Sterling 682.88107.00 How to Use This Manual, Safety Symbols Used in this Manual

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Chapter 1: Safety

1-1 How to Use This Manual

Use this manual as a guide and reference for installing, operating, and maintaining your portable hot oil temperature control unit (TCU). The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity.

This manual covers only light corrective maintenance. No other maintenance should be undertaken without first contacting a service engineer.

The Functional Description section outlines models covered, standard features, and safety features. Additional sections within the manual provide instructions for installation, pre- operational procedures, operation, preventive maintenance, and corrective maintenance.

The Installation chapter includes required data for receiving, unpacking, inspecting, and setup of the portable hot oil TCU. We can also provide the assistance of a factory-trained technician to help train your operator(s) for a nominal charge. This section includes instructions, checks, and adjustments that should be followed before commencing with operation of the portable hot oil TCU. These instructions are intended to supplement standard shop procedures performed at shift, daily, and weekly intervals.

The Operation chapter includes a description of electrical and mechanical controls, in addition to information for operating the portable hot oil TCU safely and efficiently.

The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service. Preventive maintenance sections are included to ensure that your portable hot oil TCU provides excellent, long service.

The Troubleshooting chapter serves as a guide for identification of most common problems. Potential problems are listed, along with possible causes and related solutions.

The Appendix contains technical specifications, drawings, schematics, parts lists, and available options. A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package. Refer to this section for a listing of spare parts for purchase. Have your serial number and model number ready when ordering.

Safety Symbols Used in this Manual

The following safety alert symbols are used to alert you to potential personal injury hazards. Obey all safety messages that follow these symbols to avoid possible injury or death.

DANGER! DANGER indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

WARNING! WARNING indicates a potentially hazardous situation or practice that, if not avoided, could result in death or serious injury.

Caution! CAUTION indicates a potentially hazardous situation or practice that, if not avoided, may result in minor or moderate injury or in property damage.

Upright Portable Hot Oil TCUs

Chapter 1: Safety

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Contents Upright Hot Oil Temperature Control Units Shipping Info Table of Contents Troubleshooting Safety Symbols Used in this Manual SafetyHow to Use This Manual Wear Safety Glasses and Work Gloves General Responsibility ResponsibilityRemember Operator ResponsibilityReporting a Safety Defect Maintenance ResponsibilityMechanical Features Standard FeaturesFunctional Description Models Covered in This ManualOptions Electrical FeaturesController Features Immersion Heaters Feature DescriptionsHeater Tank PumpElectrical Panel and System Components Connection LinesElectrical System Controls Safety Thermostat Pressure SwitchAir Purge Reservoir TankCooling Optional Safety Devices and InterlocksSafety Circuit Standards Fail Safe Operation Safety Device Lock-OutsInstallation Location Considerations InstallationUncrating the Equipment Rigging and Placing the TCUElectrical Connections Piping Considerations for Mobile Installations Setup ProceduresConnecting Piping Connecting Vent Piping Connecting Process PipingConnecting Cooling Water Piping Upright Unit Piping Setup Starting the Hot Oil TCU Initial Start-upPage Controller Description & Operation OperationStart-up Control Panel Switches Identifying Control Panel SwitchesSystem Status Board Indicators Identifying System Status Board IndicatorsFault Indicator Lights Status Indicator LightsMode Indicator Lights Shutting Down the Hot Oil TCU Returning Fluid to the TankPage Photocopy this page for your maintenance records MaintenanceMaintenance Schedule Preventative Pump Maintenance Preventative MaintenanceRoutine Servicing Draining the Unit for StorageAdjusting End Clearance Corrective MaintenanceCleaning the Pump Examining Internal PartsDisassembling the Pump Maintaining the PumpPump Assembly Installation of Carbon Graphite Bushings Thrust Bearing AdjustmentIntroduction TroubleshootingProblem Possible cause Corrective action OFF Problem Possible cause Corrective action Optional Components AppendixAnnex B Information Technical SpecificationsUpright Portable Hot Oil TCUs Appendix 18-24 GPM Pump Construction Drawings and DiagramsThrust Bearing Assembly Belt Tensioning Instructions Immersion Heaters Part number Description Spare Parts ListHeater Gasket Part number Description 542-00007-08 Pilot Lights Part number DescriptionPressure Switches Selector Switches and Push ButtonsControllers Part number Description Part number DescriptionSolenoid Valves Part number Description Disconnect SwitchesSensing Probe Equipment Heater Tank InsulationWarranty Returns Safety Tag InformationTCU Safety Tags Returned Material PolicyTechnical Assistance TCU Identification Serial Number Tag