit 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 missedany smaller items during unpacking. Determine that the item wasnot inadvertently taken from the area before you checked in theshipment. Notify Sterling, Inc. immediately of the shortage.

2-4 If the Shipment is Not CorrectIf the shipment is not what you ordered, contact Sterling, Inc.immediately. For shipments in the United States and Canada,call 1 (800) 783-7835 or 1 (414) 354-0970. Include the ordernumber and item. Hold the items until you receive shippinginstructions.

2-5 ReturnsImportant!

Do not return any damaged or incorrect itemsuntil you receive shipping instructions from Sterling, Inc.


3 Installation

3-1 Work RulesThe installation, operation, and maintenance of this equipmentmust be conducted in accordance with all applicable work andsafety codes for the installation location. This may include, but isnot limited to OSHA, NEC, CSA, and any other local, national,and international regulations.

• Read and follow these instructions when installing,operating, and maintaining this equipment. If the instructionsbecome damaged or unreadable, obtain additional copiesfrom Sterling/Sterlco.

• Only qualified personnel familiar with this equipment shouldwork on or with this hot oil temperature control unit.

• Work with approved 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 apower main, make sure that a fused power disconnect isinstalled to allow the disconnect to be locked in the OFFposition. Open and lock out the disconnect installed in thecontrol enclosure.

3-2 Installation RequirementsMake sure that you meet the following requirements wheninstalling and operating your 2016M hot oil temperature controlunit.

Installation Location Considerations

Locate the 2016M unit as close as possible to the process forproper circulation and temperature control. Take care whenselecting a location. The area surrounding the unit must be free ofobstructions 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 ensureproper air circulation. Special air circulation/ventilation is requiredfor units operating at temperatures exceeding 500ºF (260ºC).Vapors can escape from areas such as the reservoir tank duringhigh temperature operation.

! CAUTIONHarmful vapors may be generated from thermal fluidduring high temperature operation.

Prolonged or repeated exposure of these hot-generatedvapors may result in eye and respiratory tract irritation.

Avoid contact or inhaling harmful amounts of material.Consult the Material Safety Data Sheet (MSDS) forprecautions and instructions for the thermal fluid youare using.

Note: Before storing your 2016M temperature control unit, makesure you remove all residual water with compressed air toavoid a potential freezing hazard. See Section 6 on Page 43for more information.

Note the following table of ambient temperature ranges permittedfor storage and operation:

Ambient storage range Ambient operation rangeºF 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 wantto start the unit below an ambient temperature of 30ºF (-1ºC).

3-3 Connecting PipingMake sure that all external piping is properly sized to reduceexternal pressure drop as much as possible. Do not install processor water supply/drain piping smaller than the fittings on the unit. Ifthe water supply piping is larger than unit fittings, reduce the pipesize at the unit.


The following table lists 2016M TCU pipe sizes.

Size diameterConnection inches NPT mm (approx.)

To Process 1” NPT 25.4 mmFrom Process 1” NPT 25.4 mmCooling Water Supply ¾” NPT 19.1 mmCooling Water Drain ¾” NPT 19.1 mmOil Drain ½” NPT 12.7 mmFill Port 1” NPT 25.4 mm

Customer is responsible for converting to metric.

Notes: Always use a backup wrench to support 2016M unit pipingwhen making connections. Make sure all external piping issupported independently of the 2016M unit.

Sterling, Inc. recommends that you have strainers installedon the cooling water inlets and customer-supplied shut-offvalves on all piping connections. Use common blackwelded pipe for permanent installations.

The 2016M is designed to operate with an open,unrestricted drain line. Steam rapidly expands within theheat exchanger, so any overpressure condition frombackpressure or standing columns of water against the drainmust be avoided.

If you must use a pipe joint compound, use a compound that canwithstand the high temperatures and pressures of your 2016M unit.Always insulate all piping to prevent burn hazards and to retainheat. Make sure insulation is properly rated for maximumoperating temperatures of your 2016M unit.

Piping Considerations for Mobile Installations

Because your 2016M unit is fitted with casters, its portability iswell suited for multiple applications. You can purchase high-quality flexible metal hose from Sterling/Sterlco to enhance themobility of your 2016M unit; state the length you want whenordering.

Although they cause a drop in pressure, you can also install quickdisconnects to your 2016M unit. However, do not install checkvalves with quick disconnects unless absolutely necessary!


Connecting Process Piping

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

withstand 2016M 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 to517.1 kPa/1.7 bars to 5.2 bars) for proper operation. Untreatedwater can foul or corrode the heat transfer surfaces, slowing waterflow and causing fluid temperature control problems. Sterling, Inc.sells a complete line of water treatment equipment that can reducedowntime and maintenance costs.

Run properly-sized cooling water lines—never smaller than theoutlets on the 2016M unit. If external piping is larger than 2016Munit connections, reduce the size of the piping at the unit.

Connecting Vent Piping

You must leave the vent connection open to the atmosphere atall times. The vent connection is located on top of the reservoir.On systems with piping above the reservoir level, you must runvent piping to a minimum height of one foot (1’ / 31 cm) above thehighest point in the system. Run the piping down into an auxiliaryvented overflow chamber, such as a vented, covered 55-gallon(208-liter) drum. This practice ensures that overflow will not createa hazard to personnel.

Remember: All external piping must be supported independentlyof the 2016M unit.


! CAUTIONThe reservoir tank must be vented to prevent pressurization.

A pressurized reservoir could rupture, allowing hot fluidto escape and become a potential fire and slip hazard.

Note: Heat transfer fluids expand when heated. Expansion ratesvary, depending on fluid types and temperatures. For moreinformation on expansion rates, refer to specificationinformation for the heat transfer fluid you select.

Generally, most heat transfer fluids expand at the rate of2.5% for every increase of 50°F/°C from temperaturesabove 60°F (16°C).

Figure 22016M Unit Piping Setup

Connect the TO PROCESS hookup to the entrance of the processand the FROM PROCESS hookup to the exit of the process.Connect the COOLING WATER SUPPLY to your plant watersupply. Connect the COOLING WATER DRAIN line to an opendrain, or to the return line of your central water system. If returningto a central water system, use a condensate/return tank to avoid astanding water column on the heat exchanger drain line.


! CAUTIONIf you are routing the drain line to an open drain, make sure that

the line is directed away from personnel to avoid scalding.

Carefully select connecting lines and connectors between the 2016M unitand the process to best meet the needs and requirements of your application.

Make sure lines and connectors have a service rating ofat least 100 psig (689.5 kPa/6.9 bars), and a temperature rating

at least equal to the maximum operating temperature of your 2016M unit.

Note: To prevent debris from fouling reservoir fluid, the 2016Munit is equipped with an internal vent on the reservoir tank.Use the plug provided to close off the external fill port afterfilling the unit with heat transfer fluid.

3-4 Making Electrical ConnectionsThese units are designed for three-phase voltage operation. Referto the unit nameplate for proper voltage and amperagerequirements, and make sure your electrical service conforms.

Check the unit nameplate for correct voltage and amperagebefore making electrical connections!


! CAUTION1. 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 theelectricity when service calls are needed.

• Locate disconnects in an easily accessible location.Operators should not have to squeeze around the 2016M unitto reach disconnects, especially in case of emergency.

• When running conduit whips to the 2016M unit, make surethat whips are routed away from hot piping.

Check the unit nameplate for correct voltage and amperagebefore making electrical connections!

! DANGERIMPROPER ELECTRICALCONNECTIONS CAN DAMAGE THEUNIT AND CAUSE SERIOUSOPERATOR INJURY OR DEATH!

MAKE SURE THAT ALLELECTRICAL CONNECTIONS AREMADE BY A QUALIFIEDELECTRICIAN, AND THAT ALLCONNECTIONS ARE TIGHT.


Make all electrical supply connections at the front of the unit. Anaccess panel covers all electrical connections. Run electricalconnections to the supply terminals from either side of the unit.Make sure that all three phases are wired correctly. The pump runsbackwards if not wired properly.

- Notes -


- Notes -


4 Startup Preparations

4-1 Starting the UnitBefore you begin your heating process, perform the followingstartup procedures. Doing so ensures that all air is vented from thesystem to prevent fluid degradation and damage to the heater.

1. Add recommended heat transfer fluid to the reservoir tankuntil the level is near the top of the sight glass.

2. If so equipped, open the manual vent valve on the back ofthe unit.

3. Push the PUMP START button to start the pump, thencheck motor rotation by observing the pressure gauge.

If the gauge indicates positive pressure, rotation is correct.If not, disconnect power and reverse the incoming powerleads.

4. As fluid is drawn out of the reservoir tank to fill theprocess, the fluid level falls in the tank. Continue to addfluid to maintain the level about four inches (4”/10 cm)from the bottom of the sight glass.

Air and thermal fluid vent through the vent solenoid or themanual vent valve and into the reservoir tank.

! CAUTIONYou must purge the system of air before the heating cycle.

Personal injury and system damage can occur from a pressurized system.

Make sure that the reservoir tank vent port is not plugged.The reservoir tank must never be pressurized!

5. When the unit has built at least five (5) psi (34.5 kPa) ofpressure, wait two (2) minutes, then select a set point of100°F (38ºC) and switch the unit into Auto mode.

As the oil warms up, viscosity decreases and pressure falls.


6. Increase the set point to 150ºF, then 200ºF (65ºC, then93ºC) at two-minute intervals.

7. Any water present in the system must boil off beforecontinuing operation. Select a set point of 215ºF (102ºC)and observe the reservoir tank vent for any signs ofescaping steam.

Continue to run at this set point temperature until no moresteam appears and pressure stabilizes.

8. When fluid level stabilizes and air and water is purged fromthe system, allow the vent timer to run out.

- or -If so equipped, close the vent valve. Do not open the ventvalve at temperatures exceeding 250ºF (121ºC).

With the system properly purged, only four to six inches (4” to 6” /10 cm to 15 cm) of fluid should be visible in the sight glass. Thislets the fluid expand as it heats, also permitting process fluidadditional capacity when the pump reverses and fluid is withdrawnfrom the mold.

The 2016M unit is now ready for use. All that is now required is toselect a process set point on the controller.

Note: If all traces of water are not removed from the system,severe cavitation may occur at elevated temperatures.Indications are a rough-sounding pump, fluctuating ordropping pressure, or a rapidly rising fluid level in theexpansion tank. Repeat Step 7 if this occurs.

4-2 Shutting Down the Unit 1. Cool down the unit by switching the CONTROL MODE

switch to the MAN. COOL (manual cooling) position.

This step disables the heaters (prevents the controller fromturning them on) and, if so equipped, opens the Coolsolenoid.

You can monitor fluid temperature on the controller displayduring cool-down.

2. When fluid temperature dips below 120ºF (49ºC), press thePUMP STOP button to turn off the unit.


4-3 Returning Fluid to the TankIf you want to move the unit from one process to another (likemold changes), perform the following steps to drain the mold andprocess lines.

Note: This procedure is just the opposite of the unit startup/airpurge procedure.

1. Cool the heat transfer fluid to no more than 100°F (38ºC). 2. If so equipped, open the manual vent valve to add air into

the pipes.

3. Press the PUMP STOP button. 4. Press and hold the PUMP REVERSE button.

The pump runs in reverse, drawing fluid from the mold andlines, then drains the fluid into the reservoir tank.

5. Watch the sight glass to prevent overflow of the reservoirtank.

! CAUTIONThe reservoir tank may not have adequate volume

to contain the total system capacity of fluid.An overflowing reservoir allows hot fluid to escape

and become a potential fire and slip hazard.The total capacity of the tank is 7 gallons (26.5 liters).

If it appears that the tank may overfill, connect a line from theFILL port of the reservoir tank to a clean auxiliary container.


- Notes -


5 Using Controls and Indicators

5-1 The Microprocessor ControllerThe M2B controller is an easy-to-operate microprocessor-basedPID control device. When the process reaches the set point, thePID control cycles the cooling valve and/or immersion heater tomaintain the proper leaving water temperature.

The controller has been fully factory tested. Set the desired processtemperature set point and the controller does the rest.

Built-in range of operation on the controller is 0°F to 550°F (-18ºCto 288ºC).

Figure 3Typical M2B Graphic and Button Control Panel

SET POINT

INDEX HIALARM

UP

DISPLAY

ENTER

ALARMLO

DOWN

RUN

LO HEAT

COOL

HI HEAT

STATUS

ALARM

HI/LO

PRESSURE

SET POINTFLUID

THERMO

SAFETY

PROCESS

FAIL

PROBE MOTOR

FAIL

R

TO PROCESS

FLOW

T

FROM PROCESS

DISPLAY

TEMPERATURE CONTROL SYSTEM -- M2BSTERLING, INC.

MILWAUKEE, WI

185185


5-2 Identifying M2B Controller Panel ComponentsScreen Displays

SET POINT Numeric LEDDuring normal operation, the SET POINT LED on the controllerdisplays the process set point you want the unit to maintain. It alsodisplays parameter and pre-set function values during setup.

PROCESS Numeric LEDDuring normal operation, the PROCESS LED on the controllerdisplays the actual process temperature at the To Processthermocouple. It also lists parameter symbols during setup anderror messages if an error occurs.

Status Indicators

RUN IndicatorThe RUN indicator illuminates during normal operation and flashesduring the auto-tuning sequence.

HI HEAT IndicatorThe HI HEAT indicator illuminates when fluid heaters are at 100%capacity to rapidly raise fluid temperature.

LO HEAT IndicatorThe LO HEAT indicator illuminates when fluid heaters are at 50percent capacity.

COOL IndicatorThe COOL indicator illuminates when fluid temperature is abovethe set point and is being cooled.

Display Indicators

TO PROCESS IndicatorThe TO PROCESS indicator illuminates when the PROCESSLED screen on the controller displays the temperature of theoutgoing fluid.


FROM PROCESS IndicatorThe FROM PROCESS indicator illuminates when the PROCESSLED screen on the controller displays the temperature of theincoming fluid.

ρT IndicatorThe ρT indicator illuminates when the PROCESS LED screen onthe controller displays the difference in temperature betweenoutgoing Delivery fluid and incoming Return fluid.

FLOW IndicatorThe FLOW indicator illuminates when the PROCESS LED screenon the controller displays the flow of fluid in liters per minute; thisfunction requires the optional flow sensor.

Alarm Indicators

FLUID PRESSURE IndicatorThe FLUID PRESSURE indicator illuminates when fluid pressureis low. The TCU shuts down and resumes operation only when aproper level of fluid pressure is restored.

SAFETY THERMO IndicatorThe SAFETY THERMO indicator illuminates 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 bedisconnected to reset the M2B controller.

HI/LO ALARM IndicatorThe HI/LO ALARM indicator illuminates when an individually-setalarm condition occurs. The HI deviation is +200ºF (about +93ºC)above the set point. The LO deviation is -100ºF (about -37ºC)below the set point. Alarms reset automatically.

PROBE FAIL IndicatorThe PROBE FAIL indicator illuminates when a temperaturesensing probe fails. A delivery probe failure displays DEL on thescreen, and a return probe failure displays RET on the screen. Thealarm resets after the failed probe is replaced.


MOTOR FAIL IndicatorThe MOTOR FAIL indicator illuminates during improper pumprotation, motor out of phase, or thermal motor overload conditions.This is a fatal fault condition, requiring that main power bedisconnected to reset the M2B controller.

5-3 Using M2B Controller KeysSET POINT

SET POINT Key

Press and hold the SET POINT

SET POINT key, 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 theSET POINT LED screen.

UP

UP Arrow Key

Press the UP

UP Arrow key to increment or advance the valuesor settings on the LED screens.

DOWN

DOWN Arrow Key

Press the DOWN

DOWN Arrow key to decrement or reduce thevalues or settings on the LED screens.

Important!Do not change any of the control settings

without consulting the Sterling/Sterlco Service Department. The Sterling, Inc. warranty does not cover TCU failures

from tampering with controller settings!


ENTER

ENTER Key

Use the ENTER

ENTER key with the INDEX

INDEX key menu tostore the value or the item that was changed. If this key is notpressed, the previously-stored value or item is retained.

INDEX

INDEX Key

Each press of the INDEX

INDEX key advances the screen to thenext menu item. Refer to your Sterling/Sterlco M2B TemperatureControl Owner’s Manual for a list of functions available using thiskey.

HIALARM HI ALARM 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 theDOWN

DOWN Arrow key to decrease the alarm high limit valueon the SET POINT LED screen. Refer to your Sterling/SterlcoM2B Temperature Control Owner’s Manual for a list of functionsavailable using this key.

ALARMLO

LO ALARM Key

Press and hold the ALARM

LO

LO ALARM key, then press the UP

UP Arrow key to increase the alarm low limit value or press theDOWN

DOWN Arrow key to decrease the alarm low limit value onthe SET POINT LED screen. Refer to your Sterling/Sterlco M2BTemperature Control Owner’s Manual for a list of functionsavailable using this key.


MAN.COOL

DISPLAY

DISPLAY Key

Press the DISPLAY

DISPLAY key to advance through the displaymenu. Each key press increments to the next available function.The screen returns to delivery temperature after thirty (30) secondsof inactivity. Refer to your Sterling/Sterlco M2B TemperatureControl Owner’s Manual for a list of menus available using thiskey.

Digital Flow ScreenOptional

The optional digital flow screen displays process flow in gallonsper minute (gpm). No customer-usable control is necessary.Depending on option level and setup, flows can be measured atrates reaching and exceeding 75 gallons per minute (284 lpm).

5-4 Identifying Control Panel SwitchesThis section lists the descriptions and functions of the control panelswitches. These switches control the operation of the unit.

Figure 4Control Panel Switches

Pump StartPress the START button to start the pump in the normal forwarddirection.

START STOP REVERSE VENT AUTO OFF SILENCE

Pump StartPump Stop

Pump ReverseVent Cycle Start

Mode SelectAlarm Silence


Pump StopPress the STOP button to stop the pump and de-energize thecontroller.

! CAUTIONAlways press the Pump Stop button and allow thepump to come to a complete stop before pressing thePump Reverse button.Failure to let the pump stop before reversing maydamage the pump and drive.

Pump ReversePress the REVERSE button to start the pump in the reversedirection. Use this feature to purge oil from the mold.

Vent Cycle StartPress the VENT button to start the vent cycle timer. Use thisfeature to purge air and water from the unit and process.

Mode SelectWith the pump running, you can select the AUTO position or theMaintained (manual cooling) position with the Mode Selectswitch. Select AUTO mode to energize the controller, permitting itto monitor and control the process. The switch automaticallyreturns to the Center Default position when in AUTO mode. Theswitch stays in the Maintained position in Manual Cooling mode.

! CAUTIONAlways let the pump run for at least one (1) minutebefore switching to AUTO mode.

Never switch to AUTO mode when filling or venting theunit, except as described in the Unit Startup chapter.Improper switching can seriously damage the heater,as it could become energized with air in the system.


Alarm SilencePress the ALARM SILENCE button to silence the audible alarmon the console.

! CAUTION

After you silence the alarm, make sure you locate andcorrect the alarm condition before continuing with unitoperation.

5-5 Identifying System Status Board IndicatorsThe system status board is located next to the controller panel. Itdisplays indicator lights to show current operation status, lettingyou analyze system performance.

Figure 5System Status Board Indicators

PUMP OVERLOAD

PUMP REVERSE

PUMP FORWARD

SYSTEM STATUSMODE

POWER ON

AUTO

HEATERBYPASSRELIEF VALVE

ON SAFETYTHERMO

DELIVERY

STRAINER

RETURN

LOWPRESSURE

HEATEXCHANGER

DRAIN

COOLSOLENOIDVENT

SOLENOIDRES.TANK

LOWLEVEL

HIGHLEVEL

VENT

FILL


Use the status board to optimize unit performance. For example, ifyou observe a rapid cycling of the Heater and Cool Solenoidindicators, the unit is operating with a process inefficiency; see theTroubleshooting section for more information.

What follows is a description of system status board indicators.

Status Indicator Lights

Pump Reverse Indicator LightThe Pump Reverse indicator light illuminates when the unit pumpruns in reverse.

Pump Forward Indicator LightThe Pump Forward indicator light illuminates when the unitpump runs in the normal forward direction. This indicator typicallyilluminates continuously during normal operation.

Heater On Indicator LightThe Heater On indicator illuminates when the heater energizes.

Cool Solenoid Indicator LightThe Cool Solenoid indicator illuminates when the coolingsolenoid energizes. It is used only on the optional heat exchanger.

Vent Solenoid Indicator LightThe Vent Solenoid indicator illuminates when the ventingsolenoid energizes during venting sequences.

Mode Indicator Lights

Select the unit operating mode by using the selection switch.

Power On Mode Indicator LightThe Power On mode indicator light illuminates to indicate that thecontrol circuit is energized in the unit.


Auto Mode Indicator LightThe Auto mode indicator light indicates that the Auto mode isactive and the controller is monitoring the system and controllingthe process.

If the Auto light is off and the Cool Solenoid indicator light isilluminated, the controller is disabled and the cooling solenoid isopen, permitting maximum cooling.

If the Auto and Cool Solenoid indicator lights are off, the unit isin standby.

Fault Indicator Lights

Pump Overload Indicator LightThe Pump Overload indicator light illuminates when the pump isoverloaded. This is an alarm condition, so the audible alarmactivates to notify you of the pump overload fault, and the unitshuts down.

Always correct the alarm condition before returning to normaloperation!

Low Pressure Indicator LightThe Low Pressure indicator light illuminates when the unit haslow heat transfer fluid pressure. This is an alarm condition, so theaudible alarm activates to notify you of the low pressure fault, anddisables controller outputs, permitting the pump to continue tocirculate fluid to avoid damage. If low pressure continues past fiveminutes elapsed time, the pump shuts off.


Safety Thermo Indicator LightThe Safety Thermo indicator light illuminates when the unit isoverheating. This is an alarm condition, so the audible alarmactivates to notify you of the safety thermo fault, and disablescontroller outputs, permitting the pump to continue to circulatefluid to avoid damage.

Always correct this alarm condition before returning tonormal operation!


High Level Indicator Light (Optional)The High Level indicator light illuminates when the heat transferfluid level in the reservoir tank is too high. Carefully remove justenough fluid so this indicator light shuts off.

Low Level Indicator LightThe Low Level indicator light illuminates when the heat transferfluid level in the system is too low. This is an alarm condition, sothe audible alarm activates to notify you of the low fluid levelfault, and the controller outputs are disabled.



- Notes -


6 Preventive Maintenance

! WARNINGMake sure that your maintenancetechnicians comply with lock-out/tag-outprocedures during any servicing ormaintenance of this unit and relatedequipment, per OSHA article ART 1910.147.Before you begin servicing this unit,disconnect all power to the unit, let the unitcool down completely, and turn off thewater.Failure to follow these directives can resultin serious injury or death!

6-1 Periodic ChecksMaking Daily Checks

• Check fluid level; add fluid as needed.

• Check all connecting lines, hoses, and connectors for wear ordamage.

Making Monthly Checks

• Check for leaks developing at the pump seal, gaskets, andother similar locations.

• Check the pump drive V belt for any wear.

• Check the reservoir tank vent for any obstructions.


Making Quarterly Checks

• Check the heat transfer fluid for deterioration. If the fluid isnoticeably darker, or it seems significantly thicker, drain thesystem and replace the fluid with fresh, new recommendedheat transfer fluid.

Do a routine check of the fluid every 1,000 hours ofoperation or every three (3) months, whichever comes first.Contact Sterling, Inc. Service for information on fluidtesting.

Making Six-Month Checks

• Inspect electrical connections for secure, tight electricalterminations and ground connections. Inspect the powercable, especially at the entrance point to the electricalenclosure. Have a qualified electrician perform thisinspection.

• Check the mounting bolts on the pump, the motor, and theheater flange for tightness.

• Remove the heat exchanger tube bundle and check it for limeand mineral deposits. Carefully clean the bundle as needed.

6-2 Routine ServicingYour hot oil temperature control unit requires little in preventivemaintenance and servicing. To keep it in good, reliable workingorder, make sure you follow the following scheduled preventivemaintenance procedures.

Keep surfaces clean and free of any excessive accumulations ofdirt, oil, or debris. This is especially true for the pump. It relies onfree air circulation for proper cooling.

Check the motor air intake screen for any accumulation of dirt;clean it as needed.


Servicing the Unit Monthly or Every 500 Hours

• Lubricate the pump at the grease fittings with a high-quality lithium grease rated at 400ºF (204ºC) or higher. Useonly Dow-Corning #44 or a high temperature grease rated at400ºF or higher that is compatible with Dow-Corning #44.Do not over-lubricate.

• Adjust the pump drive belt tension. Make sure that themotor pulley is properly aligned with the pump pulley; use astraightedge to check. Tighten motor mounting bolts afterrealignment.

• Inspect the screen in the Y strainer for accumulations ofdebris. Clean as needed.

Servicing the Unit Every Three Months

Remove and clean the screen in the Y-strainer. Replace the screenif it is damaged.

6-3 Draining the Unit for StorageYou should thoroughly flush and drain the 2016M unit if you needto take it out of service for a long time, or if you expect it tobecome exposed to freezing temperatures. Sterling, Inc.recommends SterlFlush™ flushing fluid or equivalent for flushingyour 2016M unit; follow unit flushing instructions that comes withSterlFlush™ flushing fluid.

Drain plugs arc provided at the base of the heater tank, reservoirtank, and on the pump. You should also remove, drain, andreinstall the heat exchanger tube bundle before storage.

6-4 Corrective MaintenancePumps and Seals

Each 2016M unit is completely tested and calibrated beforeleaving the factory. The unit is then cooled, drained, and packedfor shipment.


If the unit stands idle for a long time before being installed in yourfactory, gaskets can dry out and possibly leak when you start theunit. 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 minorleaks upon startup; you may need to re-tighten bolts or fittingsto stop the leak.

You should expect to periodically replace the pump seal. If thepump is properly lubricated and used at moderate temperatures, theseal should last several years. The following section describes theproper procedures for replacing the seal (Mechanical seal, part no.162-00030-160). Periodic replacement of the pump drive V-belt isalso to be expected.

Note: If the pump motor wiring is disconnected for removal fromthe unit, you must check the actual direction of rotationwhen the motor is rewired to the unit. Consult ElementaryDiagrams provided in unit for additional information.

6-5 Maintaining the PumpDisassembly

! WARNINGBefore opening the pump chamber:

• Make sure that any pressure in the chamber has beencompletely vented!

• Make sure that the motor cannot be inadvertently started whileyou work on the pump!

Failure to follow these precautions may result in serious injuryor death!


Figure 618-24 GPM Pump Construction 075-00370-02


Disassembling the Pump 1. Mark the head and casing before disassembly to insure

proper reassembly. The idler pin, which is offset in thepump head, must be positioned toward and equal distancebetween port connections to allow for proper flow of liquidthrough the pump.

Remove the head from the pump. Do not allow the idler tofall from the idler pin. To prevent this from happening, tiltthe top of the head back when removing. Avoid damagingthe head gasket.

2. Remove the idler and the bushing assembly. 3. Insert a length of hardwood or brass through the port

opening between the rotor teeth to keep the shaft fromturning. Bend up the lockwasher tang with a spannerwrench. Remove the locknut and lockwasher from theshaft.

4. Loosen Allen head setscrews in the face of the thrustbearing assembly. Remove the thrust bearing assembly bythreading out of the bracket.

Figure 7Thrust Bearing Assembly

5. Loosen the radial setscrews in the thrust bearing assemblyand remove the end cap using the spanner wrench.

6. Remove the bearing spacer collars and the ball bearing.

7. Using snap ring pliers, remove snap ring from shaft.

8. Remove two nuts holding seal gland plate and seal gland inplace. Slide seal gland off of the shaft being careful not todamage the lip seal.


9. Using a soft headed hammer, gently tap on the end of the rotorshaft until the rotor and shaft assembly can be completelyremoved from the pump. Note the mechanical seal may stickto the shaft causing initial resistance when the shaft isremoved.

10. Remove the mechanical seal parts from the bracket.

11. Clean all parts thoroughly and examine for wear and damage.Check lip seals, ball bearing, bushings and idler pin and replaceif necessary. Check all other parts for nicks, burrs, excessivewear and replace if necessary.

Wash bearings in clean solvent. Blow out bearings withcompressed air. Do not allow bearings to spin; turn themslowly by hand. Spinning bearings will damage race and balls.Make sure bearings are clean, then lubricate with non-detergentSAE 30 weight oil and check for roughness. Roughness can bedetermined by turning outer race by hand.

12. Casing can be checked for wear or damage while mounted onbracket.

Pump Assembly

The seal used in this pump is simple to install. If you take careduring installation, good performance will result.

The principle of the mechanical seal is to make contact betweenthe rotary and stationary members. These parts are lapped to a highfinish, and their sealing effectiveness depends on complete contact.When requesting special seal information, make sure that you givethe pump model number and serial number.

1. Install bracket bushing if required. If bracket bushing has alubrication groove, install bushing with groove at 6:00 o’clockposition in bracket. If carbon graphite, Refer to Installation ofCarbon Graphite Bushings, page 53.

2. Coat shaft of rotor shaft assembly with non-detergent SAE 30weight oil. Start end of shaft in bracket bushing turning fromright to left, slowly pushing rotor in casing.


3. Coat idler pin with non-detergent SAE 30 weight oil and placeidler and bushing on idler pin in head. If replacing with carbongraphite bushing, Refer to Installation of Carbon GraphiteBushings, page 53.

4. Using a .010 to .015 inch head gasket, install head and idlerassembly on pump. Pump head and casing were marked beforedisassembly to insure proper reassembly. If not, be sure idlerpin, which is offset in pump head, is positioned toward andequal distance between port connections to allow for properflow of liquid through pump. Tighten head capscrews evenly.

5. Place the mechanical seal installation tapered half rings overthe shaft and apply P-80 oil supplied with the replacement seal,grease is not recommended on the sleeve and rotor shaft.Slide the rotating portion of the mechanical seal on the shaftuntil it bottoms on the shaft step. See FIGURE 6. Remove theseal installation tapered half rings. It is important when usingthe rings to make sure the thin edge is facing the direction ofthe shaft end, and that the thick end is facing the rotor.

6. Apply lubricant to the seal seat o-ring and push it in thebracket. Note the shinny side of the seat goes towards thecarbon graphite seal face.

7. Apply Dow Corning #44 high temperature silicon grease to thelip seal area in the seal gland and install on the shaft. Installthe seal gland plate and secure with two nuts.


8. Pack ball bearing with Dow Corning #44 high temperaturesilicon grease and install in the thrust bearing housing. Placebearing spacer collars inside the lip seals. Thread the end capinto the bearing housing and tighten with a spanner wrench.Tighten the radial set screws that lock the end cap in place.

9. Using the snap ring pliers, install the snap ring onto the shaft.

10 Thread the thrust bearing assembly into the bracket. Turn inuntil hand tight. This forces the rotor against the head.

11. Put lockwasher and locknut on shaft. Insert length of hardwoodor brass through port opening between rotor teeth to keep shaftfrom turning. Tighten locknut to 50 – 70 ft.-lbs. torque andbend one tang of lockwasher into slot.

12. Adjust pump end clearance. Refer to section on Thrust BearingAdjustment.

13. Lubricate all grease fittings with Dow Corning #44 hightemperature silicon grease.


Thrust Bearing Adjustment

1. Loosen axial setscrews in face of end cap on the thrust bearingassembly. If rotor shaft cannot be turned by hand, back off thethrust bearing assembly until there is a noticeable drag of theshaft. Note mechanical seal will provide some drag and this isa normal condition. The thrust bearing assembly must beturned in until it can just be turned over by hand. This ensuresthe rotor is against the head and a zero end clearance conditionexists.

2. Make a mark on the OD of the bearing housing and acorresponding mark on the bracket. Back off thrust bearinghousing the required number of marks or distance on the ODas shown below.

3. Tighten the axial setscrews in the face of the thrust bearingassembly. Make sure the rotor shaft turns freely. If it doesnot, repeat steps 1 and 2.

*Each small notch on outer end cap represents .001 inch end clearance.

! WARNINGBefore starting the pump, make sure that alldrive equipment guards are in place!

Failure to properly install the guards may resultin serious injury or death!

PUMPSIZE

Turn Outer End Cap C.C.W.

No. of Notches* or Length on O.D., Inches

G - 0.75"

HL, HV 6 1"

KK 10 1.38"


Installation of Carbon Graphite Bushings

When installing carbon graphite bushings, extreme care must betaken to prevent breaking. Carbon graphite is a brittle material andeasily cracked. If cracked, the bushing will quickly disintegrate.Using a lubricant and adding a chamfer on the bushing and themating part will help in installation. The additional precautionslisted below must be followed for proper installation:

1. A press must be used for installation.

2. Be certain bushing is started straight.

3. Do not stop pressing operation until bushing is in properposition. Starting and stopping will result in a cracked bushing.

4. Check bushing for cracks after installation.

Carbon graphite bushings with extra interference fits arefrequently furnished for high temperature operation. Thesebushings 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 ispossible to install with 450°F. temperature; however, the lowerthe temperature, the greater the possibility of cracking thebushing.


Preventative Pump Maintenance

You can extend the life of your pump and reduce the cost pergallon pumped if you perform a few preventive maintenanceprocedures.

Lubricating the PumpUsing #2 ball bearing grease and a hand-operated grease gun,gently lubricate all grease fittings after every 500 hours ofoperation or after 60 days, whichever comes first. If pump serviceoccurs in severe conditions, lubricate more frequently. Use anappropriate type of grease for hot or cold applications.

Adjusting End ClearanceAfter long periods of service, the running clearance between theend of the rotor teeth and head may be increased from wear. Thepump may lose some capacity of pressure as a result. If you resetthe end clearance, pump performance should improve.

Examining Internal PartsRemove the head occasionally and examine the idler, bushing,head and pin for wear. Replace the idler bushing and idler pin aftermoderate wear to avoid replacing more expensive parts later.

Note: Make sure the idler doesn’t slide off the idler pin duringhead removal to avoid damage and personal injury.

Cleaning the PumpA clean pump is easier to inspect, lubricate, and adjust; it runsbetter and looks better!

Storing Your 2016M UnitIf you anticipate that your unit will be out of service or stored for along time, flush and drain the pump and circulating system toprotect it from freeze-ups or rusting. See Section 6-3 on Page 45for more information.


Figure 8Customer-Recommended Spare Parts

Immersion Heaters

Part number Description722-00138-07 HTR, IMM, 12 KW, 208 V, 3”, 6 ELE722-00138-08 HTR, IMM, 12 KW, 240 V, 3”, 6 ELE722-00138-09 HTR, IMM, 12 KW, 380 V, 3”, 6 ELE722-00138-10 HTR, IMM, 12 KW, 415 V, 3”, 6 ELE722-00138-11 HTR, IMM, 12 KW, 480 V, 3”, 6 ELE722-00138-12 HTR, IMM, 12 KW, 600 V, 3”, 6 ELE

Note: 6KW heaters are modified 12 kW heaters; jumpers areremove from one leg.

Heater Gasket

Part number Description542-00007-08 GASKET, FLANGE, 3

Heater Tank

Part number Description572-87548-00 TANK, HEATER, 2016M, 3½

Manual Reset Safety Thermostat

Part number Description724-00041-00 THERMOSTAT, 200ºF — 550ºF

Note: Please give model and serial numbers when ordering parts.Prices are subject to change without notice.


Figure 8Customer-Recommended Spare Parts Cont’d.

Pressure Gauge

Part number Description037-00119-00 GAUGE, PRESSURE, 0 — 100 PSI

Optional Heat Exchangers; Tube Bundle Only

Ass’y. part no. Tube bundle only part no. Description106-00267-00 162-00047-10 3.9 SQ. FT. 2016M 550°F106-00268-00 162-00047-11 6.7 SQ. FT. 2016M 550°F

Pilot Lights

Part number Description715-10074-00 PILOT, LED, 120 V, RED, N-12, 36”, LEAD715-10075-00 PILOT, LED, 120 V, AMBER, N-12, 36”, LEAD715-10076-00 PILOT, LED, 120 V, GREEN, N-12, 36”, LEAD

Casters

Part number Description042-00016-00 CASTER, SWIVEL, 3”042-00017-00 CASTER, STATIONARY, 3”

Manual Reset Safety Thermostat

Part number Description724-00041-00 THERMOSTAT, 200ºF — 550ºF

Sight Glass Assembly

Part number Description037-00046-00 GLASS, SIGHT, 15¾




Controllers

Part number Description601-00521-06 CONTROLLER, M2B, 550ºF724-00589-01 CONTROLLER, STERLCO 4000

Selector Switches and Push Buttons

Part number Description721-01028-00 PUMP STOP721-01027-00 PUMP START721-01026-00 ALARM SILENCE717-01016-00 MODE SELECT721-01026-00 VENT721-01029-00 PUMP REVERSE717-10055-00 HALF-FULL HEAT, LOCAL-REMOTE (OPTIONAL)

Pressure Switches

Part number Description733-00029-00 SWITCH, PRESSURE

Pump

Part number Description075-00370-01 MECH. SEAL, VIKING HL4125 (0-30 GPM)

Motors

Part number Description720-09240-00 MOTOR, 1 HP 3/60/208, 230, 460 V720-09242-00 MOTOR, 1½ HP 3/60/208, 230, 460 V720-09218-00 MOTOR, 2 HP 3/60/208, 230, 460 V




Solenoid Valves

Part number Description732-00007-03 ¼” VALVE, 115 V COIL (0-125 PSI, 300°F)732-00013-01 ¾” VALVE, 115 V COIL (0-125 PSI, 300°F)

Sensing Probe Equipment

Part number Description692-07369-05 HEAT & COOL, M2B701-00003-00 TYPE ‘I’ THERMOCOUPLE

Disconnect Switches

Part number Description728-00153-00 SWITCH, DISCONNECT, 45 AMP728-00168-00 SWITCH, DISCONNECT, 100 AMP

Heater Tank Insulation

Part number Description542-88062-00 INSULATION, TANK, HEATER

Ful-Flo Relief Valves

Part number Description044-00239-00 VALVE, RELIEF, FUL-FLO, 1”

Breather Cap

Part number Description161-00072-00 CAP, BREATHER, 1”



7 Troubleshooting

Condition Possible cause Solution

Undersized connectors/lines. Increase size of connectors/water lines.Long connecting lines betweenunit and mold.

Move the unit closer to the moldand shorten connecting lines.

Serpentine flow through mold. Connect lines for parallel flowinstead of series flow.

Blocked line in mold. Check mold for metal chips ordeposits. Clean mold.Quick disconnect fitting withcheck valve.

Remove and replace fitting orvalve.

Carbon build-up in unit piping orfittings.

Clean or replace affected piping.Replace fluid.

Faulty Sterlco TCU.

Check unit by opening themanual bypass to determine ifthe TCU contols the set pointtemperature.

Temperature fluctuations/rapidcycling from hot to cold.

Reversed probes. Switch Return and Deliveryprobes.

Loss of fluid in process. Check all lines/connections/fittings.

Vent valve open.Allow vent timer to run out; or,check valve operation when unitis cold by opening the fill port.

Faulty/dirty solenoid valve;usually detected when there is asteady stream or trickle of waterout of the drain line.

Switch to Manual Cool modeseveral times to flush valve. Ifthe leak continues, disconnectthe power to the unit, turn off thewater supply, and clean orreplace the solenoid.

Unit does not heat properly/cannot achieve set point.

Degraded fluid. Drain and replace fluid.

Defective heater contactor.Visual inspection of coil andcontacts. Repair/replacedefective contactors.

Defective immersion heater.

Check resistance on all three (3)legs of heater with anohmmeter. If not all equal,contact factory for replacementheater.

Unit does not heat.

Heater burnout.

Check heater tank for scorched/discolored paint. Checkresistance on all three (3) legs ofheater with an ohmmeter.Replace heater as needed.


Troubleshooting Cont’d.

Condition Possible cause Solution

Controller heater output open.

Check the heater output with anohmmeter to ground. It shouldread in the mega-ohm range.Infinite or zero readings indicatea defective output.

Unit does not heat.(cont’d.)

Clogged Y strainer. Clean Y strainer.Water supply to unit is turnedOFF. Open water supply.

Water drain is plugged orexcessive back pressure in drainline.

Clear drain line or eliminateback pressure condition.

Heat exchanger tubes pluggedby lime deposits.

Remove tube bundles; clean/replace as required.

Unit overheats/unable to cool.

Faulty solenoid valve.

Test solenoid valve by switchingto Manual Cool mode and listenfor valve operation. Replace iffaulty.

Leaks in connecting lines. Inspect/replace faulty line orconnection.

Air in circulating lines. Perform venting sequence inChapter 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 inpiping (see Chapter 3), or boilwater off.

Vent solenoid open.Allow vent timer to run out; or,check valve operation when unitis cold by opening the fill port.

Pump running in reverse.Check motor; rewire ifnecessary. See electricaldiagrams.

Pump repair/adjustment needed. Adjust head spacing or replaceworn pump components.

Rapid drop in pressure/nopressure.

V belt broken/worn. Replace as required.

Water in fluid.Drain water from low point inpiping (see Chapter 3), or boilwater off.Noisy pump.

Severely degraded fluid. Drain and flush system. Replacefluid.


Service Notes


I Index

ρT indicator, 33

2016M Series hot oil unitillustration, 15

2016M Series TCUspecifications, 15

Adjusting End Clearance, 54Air purge, 13Alarm indicators, 33–34; Fluid

Pressure indicator, 33;Hi/Lo Alarm indicator, 33;Motor Fail indicator, 34;Probe Fail indicator, 33;Safety Thermo indicator, 33

Available options, 9

Connecting cooling waterpiping, 21

Connecting piping, 19Connecting process piping, 21Connecting vent piping, 21Connection lines, 11Control panel switches, 36Controller keys, 36; Display

key, 36; Down arrow key,34; Enter key, 35; Hi Alarmkey, 35; Index key, 35; LoAlarm key, 35; Set Pointkey, 34; Up arrow key, 34

Cool indicator, 32Cooling, 11Copyright information, 2Corrective maintenance, 45

Daily checks, 43Delivery indicator, 32Digital flow meter, 36Display indicators, 32; ρT

indicator, 33; Deliveryindicator, 32; ºC flowindicator, 33; Returnindicator, 33

Display key, 36Down arrow key, 34Draining the unit, 45

Electrical panel, systemcomponents, 12

Electrical schematic, drawing 1,26

Electrical schematic, drawing 2,26

Electrical system controls, 12Enter key, 35

Fault indicator lights, 40Fluid Pressure indicator, 33Ful-Flo valve, 10

Heater tank, 10Hi Alarm key, 35Hi Heat indicator, 32Hi/Lo Alarm indicator, 33

Immersion heaters, 9Index key, 35Installation, 18–26INSTALLATION OF CARBON

GRAPHITE BUSHINGS, 53Installation requirements, 18

Lo Alarm key, 35Lo Heat indicator, 32Lubricating the Pump, 54

M2B controller, 31M2B Controller Keys, 36M2B controller panel

components, 31–34M2B graphic, button control

panel, 31Maintaining the pump, 46Making electrical connections,

23Microprocessor controller, 31Mobile installations, 20Mode indicator lights, 39Models covered, 8Monthly checks, 43Motor Fail indicator, 34

Necessary documents, 7Noisy pump, 61

ºC flow indicator, 33

Operating range, 7

Periodic checks, 43Piping setup, 22Pressure switch, 13Preventative Pump

Maintenance, 54Preventive maintenance, 43–59Probe Fail indicator, 33Process screen, 32Pump, 10Pump Assembly, 49

Pump Maintenance: Cleaningthe Pump, 54; ExaminingInternal Parts, 54

Quarterly checks, 44

Rapid drop in pressure/nopressure, 61

Reservoir tank, 14Return indicator, 33Returning fluid to the tank, 29Returns, 17Revision number, 2RMA: return goods authorization

number, 16Routine servicing, 44Run indicator, 32

Safety considerations, 3Safety Thermo indicator, 33Safety thermostat, 13Screen displays, 32; Process

screen, 32; Set Pointscreen, 32

Set Point key, 34Set Point screen, 32Shipment not complete, 17Shipment not correct, 17Shipping damages, 16Shipping information, 16–17Shutting down the unit, 28Six-month checks, 44Spare parts, customer-

recommended, 56Standard features, 8Starting the unit, 27Startup Preparations, 27–30Status indicator lights, 39Status indicators, 32; Cool

indicator, 32; Hi Heatindicator, 32; Lo Heatindicator, 32; Run indicator,32

Storing Your 2016M Unit, 54System status board

indicators, 38

Temperature fluctuations/rapidcycling from hot to cold, 60

THRUST BEARINGADJUSTMENT, 52

Troubleshooting, 60–61

Unit does not heat, 60Unit does not heat properly/can

not achieve set point, 60


Unit overheats/unable to cool, 61Unpacking, inspection, 16Up arrow key, 34

Using controls and features:Microprocessor controller,31

Using controls and indicators,31–42

Work rules, 18


Service Notes


Parts DepartmentCall toll-free 7am–6pm CST [800] 783-7835 or call [414] 354-0970

The Sterling/Sterlco Parts Department at Sterling, Inc. is ready to provide the parts to keep your systems up andrunning. Sterling/Sterlco replacement parts ensure operation at design specifications. Please have the model andserial number of your equipment when you call. Consult the Customer Parts List included in your information packetfor replacement part numbers.

Service DepartmentCall 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 DepartmentCall [414] 354-0970 Monday–Friday, 8am–5pm CST

Sterling/Sterlco products are sold by a network of independent sales representatives. Contact our Sales Departmentfor the name of the sales representative nearest you.

Sterling/Sterlco5200 West Clinton AvenueMilwaukee, WI 53224-9518[414] 354-0970 • Fax [414] 354-6421

Sterling, Inc.

WarrantySterling, Inc. warrants all equipment manufactured by it to be free from defects in workmanshipand material when used under recommended conditions. The Company’s obligation is limited torepair or replace FOB the factory any parts that are returned prepaid within one year of equipmentshipment to the original purchaser, and which in the Company’s opinion, are defective. Each part,excluding the compressor and controller, comes with a standard 1 year warranty. Any replacementpart assumes the unused portion of this warranty. In addition, this unit comes standard with a 1year warranty on the compressor and 5 year limited warranty on the controller.

This warranty does not apply to any equipment which, in the Company’s opinion, has beensubjected to misuse, negligence, or operation in excess of recommended limits, including freezingor which has been repaired or altered without the Company’s express authorization. If the serialnumber has been defaced or removed from the component, the warranty on that component isvoid. Defective parts become the property of the warrantor and are to be returned.

The Company is not liable for any incidental, consequential, or special damages or expenses. TheCompany’s obligation for parts not furnished as components of its manufactured equipment islimited to the warranty of the manufacturers of said parts.

Any sales, use, excise, or other tax incident to the replacement of parts under this warranty is theresponsibility of the purchaser.

The company neither assumes nor authorizes any other persons to assume for it any liability inconnection with the sale of its equipment not expressed in this warranty.

Many types of Sterling, Inc. equipment carry an additional one-year service policy. Consult yourSterling/Sterlco sales representative for specific details.

PO Box 245018 • 5200 West Clinton Avenue • Milwaukee, WI 53224-9518Phone (414) 354-0970 • Fax (414) 354-6421

http://www.sterlco.com

Service Department

Call Toll Free

(800) 783-7835

Auxiliary Equipment for the Process IndustriesPO Box 2450185200 West Clinton Avenue • Milwaukee, WI 53224-9518(414) 354-0970 • Fax (414) 354-6421

Scrap Process Heating/ AutomatedRecovery Systems Cooling Parts Removal

Safety ConsiderationsTable of ContentsCharts & Figures1 General Information1-1 Introduction1-2 Necessary Documents1-3 Models Covered1-4 Standard Features1-5 Available Options1-6 Feature Descriptions

2 Shipping Information2-1 Unpacking & Inspection2-2 Shipping Damages2-3 Shipment Not Complete2-4 Shipment Not Correct2-5 Returns

3 Installation3-1 Work Rules3-2 Installation Requirements3-3 Connecting Piping3-4 Making Electrical Connections

4 Startup Preparations4-1 Starting the Unit4-2 Shutting Down the Unit4-3 Returning Fluid to the Tank

5 Using Controls & Indicators5-1 The Microprocessor Controller5-2 Identifying M2B Controller Panel Components5-3 Using M2B Controller Keys5-4 Identifying Control Panel Switches5-5 Identifying System Status Board Indicators

6 Preventative Maintenance6-1 Periodic Checks6-2 Routine Servicing6-3 Draining Unit for Storage6-4 Corrective Maintenance6-5 Maintaining the PumpCustomer-Recommended Spare Parts

7 Troubleshooting IndexContact InformationWarranty