Watlow Electric 316-42-15-1 User's Manual
Contents
1. _ 2 O D g x z 9 3S Figure 1 WATLOW IND n 6 INDUSTRIAL LOOP RD n HANNIBAL MO 63401n PHONE 314 221 2816 n FAX 314 221 3723 WATLOW IND WATROD Modular Duct Heater Installation amp Maintenance Manual I amp M NUMBER 316 42 15 1 Page 4 Date 6 11 2008 Rev 2 When installed horizontally the user must determine whether the duct wall has sufficient strength to support the unit by the flange only A frame may be necessary to support the unit in the duct This frame can have tapped holes or captive nuts to receive mounting bolts An access panel in the duct can facilitate installation DANGER HAZARD OF FIRE Electric heaters are capable of developing high temperatures so extreme care should be taken to locate heaters in safe environments Mounting heaters in atmospheres containing combustible gases and vapors should be avoided According to article 501 of the NEC the maximum surface temperature of the heater shall not exceed 80 of the auto ignition of the surrounding atmosphere when the heater is continuously energized Care should also be taken to keep combustible materials far enough away to be free of the effects of high temperatures Wiring WARNING HAZARD OF ELECTRIC SHOCK Any installation involving electric heaters must be grounded to earth to eliminate shock hazard Electrical wiring to the heaters must be installed in accordance with the National Electric Code and any state and local electrica2. mark shown on the flange below e Watlow Modular Duct Heat MEN D000000000 f O XXXX W XXX V XPH XXXX N Use 1 8 NPT tap thread the hole drilled in step b Make certain that the hole being tapped is perpendicular to the flange If it is not perpendicular electrical shorting may occur between the compression fitting and the nearby electrical jumpers d Thread the lower portion of the compression fitting in the hole tapped above e Insert thermocouple through lower portion of compression fitting threaded into flange and through hole in upper support bracket until transition fitting of thermocouple is bottomed out f Tighten upper portion of compression fitting to firmly hold thermocouple in place g Wrap thermocouple as shown in the diagram below about two times on a 2 diameter h Attach tip of thermocouple to mid section of element using the hose clamp provided The tip of the thermocouple should not be covered by the hose clamp but should extend about 3 16 from the hose clamp i Pass heat shrink provided over thermocouple leads and compression fitting Heat shrink sleeving so that it adheres to the shape of the compression fitting and thermocouple WATLOW IND n 6 INDUSTRIAL LOOP RD n HANNIBAL MO 63401n PHONE 314 221 2816 n FAX 314 221 3723 WATLOW IND WATROD Modular Duct Heater Installation amp Maintenance Manual I amp M NUMBER 316 42 15
3. gt WATLOW IND WATROD Modular Duct Heater Installation amp Maintenance Manual I amp M NUMBER 316 42 15 1 Page 1 Date 6 11 2008 Rev 2 Pre Installation e Check to make sure that heater received is the same as that ordered e Elements may come in contact with each other during shipment Minor adjustments to elements may be required prior to installation to separate them Extensive bending of elements should be avoided since dielectric strength between coil and sheath may be compromised e Watlow heaters are built to comply with UL and CSA dielectric requirements it be necessary due to atmospheric conditions humidity to perform a dielectric test prior to startup Refer to megohm test under Installation section Electric heaters are inherently dangerous Care should be taken to read and completely understand the Installation and Maintenance manual before installing and wiring the heater Any installation and maintenance performed on the heater shall be done by a qualified electrician in accordance with the National Electric Code and other electrical codes as they apply It is the users responsibility to ensure that the heater being used is properly selected and installed in the application The Caution Symbol exclamation point alerts you to a CAUTION a safety or functional hazard which could affect your equipment or its performance The warning symbol lightning bolt alerts you to a WARNING safety haza
4. of the installation Individual heater modules are designed to accommodate optional high limit thermocouple kit WARNING Install high temperature control protection in systems where an over temperature fault condition could present a fire hazard or other hazard Failure to install temperature control protection where a potential hazard exists could result in damage to equipment and property and injury to personnel WATLOW IND n 6 INDUSTRIAL LOOP n HANNIBAL MO 63401n PHONE 314 221 2816 n FAX 314 221 3723 WATLOW IND WATROD Modular Duct Heater Installation amp Maintenance Manual I amp M NUMBER 316 42 15 1 Page 2 Date 6 11 2008 Rev 2 Failure of components in a temperature control loop such as the sensor heater control relay or main temperature control can result in damage to a product in process a melt down of a heater and damaging fire To protect against this possibility over temperature protection must be provided to interrupt or remove power from the heater circuit A bulb and capillary thermostat is not recommended for this function since it may not respond quickly enough to adequately protect the heater In cases where the thermostat bulb gets too hot before the system is turned off the thermostat bulb could rupture This could result in the thermostat remaining in the ON condition since there is insufficient fluid to move contacts apart We recommend the temperature protection have appropriate third party ap
5. 1 Page 7 Date 6 11 2008 Rev 2 im q 0 An 1208 lt a wmf 7 Contact your local Watlow distributor for ordering replacement parts Check the Yellow Pages under Electrical Heating Elements in the largest industrial area nearest you Watlow warrants its products against defects in material and workmanship for 12 months from the date of delivery for custom products and 18 months for stock products providing such products are properly applied used and maintained Watlow does not warrant any product against damage from corrosion contamination misapplication improper specification or operating conditions beyond our control The terms of this warranty are the exclusive terms available to any person No person has authority to bind the Company to representation or warranty other than this warranty Watlow is not liable for incidental or consequential damages resulting from use of the product whether a claim for such damages is based upon warranty contract negligence or other fault Should any product fail under these warranty conditions it will be repaired or replaced at no charge Advanced authorization must be obtained within 30 days of failure Return Policy 1 Call Watlow Industries at 573 221 2816 for a Return Material Authorization RMA number before returning any item for repair or replacement The following information is needed to process a returned heater expediti
6. l code by qualified personnel Consult wiring diagram supplied with the unit for correct feeder wires connections If one is not supplied the factory should be consulted for the appropriate wiring diagram Feeder wire should be properly selected based on amperage electrical power rating ambient temperature and type of environment Feeder wire should also be housed in either rigid or flexible conduit which carries the same classification as the heater enclosure It is the users responsibility to properly size and install feeder wire Feeder wire line connections may be made directly to stud terminals or box type compression fittings Box type compression fittings will accept a 4 AWG maximum wire while stud terminals will accept 10 ring connector T amp B Amp etc It is essential that these connections be tight Stud terminals should be tightened to a maximum torque of 20 in lbs while the bottom nut is supported Ground connection color coded green is supplied inside the housing for ground wire Line voltage must be equal to or less than rating stamped on the heater assembly The power circuit is required to include a branch circuit overcurrent protective device a disconnect and a secondary thermal cut out with manual reset The control circuit should include the temperature controller the primary thermal cut out and an interlock with the fan motor One method to do this is with a pressure air flow switch It will open the control circui
7. or from any air handling equipment See Figure 1 for locations that should be avoided Heaters may be ganged in parallel for nearly any total wattage desired The temperature control thermocouple if so equipped should be located near the work to sense exiting air temperature Conduct process temperature sensing in the outlet stream away from the heater Minimum air velocity through the heater is 200 fom for air temperatures approaching 800 F 412 C Lower velocities will jeopardize element life Air flow over the entire face of the heater should be uniform at the design velocity The units screw or bolt in place through the 3 8 dia holes in the mounting flange When installed vertically through the top of the duct they are self supporting when the duct is capable of supporting the heater weight WATLOW IND n 6 INDUSTRIAL LOOP RD n HANNIBAL MO 63401n PHONE 314 221 2816 n FAX 314 221 3723 WATLOW IND WATROD Modular Duct Heater Installation amp Maintenance Manual I amp M NUMBER 316 42 15 1 Page 3 Date 6 11 2008 Rev 2 gt 5 2 Z 3 lt 5 T am aan 5 gt T ye gt 5 A a B 5 g oO gt 6 Oo 2 Ay 5 9 Z 0 5 S 5 oO lt 3 T 2 as m gt O 2 T gt 2 ge 3 5 5 s 5
8. ously Customer name Customer account number Contact Name Phone Number Part number P O number Quantity Reason for return Application information MSDS sheet of material s that came in contact with heater if used 2 Prior approval and an RMA number is needed when returning any unused product for credit Make sure the RMA number is on the outside of the carton and on all paperwork Return all material Freight Prepaid basis 3 Stock heaters and accessories which have not been used or modified can be returned to the plant for a 20 restocking charge Modified stock units can only be returned if they are not permanently modified for a minimum 30 restocking charge 4 All stock and modified stock must have a date code no later than 2 years from the date of shipment WATLOW IND n 6 INDUSTRIAL LOOP RD n HANNIBAL MO 63401n PHONE 314 221 2816 n FAX 314 221 3723 WATLOW IND WATROD Modular Duct Heater Installation amp Maintenance Manual 1 amp M NUMBER 316 42 15 1 Page 8 Date 6 11 2008 Rev 2 REVISIONS LEVEL DESCRIPTION INITIALS DATE 1 00 SEE PART COMMENTS 1 98 2 00 HAN2838 TBR 06 11 08 WATLOW IND n 6 INDUSTRIAL LOOP RD n HANNIBAL MO 63401n PHONE 314 221 2816 n FAX 314 221 3723
9. proval and be applied in the classification for which it was tested and approved 3 Terminal Enclosures Terminal enclosures should be selected to be compatible with the environment in which the heater will be located It is the users responsibility to determine the need for correct rating of the electrical housing This should be based on appropriate national and local electrical codes Failure to use a compatible enclosure could result in heater damage and personnel danger Standard terminal enclosures are designed for general purpose use and are rated NEMA 1 These enclosures should be applied where there will be no danger of spilled liquids dampness dirt and gaseous conditions Enclosures for wet or hazardous locations are also available but must be installed at the factory Although enclosures are supplied over the terminals units should be located in an area that will minimize the chance of being hit by falling or moving objects The terminals must be protected at all times from moisture or vapor In hazardous locations as defined in NFPA 70 NEC Article 501 explosion resistant housings must be used In order to maintain termination integrity the terminal enclosure should be kept below 400 F 204 C 4 Orientation Mounting The duct heater may be mounted vertically or horizontally from the left to right top or bottom The inlet side of the unit must be at least 48 downstream from any transition in duct size or direction
10. rd which could affect you and the equipment Installation Proper heater selection and installation will result in efficient heat transfer safe operation and long heater life 1 Megohm precheck During shipping and or storage the possibility of moisture absorption by the insulation material within the element is possible To ensure proper megohm values a minimum 500 VDC megohm meter Megger should be used to ensure that the megohm reading between the heater terminal and the heater sheath is more than 10 megohms when the unit is at room temperature If several units are interconnected the megohm of the heater is obtained by taking the reading and dividing by the number of interconnected elements This reading should be greater than 10 megohms If alow megohm value exists two alternative methods can be used to remedy the situation The best method is to remove all terminal hardware and bake out the heater at no higher than 250 F 120 C overnight or until an acceptable reading is reached The second method is to energize the unit at low voltage in air until the megohm is at an acceptable reading Care should be taken to prevent the heater sheath from exceeding 750 F 398 C for Incoloy 2 Protection of heater elements from over temperature The use of temperature controls to regulate heating process and prevent heater over temperature is highly recommended to ensure safe heater operation It is the users responsibility to ensure safety
11. ry Replacement Parts Reference the duct heater part number on the nameplate when ordering replacement parts Recommended spare parts would be Modular Duct Heater replacement module and high limit thermocouple or high limit thermocouple kit To replace individual heater module a Disconnect power and then feeder wire b Remove terminal hardware connecting module to be replaced and other adjacent modules Remove the two Allen head screws and split washers holding module to main flange d Pull module through main flange as shown below WATLOW IND n 6 INDUSTRIAL LOOP RD n HANNIBAL MO 63401n PHONE 314 221 2816 n FAX 314 221 3723 WATLOW IND WATROD Modular Duct Heater Installation amp Maintenance Manual 1 amp M NUMBER 316 42 15 1 Page 6 Date 6 11 2008 Rev 2 Reinstall new module through main flange and retighten using Allen head screws and split washers f Reinstall jumpers and feed wire 9 Check circuit resistance to ensure that modules have been properly wired 7 Split Washer Main Flange C Module 20 SF N i 4 N X BS Allen Screw To install high limit thermocouple kit a Perform steps a d above b Use a 11 32 drill to drill a pilot hole at the location depicted by the
12. t and de energize the heater when any circumstance prevents sufficient air flow through the heater The air handler should be set up to run on a time delay after the heater is de energized The correct time delay will depend on the blower rating amount of duct insulation and the total power output of heaters s The time delay allows the elements to cool and prevents overheating the adjacent duct and terminal areas Before energizing the heater the following items should have been checked with the heater power disconnected Electrical termination is tight and wiring is per wiring diagram supplied with heater Proper disconnecting means and fusing have been installed The voltage rating of the heater is the same as that being applied Megohm is within acceptable limits Proper temperature controls and safety limiting devices are in place Heater is securely installed in duct WATLOW IND n 6 INDUSTRIAL LOOP n HANNIBAL 63401n PHONE 314 221 2816 n FAX 314 221 3723 WATLOW IND WATROD Modular Duct Heater Installation amp Maintenance Manual NUMBER 316 42 15 1 Page 5 Date 6 11 2008 Rev 2 After applying power to the heater make sure that the system is being controlled properly before leaving it to run unattended Failure to do this could result in overheating resulting in personnel danger and fire Troubleshooting PROBLEM Cause Correction No power available to heater Check disconnect switch
13. to ensure it is in the ON position and that fuses are not blown Replace fuses if they are blown Fuses blowing Check heater electrical rating Applied voltage may be wrong Check fuse rating Fuses should be at least 25 more than full load amperage Disconnect heater power source Check the heater resistance to ground This should be no less than 1 Megohm Refer to Megohm checking Not enough power Check line voltage to ensure it is within specification Check full line current if voltage is correct If line current is lower the heater may be wired wrong or has open elements Air not heating to desired Not enough Kw or incorrect voltage being applied temperature Too much heat loss higher wattage heater may be required High limit tripping alarm Not enough fluid flow Too much Kw Line voltage higher than designed allowable Preventative Maintenance CAUTION HAZARD OF ELECTRIC SHOCK TURN ALL POWER TO HEATER OFF USE APPROPRIATE DISCONNECT LOCKOUTS AND ALLOW SYSTEM HEATER TO COOL BEFORE PERFORMING ANY MAINTENANCE Check line connections to make sure they are tight free of oxide build up and that no dust or dirt build up is present Re tighten to 20 in lbs as necessary Check enclosure inside for rust dirt or dust Remove rust if present with steel wool or equal and thoroughly blow clean with dry oil free air If enclosure is moisture resistant check condition of cover gasket A replacement can be obtained from the facto
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