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Thermolar
®
Tank Temperature
Maintenance System
Installation & Operation Manual for Systems Employing
THS-106 or THS-206 Electronic Controller.
Precise, efficient temperature maintenance for all types of metal and plastic tanks.
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INTRODUCTION
The Calorique Thermolar® Tank Temperature Maintenance System is
a low heat-density warming system designed to safely and efficiently
maintain the contents temperature of any tank. Ideal for process
control, adhesive storage (etc.) the THERMOLAR system provides uniform heat that won’t scorch tank contents.
When installed and operated in accordance with these instructions,
the Thermolar system complies with National Electrical Code article
427. Failure to install and operate this system in accordance with
the manufacturer’s instructions may result in an unsafe condition
and constitutes a violation of the system warranty and voids that
warranty. Note that the system must be installed on a branch circuit
that is protected by a fault detector that is suitable for equipment
protection.
PARTS & SPECIFICATIONS
PARTS — SUPPLIED BY CALORIQUE
Cross check all parts with the System Components List to ensure that
all parts are included and in good condition before beginning installation. Quantities and/or lengths are included in the System
Components List.
The following specifications are generic to the Thermolar system.
Complete specifications for the particular system being installed are
included on the System Components List.
CCoonnttrrooll UUnniitt
Included with the control unit are a strap for attaching it to the tank
and two remote thermo-sensors with 20 foot/6 m leads.
Voltage: THS-106: 120 Vac
THS-206: 240 Vac
INTRODUCTION
Confirm system voltage before connecting the system to power supply. Do
not connect systems to any voltage
other than that for which they were
designed.
Systems operated at higher than
designed voltage pose a risk of electric
shock and/or fire.
Systems operated at lower than
designed voltage may not maintain
temperature which could result in loss
of or damage to contents.
Note
The Thermolar System is designed for temperature maintenance only and typically will
not provide sufficient heat to significantly raise the temperature of tank contents.
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HHeeaattiinngg EElleemmeennttss
Calorique Thermolar heating elements are factory assembled with
an integral ground shield, adhesive backing and moisture-proof
electrical connections.
Width: 11 inches/280 mm
Maximum Temperature: Do not expose any Thermolar
heating element to temperatures in excess of
180°F/82°C. See pages 7 and
8 for maximum exposure
temperatures of standard
tank types.
Lead Length: 8 feet/3.5 m
PARTS — INSTALLER SUPPLIED
DDuucctt TTaappee
Standard grade duct tape (or equivalent) rated for at least
170°F/76°C.
PPoowweerr CCaabbllee
Used to run electrical power from branch circuit box to the control
unit. The type and length are determined by local code and individual requirements of the installation.
TToooollss
General electrician’s tools, including screwdriver, linesmans pliers,
wire cutter/stripper, etc.
IInnssuullaattiioonn
Thermal insulation of the type and thickness noted on the System
Components List must be installed on the tank to ensure proper and
safe operation.
Do not cut or otherwise
alter the Thermolar heating
elements.
1
PARTS & SPECIFICATIONS
Page 4
INSTALLATION
CCiirrccuuiitt OOvveerrccuurrrreenntt PPrrootteeccttiioonn
Fuse or circuit breaker rated for at least 120% of the system
amperage rating.
FFaauulltt PPrrootteeccttiioonn
The power supply must include a fault detector suitable for equipment protection. This may be integral with the overcurrent protection.
INSTALLATION
CONTROL UNIT
1. Determine the location of the control unit.
• If the control unit will be positioned remotely from the tank, skip to the next section,
Heating Elements.
• Attaching the control unit temporarily to the tank wall at this time will aid in aligning
the heating elements so that the power cords will reach the controller.
• Installing the control unit at eye level will make completion and operation easier.
2. Slide the strap through the slots provided on the back of the control unit.
3. Run the strap around the tank and slip the free end into the buckle.
4. Position the box about 4 feet/1.2 m from the bottom of the tank and tighten the strap to hold it
in place.
Note
For best results, insulate underneath the tank. If the underside will not be accessible after
installation of the Thermolar system, then install insulation prior to final placement of the
tank. Insulating underneath the tank will help avoid excessive heat loss, reducing operating expense and the risk of damage to sensitive contents.
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INSTALLATION
HEATING ELEMENTS
1. Attach heating elements to the tank sidewall using the adhesive backing provided. Hold the
elements in position then, working around the tank, peel the release paper from them and
press lightly into position.
2. Repeat step 1 for each heating element.
3. Once all of the elements are in place properly, firmly press the element/adhesive into place
securing the elements to the tank.
4. Seal the edges of each element with duct tape. This will ensure that insulation does not come
between the elements and the tank wall which could impede heat flow into the tank.
Do not install the
elements over
manways, fittings,
pipes, ribs, channels, insulation or anything other than
the smooth tank wall itself. Ensure that
the entire element will be in smooth,
direct contact with the surface of the
tank.
Do not fold or
overlap the heating elements.
Note
Press the elements lightly in place at this time in case they need to be repositioned later.
Note
The heating elements are most effective when placed as close to the bottom of
the tank as possible. This will allow warmer material to flow upward, promoting
convection currents and more even internal heating.
Note
If any heating elements need to be moved, do so before the adhesive sets up.
After a short time the heating elements can not be removed without seriously
damaging them.
Note
Do not install heating elements when the air and/or tank temperature is below
35°F/2°C. Below this temperature the adhesive backing initially may not stick properly.
Once the heating elements have been secured in place for at least 24 hours, temperatures at or below 35°F/2°C will not adversely affect the adhesive.
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INSTALLATION
THERMO-SENSORS
1. Using duct tape, attach the Over Limit thermo-sensor (marked with red) to the central area of
the upper-most heating element. Locate the sensor approximately 1-1/2 ft/450 mm from the
cord end of the heating element.
2. Using duct tape, attach the Maintenance thermo-sensor directly to the tank wall approximately
6 inches/150 mm from the bottom-most heating element.
CONTROL UNIT — ON TANK WALL
If the control unit is located on the tank itself, finish tightening the
strap so that the box is secured in place.
CONTROL UNIT — REMOTE LOCATION
If the control unit is located remotely from the tank, attach the control unit, using standard electrical practices, to any suitable surface,
pole, etc.
Note
Make sure that the strap does not cross any heating elements, power cords or thermosensor leads.
Note
Standard lead lengths on the thermo-sensors and heating elements are 20 ft/6 m and
8 ft/2.5 m respectively. When locating the control unit, ensure that the thermo-sensor
wires and heating element power cords are not stretched taut and do not cross over
the heating elements.
4
Over Limit Sensor
Over Limit Sensor
Maintenance Sensor
Maintenance Sensor
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INSTALLATION
ELECTRICAL CONNECTIONS
1. Measure and record the resistance of each heating element.
Record the measured resistances on the label on the back of the control unit face plate.
2. Route all wiring to the control unit as shown in the following figure.
3. Secure all wiring in place to the side of the tank using duct tape.
4. Connect each heating element and the thermo-sensors to the appropriate terminal connections
of the control unit according to the following diagram.
5. Run power supply cable from the circuit breaker box to the control unit and make the connec-
tions to the power supply connectors inside the control unit.
6. Attach remote alarms, if applicable, to the remote alarm relay points (shown on the wiring
diagram on the next page).
• Two alarm relays are provided that operate in the event that
either temperature set for over-limit or low-limit is reached.
• Note that the alarm relays do not generate an alarm signal.
External power for the alarms must be provided.
• Each relay terminal offers the option of a normally open
(NO) or normally closed (NC) switch. Do not use both settings for the same relay terminal.
Some thermo-sensors cables
may include a ground wire.
Do not connect thermo-sensor ground wires to the com-
mon line voltage ground.
Make sure that power is
turned off before working
with the input power cable.
Do not turn on
power to the system unless there
is contents in the
tank.
Note
Cut wires to length, as necessary.
Note
Local codes may require the use of an intermediary junction/switch box.
5
Metal tanks must be properly
grounded before operating
the system.
Do not run power
cords or thermosensor wires over
heating elements.
The over-limit sensor wire may be run
over the heating element to which it is
attached, but only for the shortest distance possible.
NOTE
When routing the wiring, include the small “J” curves to the lowest point of each wire.
This will help to ensure that any water that penetrates the insulation does not reach
the heating elements.
Input Power
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INSULATION
Insulate the tank using the type and thickness insulation indicated
on the System Component List. This insulation factor has been used
to calculate the heating load required by the system: using less insulation may result in contents damage.
OPERATION
PROGRAMMING
The programmable controller provides four different user-settable
parameters
Maintenance Temperature: The desired contents temperature.
Differential: The precision of temperature control.
Over-Limit Temperature: The highest temperature that the
heating elements, the tank contents or
the tank itself should reach.
Low-Limit Temperature: The lowest allowable contents
temperature.
OPERATION
6
Note
Make sure that the control unit cover is securely in place before insulation is applied to
the tank to ensure that no insulation gets into the control unit itself.
Note
If using blown-on insulation, create a dam around the control unit cover to ensure that
it may be removed to allow for programming and the indicator lights to be seen.
Input Power
Maintenance Sensor
Over Limit Sensor
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OPERATION
The over-limit and low-limit temperatures are used in conjunction
with the on-board indicator lights and/or remote alarms to indicate
a fault situation. If the over-limit temperature is reached, power to
all elements will be shut off.
To set temperatures:
1. Press the Scroll button one or more times until the desired function setting LED is lit.
The LCD display now indicates the current function setting.
2. Use the L and M buttons to set the temperature higher or lower than the current setting.
See the following section, Operating Temperatures, for a list of acceptable temperatures.
3. Press the Scroll button one or more times to either highlight another function or until all func-
tion lights are out, which returns the control unit to operating mode.
MAXIMUM OPERATING TEMPERATURES
Metal Tanks
Maintenance Temperature: up to 160°F/70°C
Over Limit Temperature: up to 170°F/75°C
Low Limit Temperature: up to 155°F/65°C
Crosslinked Polyethylene Tanks
Maintenance Temperature: up to 130°F/55°C
Over Limit Temperature: up to 140°F/60°C
Low Limit Temperature: up to 125°F/50°C
When programming the control unit is complete, ensure
that all function lights are
out. When the system is in
programming mode (when one of the
function lights is lit) the heating elements will still operate but there is a
possibility that the programming may
be changed inadvertently.
Do not exceed
the temperatures
noted at left.
Temperature settings above those listed may result in
damage to the Thermolar system, the
tank and/or the tank contents.
Ensure that the
temperature of
the contents
being loaded into
a tank does not exceed the maximum
temperature setting as noted at left.
Note
The control unit will normally be preprogrammed with the temperatures specified
when the system was ordered. Before operating the system, confirm the temperature
programming.
Note
Set the over-limit temperature at least 10°F/5°C higher than the maintenance
temperature.
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MAXIMUM OPERATING TEMPERATURES (continued)
Linear Polyethylene Tanks
Maintenance Temperature: up to 120°F/50°C
Over Limit Temperature: up to 130°F/55°C
Low Limit Temperature: up to 115°F/45°C
OPERATION
Under normal operating conditions, no adjustment is necessary. It is
suggested that the liquid level within the tank be maintained to at
least the level of the highest heating element. This will ensure that
each heating element is operating at its peak efficiency.
TEMPERATURE ALARMS
User intervention may be required if either the over-limit or low-limit
alarm lights are illuminated or if remote alarms (if installed) are activated. Under these circumstances, check for the following indications:
• Does the system or exterior of the tank look damaged in any
way?
Determine the extent of the damage and contact Calorique
technical support at (508) 291-4224 for possible corrective
action.
• Are the heating elements damaged?
To determine if the elements have been damaged:
1. Remove the system from power.
2. Disconnect each heating element from the terminal strip in the control unit.
3. If possible, visually inspect each element for obvious damage.
4. Using an accurate ohm or multimeter, determine the resistance of each element. These readings
should be between the following (depending on voltage):
OPERATION
8
Note
In normal operation, the over-limit temperature alarm and relay may occasionally be
activated. If the over-limit alarm and relay remain on for more than 5 minutes at a
time remedial action should be followed.
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OPERATION
15840
high resistance (120 volt elements) =————————
rated heat output in watts
13680
low resistance (120 volt elements) =————————
rated heat output in watts
63360
high resistance (240 volt elements) =————————
rated heat output in watts
54720
low resistance (240 volt elements) =————————
rated heat output in watts
The number of watts is given on the System Components List.
If the resistance reading does not fall within the above numbers, contact Calorique technical
support at (508) 291-4224 for remedies.
• Is the input voltage to the heating elements correct?
• The design voltage is clearly marked on the faceplate of the
control unit. Operating heating elements at greater than
their design voltage can cause overheating of the elements
and tank contents. Operating elements at lower than their
design voltage may result in insufficient heat output to
properly maintain contents temperature.
• If the input voltage is not correct: disconnect the system
from power and contact Calorique technical support.
• Is there material in the tank?
• An empty tank, or a tank with a contents level below the
level of the heating elements will, in a short time, result in
an over-temperature situation.
• If no: either fill the tank or shut off the heating system until
the tank has been filled.
• If yes: check to see if the material is thick and sludge-like. If
it is, then mechanical agitation (mixing) may be required to
ensure that heat is evenly distributed through the contents.
If the material has a low viscosity (like water), proceed to
the next troubleshooting question.
• Is each heating element operating?
Check the Heater Circuits Active indicator lights. When the Main
Heater Relay light is illuminated, each heater circuit light should
also be lit (unless there is no heating element attached to the
particular circuit). Ensure that any non-operating element is correctly wired into the control unit. If it is (they are): contact
Calorique technical support.
• If the above remedies do not fix the problem, call Calorique
technical support at (508) 291-4224 for additional help.
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Calorique Ltd.
2380 Cranberry Highway
West Wareham, MA 02576, USA
(508) 291-4224 • (508) 291-2299 fax
Copyright © 1997-2003 Calorique, Ltd.
All Rights Reserved. Printed in USA
CM2001 — 2003-04
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