Operation and Installation Manual Royal Series Water Temperature Control Units Important! Read Carefully Before Attempting to Install or Operate Equipment Part No. 682.88105.00 Revision G Bulletin No. SC1-610.
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 2008 All rights reserved. Effective 4/15/08 Part No. 682.88105.00 Revision G Bulletin No.
Safety Considerations Sterling Royal Series temperature control units are designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. To avoid possible personnel injury or equipment damage when installing, operating, or maintaining this equipment, use good judgment and follow these safe practices: Only PROPERLY TRAINED personnel familiar with the information within this manual should work on this equipment.
Table of Contents 1 General Information ................................................ 6 1-1 1-3 1-4 1-5 2 Shipping Information ............................................. 12 2-1 2-2 2-3 2-4 2-5 2-6 3 Introduction ................................................................................... 33 Startup Checklist ........................................................................... 33 Starting the Temperature Control Unit ..........................................
6-2 6-3 6-4 6-5 6-6 7 I Corrective Maintenance ................................................................ 39 Restoring the Controller to Factory Setup ..................................... 41 Electrical Connections................................................................... 41 Safety Devices .............................................................................. 42 Cleaning and Storage ................................................................... 44 Troubleshooting .............
1 1-1 General Information Introduction Sterling/Sterlco Royal Series water temperature control units are reliable, accurate, and easy-to-use process temperature control units. They are self-contained, portable, and shipped ready to use. The Royal Series water temperature control unit is designed to circulate water through your process and to precisely, automatically, and reliably maintain it at a specified temperature.
1-2 Necessary Documents The following documents are necessary for the operation, installation, and maintenance of Sterling/Sterlco Royal Series water temperature control units. Additional copies are available from Sterling. Familiarize the appropriate personnel with these documents: This manual. The controller operation manual. The electrical schematic and connection diagram placed inside the control enclosure. The operation and installation manuals for accessories and options selected by the customer.
1-5 • Forward-facing liquid-filled To and From Process pressure gauges • Independent high temperature safety thermostat • Non-fused lockable rotary disconnect • Branch fusing • ¼” cooling solenoid valve on ¾ to 3 hp (0.56 to 2.24 kW) models; ½” slow-close cooling solenoid valve on 5, 7½, & 10 hp (3.73, 5.60, & 7.46 kW) models • EPDM/NI-Resist pump seal • Adjustable low supply water pressure switch; factory-set at 16 psig (110 kPa/1.1 bars) • 150 psig (1,034 kPa/10.
Remote set point and retransmission; 0-20 mA and 4-20 mA RS-232 or RS-485 communications Remote sensor; 10 ft. (3 m) • Remote controller enclosure • Heaters available in 12 kW, 18 kW, 24 kW, 36 kW, and 48 kW on direct-injection compact models; 36 kW and 48 kW heaters available on direct-injection upright models • Closed-loop heat exchanger available in 3.7 sq. ft. (0.344 sq. m) on compact models; 3.7, 7.4, 11.2, 18.1, and 27.0 sq. ft. (0.135, 0.688, 1.042, 1.683, and 2.511 sq.
Figure 1 Typical Royal Series Water Temperature Control Unit and Specifications Direct Injection TO PROCESS FROM PROCESS COOLING WATER OUT COOLING WATER IN T HIS EQUIPM ENT CONT AINS F LUID, PIPING AND CONNECTIONS W HICH MAY BE EXTREM ELY HOT AND COULD CAUSE SERIOUS BURNS AND PERSONAL INJURY. RECOGNITION O F AND COMPLIANCE WITH T HE F OLLOWING PRECAUT IONS ARE THE SOLE RESPONSIBILITY OF THE USER O F T HIS EQUIPMENT. 1 . EQUIPMENT MUST BE PROPERLY GROUNDED.
Figure 2 Typical Royal Upright Series Water Temperature Control Unit and Specifications 7/8” 4948" 3 3/4" 28" 13" Model number 460 230 2012, 9 kW heater letter hp C ¾ D 1 F 2 G 3 H 5 J 7½ K 10 kW 0.56 0.75 1.50 2.24 3.73 5.60 7.46 Pump gpm 30 35 50 60 75 90 120 H lpm psig kPa 113.6 25 172.4 132.5 30 206.9 189.3 30 206.9 227.1 35 241.3 283.9 54 372.3 340.7 63 434.4 454.2 55 379.2 in. 48 Dimensions W D cm in. cm in. cm 122 13 33 Shipping weight lbs. Kg 210 96 240 109 270 123 28 71.
2 Shipping Information 2-1 Unpacking and Inspection You should inspect your Sterling/Sterlco Royal Series temperature control unit for possible shipping damage. If the container and packing materials are in re-usable condition, save them for reshipment if necessary. 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.
2-3 If the Shipment is Not Complete Check the packing list. The apparent shortage may be intentional. Back-ordered items are noted on the packing list. You should have: Sterling/Sterlco Royal Series water 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 missed any smaller items during unpacking.
2-6 Uncrating Your New Royal Series System Royal Series water temperature control units are shipped fastened to a skid and covered with a cardboard box. Carefully remove the staples on the bottom of the box, lift off the box, and remove the bolts holding the unit to the skid. Caution! Be careful when cutting straps. Straps may spring back and cause injury! From the side, slip two lifting straps between the skid and temperature control unit. Spread the straps from the center line so it is balanced.
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3 3-1 Installation Installation Location Considerations Royal Series systems are portable and can be installed almost anywhere. As with all equipment installations, follow all applicable codes and regulations. The recommended ambient temperature range for Royal Series installations is from +14ºF (-10ºC) to a maximum operating ambient temperature of 131°F (55ºC). Recommended ambient storage temperature range is from -13ºF to 149ºF (-25ºC to 65ºC).
Note: Use a backup wrench to support Royal Series system piping when making process piping connections. ! CAUTION All external valves, fittings, and hoses must be rated at a minimum of 150 psig and 250°F (1,034.25 kPa/10.34 bars and 121ºC). The exception is when the temperature control unit is optionally rated for 300ºF (149ºC) operation; external valves fittings and hoses must then be rated at a minimum of 150 psig and 300ºF (1,034.25 kPa/10.34 bars and 121ºC).
Ferrous piping is recommended to minimize galvanic action. If piping must be copper, use dielectric unions at the unit. 3-5 Piping Considerations for High Mobility Installations Mobile Royal Series systems must use high quality hose rated for at least 150 psig and 250°F (1,034.25 kPa/10.34 bars and 121ºC). Special 300°F (149ºC) high temperature Royal Series systems must use hosing rated at 150 psig and 300°F (1,034.25 kPa/10.34 bars and 149ºC) or greater.
Deionized Water Stainless steel (316 SS minimum) or PVC plastic components must be used with deionized water. Sterling recommends stainless steel because of the temperature constraints with plastic. 3-7 Making Process Water Connections Closed Circuit/Direct Injection On the back of each unit, the connections are labeled appropriately. For Direct Injection units connect the TO PROCESS hookup to the entrance of the process and the FROM PROCESS hookup to the exit of the process.
FROM PROCESS — 1½” NPT Water from the process re-enters the Royal Series system to be tempered and re-circulated back into the process. 3-8 Making Cooling Water Connections WATER IN — ¾” The cooling water supply inlet from a cooling tower, a chiller, or a city water supply. ! CAUTION If a non-relieving device such as a regulator, ball valve, or check valve is installed on the WATER IN line, you MUST install an expansion tank of at least ½ gallon (about 2 liters) capacity.
Water Out Size Depends on Solenoid Used The cooling water outlet leading back to the cooling tower, chiller, or drain. Net supply pressure must be between 25 psig and 55 psig (172.38 kPa/1.72 bars and 379.2 kPa/3.79 bars). Net supply below 15 psig (103.43 kPa/1.03 bars) may allow water to flash to steam, cavitate the impeller, and damage the pump, which prevents the unit from cooling properly. Operation above 55 psig (379.2 kPa/3.
Figure 4 Typical Piping Schematic M Page 22 Royal Series Water Temperature Control Units
Figure 5 Pump Curves; 60 Hz Pump Curves; 50 Hz • Consult Factory for 10 hp Curves Figure 6 Pressure Drops Model hp kW 0.75 hp 0.56 kW 1.00 hp 0.75 kW 2.00 hp 1.50 kW 3.00 hp 2.24 kW 5.00 hp 3.73 kW 7.50 hp 5.60 kW 10.00 hp 7.46 kW 9 kW htr 12.7 amps 13.1 amps 14.7 amps 16.1 amps 18.9 amps 22.3 amps 26.0 amps Pressure drop flow and loss flow gpm loss psi flow lpm 30.0 gpm 0.0 psi 113.6 lpm 35.0 gpm 1.0 psi 132.5 lpm 50.0 gpm 1.5 psi 189.3 lpm 60.0 gpm 2.0 psi 227.1 lpm 75.0 gpm 2.5 psi 283.9 lpm 90.
3-10 Making Electrical Connections Royal Series systems are designed for three-phase voltage operation. Refer to the unit nameplate for proper voltage and amperage requirements. Make sure you provide a correctly sized and protected supply of electrical power to the unit. Important! Refer to National Electric Code (NEC) Article 430-24 through 430-26 for proper feeder conductor and supply disconnect sizing. Maintain a safe ground and disconnect the power supply before servicing the unit.
Bring properly sized power leads and ground from a fused disconnect (installed by your electrician) to the unit. Provide external overcurrent protection to the unit, using circuit breakers or fuses. If you use fuses, make sure that they are dual-element timedelay fuses, sized according to your electrical code. Make sure that all electrical connections are tight. Important! 1. Electrical connections must comply with all applicable electrical codes. 2.
Figure 7 Typical Electrical Wiring Schematic Please refer to the electrical wiring diagrams supplied with your unit’s Customer Information Packet.
4 4-1 Identifying Controls and Features Identifying Mechanical Controls and Features To and From Process Probes Two (2) 1,000-ohm (1 KΩ) platinum RTD probes are included with your Royal temperature control unit. One is located downstream from the heater to sense To Process temperature; the other probe is located upstream from the pump to sense From Process temperature. Safety Thermostat The safety thermostat mounted on the side of the heater tank protects against thermal runaway.
Low Pressure Cutout Switch This switch, set at 16 psig with a 2 psig differential (110.3 kPa/ 1.10 bars with a 13.79 kPa/0.14 bars differential) shuts down the unit if the COOLING WATER IN or MAKEUP water pressure drops below 16 psig (110.3 kPa/1.10 bars). Pumps Pumps range in power from ¾ hp to 10 hp (0.56 kW to 7.46 kW) and are equipped with 3-phase ODP motors and seal flush lines as standard. The pump is a bronze-fitted close-coupled centrifugal type.
Motorized Modulating Valves Optional Optional motorized modulating valves are recommended for large cooling applications where the process temperature is very near the cooling water supply temperature and the temperature controller unit pump is used as a booster. The gradual shutoff they provide also eliminates water hammer. The option includes a complete valve and motor package in place of a long-life solenoid valve. The motorized modulating valve has infinite positioning.
Cooling The controller automatically regulates cooling by opening and closing the solenoid valve or modulating valve. For direct injection, the unit cools by removing the required amount of warm water from the system. This process permits an equal amount of cool plant water to enter the system well ahead of the pump, allowing it to blend with the system water. The water supply temperature governs the minimum operating temperature of the unit.
Pressure Switch A pressure switch built into each unit keeps the system from starting until the water supply is turned On and subjected to the minimum water supply pressure. This feature protects the pump seal and the heater from damage through attempted operation without water. The pressure switch is set at approximately 16 psig (110.32 kPa/1.10 bars) for 250°F (121ºC) units or 55 psig (379.23 kPa/3.79 bars) for 300°F (149ºC) units prior to leaving the factory.
M2B+ Start Up Disconnect Switch 1. Turn disconnect switch to ON position. 2. Press START. The unit will automatically vent for approximately one minute. 3. If needed, press and hold the vent button to purge any additional air from the process loop. 4. Set process temperature (SETPOINT) by pressing the Up Arrow or Down Arrow keys. 5. If the unit does not maintain its process value, allow your process to reach the set point temperature. Then Autotune the control by pressing key. Shut Down 1. 2.
5 5-1 Startup and Operation Introduction The checklist below outlines start-up procedures for Royal Series water temperature control units. This list assumes that installation information located in this manual has been read and followed. 5-2 Startup Checklist Check the shipping papers against the serial tag to make sure that system size, type, and voltage is correct for the process under control.
Connect the main power to the unit disconnect switch, and press the START switch to check for proper pump rotation direction as described in Section 5-6. Pump rotation should be clockwise, viewed from the motor end. Check your work and proceed to the Startup Procedure section on the following page. 5-3 Starting the Temperature Control Unit Turn ON the water supply, turn the rotary disconnect to the ON position, and push the START button.
! CAUTION 1) Your Royal Series system operates with hot water under pressure. To reduce the risk of scalding: • • • • Always wear work gloves and safety glasses when operating the unit. Never operate the unit with panels or shields removed. Pipe the relief valve to an open drain. Never install a fitting or hose that is rated less than 150 psig and 250°F (1,034.25 kPa/10.34 bars and 121ºC).
TCU systems provide temperature control on processes by directly heating the process water and injecting cooling water into the process water. When the unit is energized, the pump starts and a one minute vent sequence opens the cooling/vent valve to remove any air trapped in the process piping. If the cooling water supply pressure is insufficient, the low cooling water pressure cutout switch (set at 16 psig, 10 psig differential [110.32 kPa/1.10 bars, 68.95 kPa/0.
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6 Unit Maintenance ! CAUTION Never attempt to service a unit until a qualified electrician has opened and locked out the main disconnect using OSHA 1910.147 standards. The water supply should be turned off and internal pressure should be relieved before you remove panels. All electrical connections must be done by a qualified electrician. ! WARNING Disconnect all power to the unit, let the unit cool down, and turn off the water prior to any servicing.
Periodic Checks Every Six Months Inspect all electrical connections for secure attachment and for safe and secure ground connections. Inspect the power cable, especially at the entrance point to the unit. This inspection should be made by a qualified electrician. Check for leaks, especially under the pump, as it may indicate a worn pump seal. 6-2 Corrective Maintenance Pumps and Seals Before leaving our factory, we test each unit extensively, then we calibrate each unit.
It is also fitted with high temperature flexible components for maximum heat resistance. These same components remain flexible even at low temperatures. Thus, the standard seal is a fine combination of heat resistant and wear resistant components. Unfortunately, even under normal use, the seal will eventually wear and require replacement. A small puddle underneath the unit is a sign of rotary seal wear, and if investigation confirms the pump as the source, the seal should be replaced as soon as practical.
Heaters Heaters may need to be cleaned chemically or mechanically to remove deposits and dirt that reduce heat transfer and cause hot spots. Hot spots cause premature heater failure. Install a new gasket when reassembling. Make sure a qualified electrician disconnects and reconnects heater wires. Solenoid Valves Clean annually, more often if using high mineral content water or on high service level units. Sluggish operation, excessive leakage, and/or noise indicate cleaning is necessary.
6-5 Safety Devices Caution! Make sure that only qualified electricians test safety devices! Safety devices should be tested for function every six (6) months. Perform the following procedures for testing: Motor Overload Disconnect main power. Open the electrical enclosure and rotate the manual TEST button on the motor overload to the tripped position. Close the enclosure and reconnect main power. Push the START button. The unit should not start and the Pump Overload indicator should illuminate.
! CAUTION HAZARDOUS ELECTRICAL CURRENT PRESENT. Maintain a safe ground and disconnect the power supply before servicing the unit. Make sure a qualified electrician makes electrical connections; disconnect/lock out electricity using OSHA 20CFR 1910.147 standards when servicing the unit. To adjust the pressure switch: Using a small, flat-blade screwdriver, carefully remove the plug at the top of the switch.
Make sure that the high limit on the controller is set to the values listed in the following table, based on the switch adjustment. This prevents the pump from cavitating and damaging the seal, the switch, and heater element(s). psig 5 psig 10 psig 15 psig kPa 34.4 kPa 68.9 kPa 103.4 kPa Max. temp. ºF 227ºF 240ºF 250ºF Max. temp. ºC 108ºC 116ºC 121ºC Safety Thermostat Disconnect main power. Open the electrical enclosure and disconnect the neutral lead on the safety thermostat from the terminal strip.
7 Troubleshooting Condition Possible cause No power. Unit does not turn on. Wrong voltage supplied to unit. Defective on/off switch. Control circuit fuse blown. Defective control transformer. Broken or loose wire in pump motor control circuit. Pump motor contactor holding coil is open. Unit does not run. Repair or replace. Low water pressure light on. Water supply to unit is turned off. Open water supply. Pump running in reverse. High pump pressure. Locate and repair.
Condition Possible cause Undersized connectors/ water lines. Long connecting lines between unit and mold. Serpentine flow through mold. Blocked water line in mold. Temperature fluctuations/ rapid cycling from hot to cold. Quick disconnect fitting with check valve. Lime buildup in unit piping. Faulty TCU. Reversed probes. Drain is plugged or excessive back pressure is in drain line. Faulty solenoid valve. Controller Cool output relay open. Solenoid valve is not operating, but COOL LED is on.
Condition Possible cause Defective heater contactor. Defective immersion heater. Controller heat output open. Heater contactor is not energizing, but HEAT LED is on. Immersion heater elements dirty. Unit does not heat/cannot achieve set point. Immersion heater element is burned out. OUT1 indicator is on, but no voltage on heater contact. Cooling valve is leaking. Solenoid valve is not operating, but COOL LED is on. Magnetism on coil. Faulty/dirty solenoid valve.
I Automatic vent, 30 Available options, 8–9 Checking motor rotation direction, 35 Cleaning and storage, 43 Closed circuit/direct injection connections, 19 Communications, 31 Controller operation, 31 Cooling regulation, 30 Cooling water connections, 20 Copyright information, 2 Corrective maintenance, 38–40 Cutout switch, low pressure, 28 Deionized water applications, 19 Disclaimer information, 2 Distilled water applications, 18 Draining, 37 Electrical connections, 24, 40 Electrical subpanel, 26 Electricals,
Parts Department Call toll-free 7am–5pm CST [800] 423-3183 or call [262] 641-8610, Fax [262] 641-8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone or fax order, please have the model and serial number of your unit when you contact us. A customer replacement parts list is included in this manual for your convenience.
