PROCESS HEATING COMPANY UNITIZED HEATER KIT Installation, Operation & Maintenance Manual

INSTALLATION,

OPERATION

AND

MAINTENANCE

MANUAL

UNITIZED HEATER

PROCESS HEATING COMPANY, INC.

POST OFFICE BOX 84585

SEATTLE, WASHINGTON 98124-5885

PHONE: [phone] FAX: [phone]

KIT

WARNINGS

1) READ AND UNDERSTAND ALL TAGS AND INSTALLATION AND
OPERATING INSTRUCTIONS BEORE COMMENCING.

2) CHECK THAT THE ELECTRICAL SERVICE WILL HANDLE THE LOAD.
UNIT MUST BE ADEQUATELY GROUNDED.

3) ALL WIRING SHOULD CONFORM TO REQUIREMENTS OF NATIONAL
AND LOCAL ELECTRICAL CODES AND STANDARDS.

4) ONLY LICENSED ELECTRICIAN SHOULD CONNECT POWER TO PANEL
AND SYSTEM.

5) NEVER EXPOSE HEATER TUBES TO AIR WITH POWER ON.

6) CARE SHOULD BE USED WHEN WORKING AROUND TUBES WHEN
CLEANING OR INSTALLING. WALLS ARE LESS THEN ¼” THICK.

7) IF THERE ARE ANY QUESTIONS CONCERNING THE RATINGS OR
INSTRUCTIONS PLEASE CONTACT YOUR LOCAL DISTRIBUTOR OR THE
FACTORY. PHONE [phone] FAX [phone]

2

ADDITIONAL IMPORTANT INFORMATION

1) THESE INSTRUCTIONS CANNOT POSSIBLY COVER EVERY SITUATION
CONCERNING THE OPERATION, INSPECTION, ADJUSTMENT AND TEST
OF THE EQUIPMENT FURNISHED. PROCESS HEATING COMPANY
(PHCo), IN THE FURNISHING OF THIS EQUIPMENT AND THESE
INSTRUCTIONS, MUST PRESUME THAT THE OPERATING AND
MAINTENANCE PERSONEL USING THIS EQUIPMENT HAVE SUFFICIENT
TECHNICAL KNOWLEDGE AND EXPERIENCE TO APPLY SOUND
SAFETY AND OPERATIONAL PRACTICES WHICH MAY NOT BE
MENTIONED.

2) IN APPLICATIONS WHERE PHCo FURNISHED EQUIPMENT THAT IS TO
BE INTEGRATED WITH A PROCESS OR OTHER EQUIPMENT, THESE
INSTRUCTIONS SHOULD BE THOROUGHLY REVIEWED TO DETERMINE
THE PROPER INTEGRATION OF THE EQUIPMENT INTO THE OVERALL
PLANT OR SYSTEM OPERATIONAL PROCEDURES.

3) PHCo DOES NOT SUPPLY, RECOMMEND OR APPROVE THE VARIOUS
SYSTEMS IN WHICH ITS PRODUCTS ARE OR MAY BE USED. UNLESS
DESIGNED, MANUFACTURED AND USED PROPERLY, VARIOUS
SYSTEMS MAY BE INHERENTLY UNSAFE OR DANGEROUS. THE USER
SHOULD CHECK AND COMPLY WITH ALL FEDERAL, STATE AND LOCAL
REGULATIONS AND OTHER REGULATIONS AND RECOMMENDATIONS
SUCH AS: NFPA, UL, API, OSHA, ETC.

3

PREPERATION

1) REMOVE JACKETING AND INSULATION FROM SECTION OF TANK
HEATER IS TO BE INSTALLED THROUGH.

2) MARK LOCATION OF OPENING ON TANK. HEATER SHOULD BE
KEPT AS LOW AS POSSIBLE IN TANK.

CAUTION

BEFORE BURNING OR WELDING ON TANK, CLEAN THOROUGHLY
AND KEEP WELL VENTILATED.

INSTALLATION

1) BURN OPENING IN TANK SLIGHTLY LARGER THAN HEATER TERMINAL
BOX (SNUG FIT). REMOVE SLAG AND GRIND OPENING SMOOTH.

2) REMOVE BLOCKING FROM SUPPORT PLATE(S) AND SLIDE HEATER
THROUGH OPENING IN TANK. STOP AT MARKED “WELD LINE” ON
HEATER TERMINAL BOX.

3) HEATER TUBE SUPPORT PLATE(S) SHOULD BE ATTACHED TO TANK
BOTTOM. LEVEL HEATER TUBES AND WELD SUPPORT(S) TO TANK.
DO NOT

4) WELD HEATER TERMINAL BOX TO TANK. TERMINAL BOX IS ¼”
THICK STEEL. WELD MUST BE LIQUID TIGHT.

5) TANK DISCHARGE SHOULD BE KEPT 2” TO 3” ABOVE HEATER TUBES.
NEVER EXPOSE HEATER TUBES TO AIR WITH POWER ON.

6) HAVE LICENSED ELECTRICIAN CONNECT PROPER VOLTAGE AND
PHASE TO THE LINE SIDE OF THE MAIN DISCONNECT SWITCH USING
SUITABLE WIRE GAUGE FOR HEATER LOAD. UNIT MUST BE
PROPERLY GROUNDED.

7) CHECK ALL CONNECTIONS TO INSURE THEY ARE ALL TIGHT SINCE
VIBRATION IN TRAVEL CAN LOOSEN WIRE CONNECTIONS.

WELD HEATER TUBES TO SUPPORT PLATE(S).

4

OPERATION

1) TURN ON THE MAIN DISCONNECT SWITCH.

2) PUSH THE RED HIGH LIMIT RESET PUSHBUTTON TO PULL IN THE
CONTACTOR AND PROVIDE LOAD POWER.

3) THE INDICATING TEMPERATURE CONTROL (IN ENCLOSURE DOOR)
SHOULD BE SET TO DESIRED PROCESS TEMPERATURE BY PRESSING
UP/DOWN ARROWS AND THEN PRESSING ENTER (HALF CIRCLE) KEY
(FACTORY SET TO 125°F).

4) THE HIGH LIMIT CONTROL (PROCESS TEMPERATURE SENSING) IN
THE PANEL, MOUNTED ON THE BACK PANEL UNDER THE MAIN
CONTROLLER TO THE LEFT SIDE, SENSES PROCESS TEMPERATURE
AND WILL DISCONNECT POWER TO THE HEATERS IF OVER
TEMPERATURE OCCURS. SETPOINT SHOULD BE APROXIMATELY 20°

TO 25°F ABOVE PROCESS TEMPERATURE. WHEN THE TEMPERATURE
RETURNS TO BELOW THE HIGH LIMIT SETPOINT THE POWER WILL
RETURNED TO THE HEATING CIRCUIT ALLOWING THE HEATERS TO
COME ON BUT THE RED HIGH LIMIT RESET PUSHBUTTON WILL BE
ILLUMINATED UNTIL MANUALLY RESET (INDICATING THAT THERE WAS
A HIGH LIMIT OCCURANCE). THE CAUSE OF THE MALFUNCTION
SHOULD BE INVESTIGATED AT ONCE. POSSIBLE REASONS ARE:

• Thermocouple failure on the main temperature controller (indicated by “no”

in the upper display of the controller).

• “Over Ranging” of the main temperature controller (indicated by “over” in

upper display).

• Temperature controller setting higher then Hi-Limit controller setting.

• Main temperature controller out of calibration.

• Hi-Limit controller out of calibration.

• Heater magnetic contactor locked in closed position because of “welded”

contacts or mechanical binding.

5

MAINTANENCE

1) PERIODICALLY CHECK ALL WIRING CONNECTIONS TO INSURE THEY
ARE TIGHT AND FREE OF OXIDATION.

2) PERIODICALLY CHECK CONTACTS ON THE CONTACTORS FOR WEAR
AND REPLACE CONTACTOR IF WORN.

3) TANK SHOULD BE CLEANED AT REGULAR INTERVALS.

4) BE SURE TO SEE THAT TANK HAS ADEQUATE INSULATION.
INSULATION TENDS TO BREAK DOWN IN TIME THUS COSTING
DOLLARS IN LOST EFFICIENCY.

6

on

PHCo

Products

Manufactured by

Process Heating Company

THE ABOVE WARRANTY IS SUBJECT TO THE TERMS &

and delivered to the initial user are subject to the fol-

lowing limited warranty: PHCo warrants its Patented

Heating Elements to be free from defects in workmanship

and materials for a period of five (5) years (one (1) year

for drop-in style) after the date of delivery to the initial

user when operated under normal use and service and in

accordance with printed instructions provided by PHCo.

All other parts and components provided by PHCo as

part of the unit are warranted to be free from defects in

material and workmanship for a period of one (1) year

from date of delivery to the initial user.

CONDITIONS ON THE REVERSE SIDE OF THIS DOCUMENT

, INCLUD-

OTHER

nship and materials

, OR FOR ANY

less the same is in writ-

o its transaction with you (the

r after tender of delivery (five (5)

f such fact within thirty (30)

y are exclusive of all other

er the purchase price paid for that

aim relating to any item sold.

lity on account of any claim as-

r with a non-defective item), then

basis, if PHCo’s liability on account

o.

that is greater than their normal.

terms of this contract.

waived or varied by course of

tute a waiver of the same or any

rules. Any action to enforce

or state court located in King

jurisdiction over them person-

be dismissed at the instance of

ontract, tort or otherwise) may be com-

-in style elements), and if Buyer notifies PHCo in writing o

OTHERS FOR ANY SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES

Unless otherwise agreed in writing by Process Heating Company (“PHCo”), all of the following terms & conditions shall apply t

“buyer”):

1. LIMITED WARRANTY; DISCLAIMERS. PHCo warrants that the goods sold under this contract shall be free from defects in workma

at the time delivery is tendered. If there is discovered any failure of goods to conform to this warranty within one (1) yea

years in the case of immersion type heating elements other than drop

days following such discovery, PHCo at its own expense either will repair the defective item, or replace it, or refund to Buy

item (with choice between repair, replacement or refund to be made solely by PHCo). The foregoing limited warranty and remed

warranties, express or implied, and constitute PHCo’s exclusive liability, and Buyer’s exclusive remedy, on account of any cl

PHCo DISCLAIMS ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. If PHCo should elect to repair or replace a

defective item and if for any reason the repair or replacement should fail in its essential purpose (which is to provide Buye

PHCo’s liability nevertheless shall be limited to the purchase price charged by PHCo for the goods. PHCo shall have no liabi

serted under principles of negligence or other tort, breach of any statutory duty, indemnity or contribution, or on any other

of such claim would exceed or in any respect differ from its liability under forgoing limited warranty and exclusive remedy.

2. LIABILITY OF PHCo UNDER THE FOREGOING LIMITED WARRANTY SHALL EXIST ONLY IF: a. The goods are installed, operated and tested in accordance with the PHCo approved installation and operation instruction. b. The goods are used and maintained in conformity with installation and operation instructions approved or published by PHC

c. Written authorization must be given by PHCo before any warranty work is done. The above limited warranty shall be void and no longer in effect if the goods are subject to abuse, strain, impact or loading

3. LIMITATION OF LIABILITY. UNDER NO CIRCUMSTANCES SHALL PHCO OR ANYONE ELSE INVOLVED IN THE MANUFACTURE OR

SALES OF THE GOODS BE LAIBLE TO BUYER OR

ING BUT NOT LIMITED TO LOST PROFITS, EVEN IF PHCO HAS BEEN ADVISED OF THE POSSIBILTY OF SUCH DAMAGES

DAMAGES OR SUMS PAID BY BUYER OR OTHER THIRD PARTIES. THE FOREGOING LIMITATION OF LIABILITY SHALL APPLY

WHETHER ANY CLAIM FOR ANY SUCH DAMAGES IS BASED UPON PRINCIPLES OF CONTRACT, WARRANTY, NEGLIGENCE OR

TORT, BREACH OF STATUTORY DUTY, PRINCIPLES OF INDEMNITY OR CONTRIBUTION, THE FAILURE OF ANY LIMITED OR EXCLUSIVE

REMEDY TO ACHIEVE ITS ESSENTIAL PURPOSE, OR ANY OTHER BASIS.

4. AUTHORITY OF PHCo’s AGENTS. No agent, employee or representative of PHCo has any authority to bind PHCo to any other affirmation, representa-

tion, promise or warranty concerning the goods sold under this contract, unless it is in writing and included as part of the

5. MODIFICATION OF WAIVER. No subsequent waiver or modification of this Limited Warranty and Liability shall be effective un

ing and signed by the party against whom such waiver or modification is asserted. No waiver in any one instance shall consti

other term or condition on any subsequent occasion. None of the express terms of this Limited Warranty and Liability may be

dealing or usage of trade.

6. DISPUTES. This agreement shall be governed by the laws of the State of Washington without reference to its choice of law

any of the terms or conditions of this agreement may be commenced or maintained at the option of either party in any federal

County, Washington having jurisdiction over the matter, and both parties consent in advance to the exercise by such courts of

ally. No action by either party arising out of or relating to this contract (including any action based upon principles of c

menced more than one (1) year after the cause of the action has accrued, and any action commenced by a party thereafter shall

the other party.