Watlow FLUENT Installation Guide
FLUENT® Product Guide
Product Guide
FLUENT® Product Guide
General
The purpose of this product guide (the “Guide”) is for Watlow Electric Manufacturing Company (“Watlow®”) to convey
certain recommendations, advisories and requirements regarding your purchase and use of the product(s) described
below (the “Product”). This guide is not intended to be an exhaustive list of recommendations, advisories or
requirements for the use of the product. Please visit Watlow’s website (http://www.watlow.com/) or contact Watlow
customer service (1-800-WATLOW2) for more information regarding Watlow’s products. To ensure the proper use
of the product, each user of the product should carefully review this guide. FAILURE TO COMPLY WITH THE
INFORMATION PROVIDED HEREIN SHALL CAUSE YOU TO ASSUME ALL RISK AND LIABILITY ARISING OUT
OF SUCH FAILURE.
Product Description
This guide applies to Watlow FLUENT® in-line heaters. The product can be distinguished via marking on the outer
metal sheath.
FLUENT® model number
Nominal operating voltage and total power
product serial number
patent site
Safety
The following markers utilized throughout this guide shall have the meanings set forth below:
DANGER – This is a danger statement that is related to the use of this product. Failure to heed these
messages will result in serious personal injury or death.
WARNING – This is a warning statement that is related to the use of this product. These statements warn
of actions that may result in physical injury or death.
WARNING – Risk of Electric Shock – This is a warning statement that warns of the presence of electrical
voltages, which can cause physical injury or death.
CAUTION – This is a caution statement that is related to the use of this product. These statements caution
against actions, which may damage the product or associated equipment.
DANGER – Care should be taken to read and completely understand this guide before installing and wiring
the product. The product is designed to become hot while in operational use. The end user must conduct
their own risk assessment to identify if there is any residual risk pertaining to direct contact with hot
surfaces. There is potential risk of rupture or other malfunction of the product if it is not installed in
accordance with this guide or other installation instructions provided by Watlow. It is the end user’s
responsibility to ensure that the product is properly selected and installed in accordance with applicable
recommendations given within this guide. Note: this guide does not cover all foreseeable end-use
applications, therefore, consult your local Watlow representative with any additional questions or concerns.
© 2019 Watlow Electric Manufacturing Company.
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FLUENT® Product Guide
FLUENT® Product Guide
WARNING – Risk of Electric Shock – Any installation and maintenance performed on this product shall
be performed by a qualified electrician in accordance with applicable national and local electrical codes.
It is the end user’s responsibility to ensure that proper precautions are taken to ensure that necessary
personal protective equipment is utilized by persons installing and maintaining any equipment.
Pre Installation
The following sets forth general safety instructions and requirements relating to the use of the product.
CAUTION – Watlow products are built to comply with UL® and CSA dielectric requirements. However, due
to atmospheric conditions, it may be necessary to validate by performing a dielectric test prior to startup.
(Refer to megohm test under the Installation section.)
1. Upon receipt of the product, inspect for any damage occurring during shipment. If you have any concerns about
the condition of the product, do not install such product and contact your Watlow representative prior to taking
further action with the product.
2. Upon receipt of the product, confirm that the product received is the same as the product that was ordered. In the
event of a discrepancy, please contact your Watlow representative prior to taking further action with the product.
Installation
Proper product selection and installation will help to ensure heat transfer efficiency, safety and increased product life.
The following sets forth instructions and requirements relating to the installation of the product.
1. Megohm pre-check
WARNING – Risk of Electric Shock – The bake-out procedures listed below should only be performed
by qualified personnel. If the procedure calls for connecting electric power to the product, this shall
only be performed by a qualified electrician, in accordance with applicable national and local electrical
codes.
During shipping and/or storage, the possibility of moisture absorption by the insulation material within a heater
element is possible. To determine if the proper megohm value is present, use a 500VDC (minimum) megohm meter
to measure the insulation resistance between the product power terminals and the product’s outer protection tube.
This value should be greater than 200 megohms when the unit is at room temperature.
If a low megohm value exists, bake the product in an oven at 177°C (350°F) ± 27°C (50°F) for a duration of 12 to 24
hours. After baking, repeat the megohm insulation resistance test to verify that 200 megohms insulation resistance
has been achieved. If the product fails a second insulation resistance test, contact your Watlow representative or
customer service at the phone number indicated in this guide.
CAUTION – Do not exceed 204°C (400°F) if an oven bake-out is performed.
2. Heater orientation and mounting
When flowing liquids through the product, it should be mounted vertically with the inlet (side with the lead exits)
on bottom and the outlet on top. Failure to mount the product in this orientation can cause overheating and failure
of the product. For gaseous fluids, any product orientation is possible as long is it is not downwards. The direction
of the flow must go from inlet (lead exit) to outlet.
CAUTION – Failure to orient the product in the correct position or flow the fluid from the inlet (lead exit) to
the outlet can result in failure of the product.
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FLUENT® Product Guide
FLUENT® Product Guide
WARNING – Electric heaters are capable of developing high temperatures, so to minimize the risk of
fire extreme care should be taken to locate the product in a safe environment. Mounting products
in atmospheres containing combustible gases and vapors should be avoided. You must ensure that
combustible materials are maintained far enough away from the product to ensure that they are free of
the effects of high temperatures.
This product is not suitable for use in hazardous (classified) locations.
The best way to mount the product in place should be determined by the end user.
Application Orientation
3. Protection of heater elements from over temperature
The use of a temperature controller to regulate the heating process and prevent product failure is critical to
ensure safe operation. It is the end user’s responsibility to ensure safety of the installation. The maximum heater
engine operating temperature for the product is 350°C as measured by the integrated thermocouple. This thermocouple must be connected to a controller that provides a latching high limit at a maximum value of 350°C. The
high limit set point should be reduced if the normal operating conditions allow for it. The recommended high limit
temperature set point is the value of the integrated thermocouple during normal operating conditions plus 30°C.
WARNING – Install high temperature controller protection using the integrated thermocouple. The
high limit must be latching and the temperature set point should not exceed 350°C. Failure to install
temperature controller protection could result in damage to equipment, property and/or injury to personnel.
CAUTION – Failure of components in a temperature control loop, such as the sensor, heater control relay
or main temperature controller, can result in damage to a product in process, a product failure and/or
damaging fire. To protect against this possibility, over-temperature protection must be provided to interrupt
or remove power from the heater circuit during abnormal conditions. To limit this risk, perform a functional
test of all temperature limiting devices on a regular interval.
CAUTION – Certain heating applications may accompany volumetric expansion and/or phase change. In all
cases, ensure that appropriate safeguards against over-pressurization are included in system design.
All temperature limit devices must have appropriate third-party approval and be applied in the classification for which
it was tested and approved. The high temperature limiting device(s) should function independently from the process
temperature controller. This is a high performance product and requires a PID controller with a fast relay (refresh rate
of 10Hz or better) in order to be controlled effectively.
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