Alto Shaam TM Installation Manual

Gasket

Cover

Service Entrance Plate

Chromalox

DIVISION 4 SECTION

SALES

REFERENCE

DATE

SERVICE REFERENCE

Installation, Operation

and

Maintenance Instructions

PD457-2

AUGUST, 2010

(Supersedes PD457-1)

161-306157-001

GENERAL

FIRE/EXPLOSION HAZARD. Do not exceed the Pressure-Temperature rating of the flange as listed in ANSI B16.5.

Chromalox TM- Series industrial flanged immersion heaters are

designed for a wide variety of heating applications.

1. Heater Construction Characteristics: A. High quality resistance wire held in place by compacted

Magnesium Oxide Refractory enclosed in a wide variety of sheath materials.

B. Low to high watt densities. C. Standard selection of sheath materials include copper, steel,

INCOLOY

alloy and stainless steel. This broad selection of sheath materials will operate successfully in many corrosive solutions.

IMPORTANT: It is the responsibility of the purchaser of the heater to make the ultimate choice of sheath material based upon their knowledge of the chemical composition of the corrosive solution, character of the materials entering the solution, and controls which he maintains on the process.

FIRE/EXPLOSION HAZARD. Sheath corrosion can result in a ground fault which, depending upon the solution being heated, can cause an explosion or fire.

D. Pipe flange sizes in 3, 5, 6, 8, 10, 12 and 14 inches are standard.

Other sizes are also available.

E. Units are available with E1 General Purpose, E4 Moisture

Resistant and E2 Explosion/Moisture-Resistant terminal enclosures.

FIRE HAZARD. An integral thermostat, if provided, is designed for temperature control service only. Because the thermostat does not fail safe, it should not be used for temperature limiting duty. Wiring to this device is the responsibility of the user.

The system designer is responsible for the safety of this equipment and should install adequate back-up controls and safety devices with their electric heating equipment. Where the consequences of failure could result in personal injury or property damage, back-up controls are essential.

"B" Immersion Length

(See Table 1 Below)

Min. Non Heated Length

TM Series Flanged Immersion Heater with General Purpose (E1) Terminal Enclosure

Moisture Resistant (E4)

Terminal Enclosure

Explosion Resistant & Moisture Resistant (E2)

Terminal Enclosure

Type TM- Series

Industrial Flanged Immersion Heaters

Note: These instructions relate to all enclosure styles shown within.

Note:

Cold ends listed are standard. However, special cold ends may be used upon request.

TM Series Flanged Immersion Heater with

General-Purpose (E1) Terminal Enclosure

Flange Size Cold End

3” 4”

4” 4”

5” 4”

6” 4”

8” 6”

10” 6”

12” 6”

14” 6”

Table 1

INSTALLATION

ELECTRIC SHOCK HAZARD. Disconnect all power before installing or servicing heater. Failure to do so could result in personal injury or property damage. Heater must be installed by a qualified person in accordance with the National Electrical Code, NFPA 70.

1. Before installing, unpack and check your TM series immersion

heater for any damage that may have occurred during shipment. Report any claims to you carrier if damage has ocurred in shipment. Do not operate damaged equipment. Consult

factory for instructions.

2. Check to ensure that the line voltage is the same as that stamped

on the nameplate. Verify wattage and capacity versus the requirements at installation site.

3. Do not bend the heating elements. If bending is necessary,

consult factory.

4. IMPORTANT: Mount the heater in the tank so that the liquid

level will always be above the effective heated portion of the heater. If the heater is not properly submerged, it may overheat and damage the heating elements (see Figure 1).

FIRE HAZARD. If the heater is not properly submerged, the heating elements will overheat and could result in a fire or damaged equipment.

5. Where work will pass over or near equipment, additional protec-

tion such as a metal guard may be needed.

6. Heater must not be operated in sludge.

7. The gasket surface must be clean and dry before the heater is seat-

ed (see Figure 2).

8. Closed Tank Installation Note: When heating in closed vessels, controls and

back-up controls must be used to prevent buildup of temperature and/or pressure.

A. Horizontal Position (Figure 3)

A1. Place heater at an elevation so that natural circulation can

take place.

A2. Position outlet and inlet in a vertical plane, facing upward

to prevent air pockets. Be sure all trapped air is removed from the closed tank. Bleed the air out of the liquid piping system and heater enclosure prior to operation.

A3. IMPORTANT: Heater should never be located at the

highest point of the water system. Provide expansion tank if necessary.

A4. Heaters shall be supported if the immersion length is greater

than 36”.

B. Vertical Position (Figure 4)

9. A drip loop is recommended to minimize passage of moisture

from condensation along wiring into terminal box enclosure and connections.

FIRE HAZARD. Since heaters are capable of developing high temperatures, extreme care should be taken to:

A. Use explosion-resistant terminal enclosures in hazardous loca-

tions. See Chromalox catalog for selection of explosion-resistant terminal enclosure for hazardous locations.

B. Avoid contact between heater and combustible materials. C. Keep combustible materials far enough away to be free of the

effects of high temperatures.

FREEZE HAZARD. This unit may be equipped with a thermowell for process control or over-temperature control. Do not allow moisture to accumulate in thermowell. Freezing temperatures can cause damage that may result in the heated medium leaking into terminal enclosure.

Note: Locate Heater as low as possible for maximum heated liquid storage capacity. Heat does not move downward.

Figure 1 - Open Tank Installation

Expected Low Liquid

Level

This Portion of the Heater Above Liquid Level and

Exposed to Air Will Lead to Premature Failure of Element

Expected Maximum

Sediment Level

Figure 2 - Flanged Mounting

Care must be taken to ensure the heated portion does not extend into the coupling area.

Gasket

Cold End (See Warning)

Element

Tank Wall

Standard

Pipe Flange

Weld

Locate Drain Pipe at Bottom of Heater,

Sediment Deposits may be

Removed Through Drain Pipe

Maximum Sediment Level.

Install Heater Above

This Level But As

Near to it as Possible for Maximum

Heated Liquid Storage Capacity

Suitable

Wiring

Drip Loop Recommended

to Minimize Passage of Moisture

Along Wiring Into Terminal

Wiring and Connections

Outlet

Inlet

Figure 4 - Closed Tank in Vertical Position

Heater

Outlet

Inlet

Note: In A Forced Circulation System, Use Pump In Inlet Side.

Figure 3 Closed Tank in Horizontal Position

WIRING

ELECTRIC SHOCK HAZARD. Any installation involving electric heaters must be performed by a qualified person and must be effectively grounded in accordance with the National Electrical Code to eliminate shock hazard.

1. Electric wiring to heater must be installed in accordance with

the National Electrical Code, International Electric code and/or with local codes by a qualified person.

2. When element wattages are not equal, heaters must not be

connected in series.

3. Electrical wiring to heater should be contained in rigid con-

duit or in sealed flexible conduit to keep corrosive vapors and liquids out of the terminal enclosure. If high humidity is encountered, the conduit should slope away from the heater.

4. If flexible cord is employed, a watertight connector should be

used for entry of the cord into the terminal enclosure. Outdoor applications require liquid-tight conduit and connectors.

5. Bring the power line wires through the opening in the terminal box.

6. Heaters are prewired and tagged for easy installation of elec-

trical wiring to the heater. Typical tagging of the individual circuits of Chromalox TM industrial flanged heaters are shown in the following tabulation:

Note: Bussing tags are made with a non-conducting material. Please leave in place for proper identification during wiring.

7. Check for loose terminal connections and tighten if necessary.

Made to order items are prewired and tagged at the factory. Wiring of made to order items may differ from those shown in the tabulation.

Carefully check voltage and phase on the heater nameplate and select either the appropriate wiring shown above or check for the appropriate wiring diagram in the heater terminal enclosure. For

reference purposes, some typical wiring diagrams are shown in the following figures.

8. The current carrying capacity of the power supply leads should

exceed the heater amperage by at least 25%. Be sure to consider the ambient operating temperature and apply the appropriate correction factor to the ampacity rating of the wire. Heaters with the same voltage and wattage may be connected in series for operation at a higher voltage.

INSTALLATION (cont’d)

THERMOSTATS

10. To prevent moisture accumulation in cryogenic applications

or when heater is exposed to freezing temperatures:

A. Slope conduit away from enclosure (drip loop). B. Seal all conduit openings to moisture/explosion resistant

terminal enclosure.

C. Insulate terminal enclosure. D.

Fill thermowell(s) with silicone fluid when heater is mounted with terminal enclosure up.

BEFORE ENERGIZING

1. Check that the gasket is in place and the flange is securely bolted

to the tank.

2. Check that power supply connections are made according to the

wiring diagram. Also check for positive connection of all bus bars and power supply leads.

3. Check all bussing hardware is tightened to 20-25 in-lbs.

4. Check all bussing to element connections are tightened to 14-17

in-lbs.

FIRE OR SHOCK HAZARD: Moisture accumulation in the element refractory material, element over-temperature, or sheath corrosion can cause ground fault to the element sheath, generating arcing and molten metal. Install Ground Fault Circuit-Interrupter (GFCI) to prevent personal injury or Equipment Ground Fault Protection to prevent property damage.

1. Integrally mounted thermostats are available: single throw models.

2. Electrical rating of thermostats:

3. Thermostats may be connected directly to heaters that are rated

within the electrical capacities specified. When the heater phase or amperage exceeds the contact rating of the thermostat, the heater should be controlled by a magnetic contactor with the thermostat wired for pilot duty. Refer to the thermostat instruction sheet packed with the heater.

If optional thermostat kit is purchased, please refer to instruction manual shipped with kit for proper bracket and thermostat mounting

5. WARNING: To maintain third party listing on an E4 housing, do

not add any sparking device, such as a thermostat, inside the terminal enclosure.

Thermostat Type

Voltage T1 T2

120 30 Amps 30 Amps

240 30 Amps 30 Amps

480 Pilot Duty Pilot Duty

No. Circuits Phase Tagging

1 1 L1 & L2 1 3 L1, L2 & L3

2 3

AL1, AL2, AL3

BL1, BL2 BL3

3 3

AL1, AL2, & AL3

BL1, BL2 & BL3 CL1, CL2 & CL3

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