ACS Sterling Royal Series User manual

Royal Series 2016-U Series Oil Temperature Control Units
Reference Manual (PN: 882.12044.00) for
Complete Operation and Installation Instructions
(Available online at www.sterlco.com)
Sterling Products, Inc. Part No: 682.98487.08
2900 S. 160th Street • New Berlin, WI 53151 USA Bulletin No: HC2-340
Tel. [phone] •Fax [phone]
Safety Concerns
Quickstart Installation Checklist
(Refer to main manual for complete installation instructions).
1. Connect 3-phase power based on nameplate data.
2. Install properly sized plumbing between temperature control
unit and primary processing equipment (supply and return).
3. Install properly sized plumbing between temperature control
unit and cooling water supply and return. You must provide
cooling water at 25 psig to 75 psig (172.4 kPa to 517.1
kPa/1.7 bar to 5.2 bar).
4. Ensure proper pump rotation. (The pump motor should be
moving clockwise while looking at the motor fan end).
Unit Operation
(Refer to main manual and controller manual for complete operating instructions).
Start Up
1. Add fluid to the reservoir tank until the level is near the top of the sight glass.
2. Turn disconnect switch to ON position.
3. Depress the "Pump Start" button to start the pump.
4. Maintain the level about 4 inches from the bottom of the sight glass.
5. Air and Oil will be vented through the Vent Solenoid and into the reservoir tank for 10 minutes.
6. 2 minutes after the unit has built at least 5psi of pressure, select a set point of 100°F (PV) by pressing the
SCROLL key until SP1 appears in the upper display. Then press the UP Arrow or
DOWN Arrow keys to adjust the setpoint.
7. With 2 minute intervals increase the setpoint to 150 and 200°F.
8. Select a setpoint of 215ºF (102ºC) and continue to run until no more steam appears and pressure has
stabilized.
Shut Down
1. Switch the Mode switch to the “Manual Cool” position.
2. Allow temperature to stabilize at 120°F (50°C).
3. Push the Pump Stop button to de-energize the unit.
Standard Controller
Control Panel Switches

Royal Series 2016-U Series Oil Temperature Control Units
Reference Manual (PN: 882.12044.00) for
Complete Operation and Installation Instructions
(Available online at www.sterlco.com)
Sterling Products, Inc. Part No: 682.98487.08
2900 S. 160th Street • New Berlin, WI 53151 USA Bulletin No: HC2-340
Tel. [phone] •Fax [phone]
Spare Parts Location
(See next page for Spare Parts List)

Royal Series 2016-U Series Oil Temperature Control Units
Reference Manual (PN: 882.12044.00) for
Complete Operation and Installation Instructions
(Available online at www.sterlco.com)
Sterling Products, Inc. Part No: 682.98487.08
2900 S. 160th Street • New Berlin, WI 53151 USA Bulletin No: HC2-340
Tel. [phone] •Fax [phone]
Spare Parts List
(See previous page for Spare Parts Location)
Cooling Heat
Exchanger -
Valves
Complete Heat
Exchanger
Replacement Tube
Bundle
1a
3.9 sq. ft. U-tube
106.00267.00
162.00047.10
6.9 sq. ft U-tube
106.00268.00
162.00047.11
13 sq. ft. U-tube
106.00169.00
162.00047.12
21 sq. ft. U-tube
106.00170.00
162.00047.13
1b
¾inch (1.9 cm)
732.00013.02
Immersion
Heaters
230/3/60
460/3/60
575/3/50
2
12-kW (1 req’d)
722.90603.04
722.90603.13
722.90603.16
12-kW contactor (2 req’d)
726.00270.02
726.00265.02
726.00265.02
18-kW (1 req’d)
722.90603.05
722.90603.14
722.90603.17
18-kW contactor (2 req’d)
726.00271.02
726.00269.02
726.00268.02
24-kW (1 req’d)
722.90603.06
722.90603.15
722.90603.18
24-kW contactor (2-req’d)
726.00272.02
726.00270.02
726.00269.02
36-kW (2 req’d)
722.90603.05
722.90603.14
722.90603.17
36-kW contactor (2 req’d)
726.00273.02
726.00271.02
726.00271.02
48-kW (2 req’d)
722.90603.06
722.90603.15
722.90603.18
48-kW contactor (2 req’d)
726.00346.02
726.00272.02
726.00271.02
Motor Pumps
230/3/60
460/3/60
575/3/50
3
18 to 24 gpm Pump
075.00370.02
075.00370.02
075.00370.02
1-HP (0.75 kW) motor
720.09240.00
720.09240.00
720.09274.00
1-HP (075 kW) MCP
726.00334.00
726.00330.00
726.00330.00
1.5-HP (1.1 kW) motor
720.09242.00
720.09242.00
720.09028.00
1.5-HP (1.1 kW) MCP
726.00336.00
726.00334.00
726.00334.00
2-HP (1.5 kW) motor
720.09218.00
720.09218.00
720.09322.00
2-HP (1.5 kW) MCP
726.00336.00
726.00334.00
726.00334.00
50 gpm Pump
075.00421.02
075.00421.02
075.00421.02
3-HP (2.25 kW) motor
720.09638.00
720.09638.00
720.09247.00
3-HP (2.25 kW) MCP
726.00337.00
726.00336.00
726.00334.00
Pump Seal
Kits
4
075.00370.02 Pump
162.00030.144
075.00421.02 Pump
162.00030.161
Common Parts
5
Pressure switch **
733.00029.00
6
Safety thermostat (1 per heater)
724.00735.00
Safety thermostat probe (1 per heater)
701.00115.00
7
Relief valve
044.00138.00
8
18 to 24 gpm Ful-flo bypass valve
044.00239.00
50 gpm Ful-flo bypass valve
044.00164.00
9
Type “K” thermocouple
701.00036.00
Temperature control module with relay outputs
724.00756.02
AEC
Document #
2005-spares-tcu
** Reference complete manual (PN: 682.88108.00) for proper settings and installation.

Royal Series 2016-U Series Oil Temperature Control Units
Reference Manual (PN: 882.12044.00) for
Complete Operation and Installation Instructions
(Available online at www.sterlco.com)
Sterling Products, Inc. Part No: 682.98487.08
2900 S. 160th Street • New Berlin, WI 53151 USA Bulletin No: HC2-340
Tel. [phone] •Fax [phone]
Troubleshooting - Quick Guide
Problem
Possible cause
Solution
Unit does not turn on
No power
Check main disconnect, fuses, wiring, and power lead to unit.
Wrong voltage supplied to unit
Voltage must be within plus or minus 10% of nameplate rating
Defective START push button
Replace
Control circuit fuse blown
Replace
Defective control transformer
Check transformer. Replace if necessary.
Unit does not run
Broken or loose wire in pump motor control
circuit
Locate and repair
Pump motor contactor holding coil is open
Repair or replace
Pump overload light on
Reset and test each leg for balanced amp draws
Temperature
fluctuations/rapid cycling
from hot to cold.
Undersized connectors/lines.
Increase size of connectors/fluid lines.
Long connecting lines between unit and mold.
Move the unit closer to the process and shorten connecting
lines.
Blocked line in process.
Check process for debris or deposits. Clean mold.
Carbon build-up in unit piping or fittings.
Clean or replace affected piping. Replace fluid.
Unit overheats or does not
cool.
Water supply to unit is turned OFF.
Open water supply.
Water drain is plugged or excessive back
pressure in drain line.
Clear drain line or eliminate back pressure condition.
Heat exchanger tubes plugged by lime
deposits.
Remove tube bundles; clean/replace as required.
Faulty solenoid valve.
Test solenoid valve by switching to Manual Cool mode and
listen for valve operation. Replace if faulty.
Unit does not heat
properly/cannot achieve
set point.
Loss of fluid in process.
Check all lines/connections/fittings.
Vent valve open.
Allow vent timer to run out; or, check valve operation when unit
is cold by opening the fill port.
Faulty/dirty solenoid valve; usually detected
when there is a steady stream or trickle of
water out of the drain line.
Switch to Manual Cool mode several times to flush valve. If the
leak continues, disconnect the power to the unit, turn off the
water supply, and clean or replace the solenoid.
Degraded fluid.
Drain and replace fluid.
Unit does not heat.
Defective heater contactor.
Visual inspection of coil and contacts. Repair/replace defective
contactors.
Defective immersion heater.
Check resistance on all three (3) legs of heater with an
ohmmeter. If not all equal, contact factory for replacement
heater.
Heater burnout.
Check heater tank for scorched/discolored paint. Check
resistance on all three (3) legs of heater with an ohmmeter.
Replace heater as needed.
Clogged Y strainer.
Clean Y strainer.
Controller heater output open.
Check the heater output with an ohmmeter to ground. It should
read in the mega-ohm range. Infinite or zero readings indicate a
defective output.
Rapid drop in pressure/no
pressure.
Leaks in connecting lines.
Inspect/replace faulty line or connection.
Air in circulating lines.
Preform venting sequence in Chapter 3.
Low fluid.
Check fluid level in sight glass. Add fluid if required.
Defective Ful-Flo valve.
See Chapter 3.
Water in fluid.
Drain water from low point in piping (see Chapter 3), or boil
water off.
Vent solenoid open.
Allow vent timer to run out; or, check valve operation when unit
is cold by opening the fill port.
Pump running in reverse.
Check motor; rewire if necessary. (See electrical diagrams)
Pump repair/adjustment needed.
Adjust head spacing or replace warn pump components.
V belt broken/worn.
Replace as required.
Noisy pump.
Water in fluid.
Drain water from low point in piping ( see Chapter 3), or boil
water off.
Severely degraded fluid.
Drain and flush system. Replace fluid.