Chromalox PN403-1 User's Manual
Contents
1. LTFX 128 008E2 4 150 OCE 06080 2 483 LTFX 1212 012E2 4 150 OCE 06080 2 483 LTFX 3210 024E2 8 150 OCE 06080 2 483 LTFX 3215 036E2 8 150 OCE 06080 2 483 LTFX 3225 060E2 8 150 OCE 25200 2 4803 LTFX 4225 090E2 10 150 OCE 25225 2 4803 LTFX 8215 120E2 LTFX 9220 180E2 12 150 14 150 OCE 15150 2 4803 OCE 25200 2 4803 COO Boo Go w w w w w LTFX 12225 240E2 14 150 N OCE 25200 2 4803 Limited Warranty Please refer to the Chromalox limited warranty applicable to this product at http www chromalox com customer service policies termsofsale aspx Chromalox PRECISION HEAT AND CONTROL Se ee ET 2150 N RULON WHITE BLVD OGDEN UT 84404 Phone 1 800 368 2493 www chromalox com TA S7 EF Litho in U S A2. Chromalox e H SERVICE REFERENCE Installation Operation and REFERENCE Supersedes PN403 PN403 1 RENEWAL PARTS IDENTIFICATION seer pop ee Type LTFX Unitary Electric Immersion Heaters Specifications E4 Moisture Resistant Housing Immersion ANSI Flange Number Tube Watt Density __ Matching Control Panel Heater Model Circuits Length In Size of Tubes Diameter Outside PCN Model LTFX 125 004E4 328858 4468 30211 LTFX 128 008E4 328858 4468 30211 LTFX 1212 012E4 328858 4468 30211 LTFX 2212 024E4 328858 4468 30211 LTFX 3212 036E4 328890 4468 30211 LTFX 2325 060E4 329920 4468 60211 LTFX 3325 090E4 N A 4468 90211 LTFX 4325 120E4 N A 4432 348 51100 LTFX 6325 180E4 N A 4432 348 51100 LTFX 8325 240E4 N A 4432 348 51100 wo i 3 150 10 150 10 150 12 150 14 150 u v lo ro Go a a a ami ank CO M H INJ V Nj e j Specifications E2 Explosion Moisture Resistant Housing Immersion ANSI Flange Tube Watt Density __ Matching Control Panel Heater Model kW Volts Phase Circuits Length In Size Diameter Outside PCN Model LTFX 125 004E2 4 150 LTFX 128 008E2 4 150 Note Explosion Resistant LTFX 1212 012E2 4 150 Control Panels are available TEATER eee sorted pana ait des ple ale 2 u hazardous location may offer LTFX 3225 060E2 8 150 significant cost savings LTFX 4225 090
3. E2 10 150 Please refer to section H of LTFX 8215 120E2 12 150 the catalog for available LTFX 9220 180E2 14 150 Panel options LTFX 12225 240E2 240 14 150 Note For horizontal mount only wo 4 CO CO B C c o w E Go ra D3 mi k fai N 2010 Chromalox Inc GENERAL The Chromalox Unitary Electric Immersion Heater Model LTFX is an engineered pretested package designed to give years of virtually maintenance free service and it is shipped ready for installation into a storage tank LTFX provides low watt density heating over a large heating surface with precise temperature con trol for such materials as asphalt fuel oil pitch and tar liquid sugar lube oils linseed oil biodiesel glycerin ethanol and many other heat sensitive compounds The open coil heating elements OCE are housed in either 2 or 3 Schedule 40 carbon or stainless steel pipes which are weld ed into the 150 ANSI flange Once the Unitary Immersion Heater is mated to your tank the heating elements may be removed and replaced without draining the tank Since excessive temperatures may permanently damage the heater and cause premature failure the use of temperature con trols limiting controls and liquid level sensors are recommended AWARNING The system designer is responsible for the safety of this equipment and should ins
4. and tuning the control scheme 1 Turn the master circuit breaker off and open the control box door 2 Set the indicating temperature control at the desired temperature and the over temperature cutout at 50 F above this temperature 3 Interlock the liquid level control with the cutout device 4 Close the control box door and turn the circuit breaker on To ener gize the heater circuits turn the on off selector switch to the on position MAINTENANCE AWARNING ELECTRIC SHOCK HAZARD Disconnect all power before installing or servicing heater Failure to do so could result in personal injury or property dam age Heater must be installed or serviced by a qualified person in accordance with the National Electrical Code NFPA 70 1 Make certain both the terminals and the ceramic insulators are free from contact with oil liquid or other foreign matter NOTE Chromalox cannot be responsible for failures or damage caused by contamination on the ceramic insulators Make certain the heaters are not exposed to contaminants 2 Check electrical connections at heater terminals and tighten if neces sary This will help avoid hot terminals which may destroy wire insu lation or heater terminals 3 Check overheat operation to assure heater protection Element Replacement Moisture Resistant Housing Only Option To remove the OCE heating elements first turn the circuit breaker to the off position 2 Next remove the housing lid ele
5. d mating surface for any debris oils or contamination NOTE Surfaces must be in suitable condition to ensure proper hazardous rating 5 Connect the new element to the flamepath module and slide into tube Flamepath module bolting must be tightened to XXX ft Ibs of torque 6 Reattach element wiring When reinstalling housing lid be sure to prop erly align gasket and tighten housing bolts to 40 50 in lbs TYPE LTFX RENEWAL PARTS IDENTIFICATION Table C E4 Housing Renewal Parts Identification Heater Immersion ANSI Model Length In Flange Size LTFX 125 004E4 60 4 150 wo Number of Tubes Tube OCE Replacement Diameter Element No OCE Model No 2 OCE 05040 2 483 4 LTFX 128 008E4 96 4 150 LTFX 1212 012E4 4 150 2 OCE 06080 2 483 OCE 12120 2 483 LTFX 2212 024E4 6 150 OCE 12120 2 483 LTFX 3212 036E4 6 150 OCE 12120 2 483 LTFX 2325 060E4 8 150 OGCE 25300 3 483 LTFX 3325 090E4 10 150 OGCE 25300 3 483 LTFX 4325 120E4 10 150 OCE 25300 3 483 LTFX 6325 180E4 12 150 09109 GO 09 www w OCE 25300 3 483 00 Joo po co po LTFX 8325 240E4 14 150 Table D E2 Housing Renewal Parts Identification Heater Immersion Model Length In LTFX 125 004E2 ANSI Flange Size 4 150 wo OCE 25300 3 483 Tube Diameter OCE Element No Number of Tubes Replacement OCE Model No OCE 05040 2 483 4
6. e gasket s if applicable and service entrance plates by tightening the Allen head screws to 4 5 in lbs The Octobox style of housing can be removed for ease of access to element bussing or to better locate the power conduit s entry point To accomplish simply remove the Allen head screws on the outside of the housing When reinstalling be sure to prop erly align gasket if applicable and tighten to 40 50 in lbs Tip for Reinstalling Gaskets Place Allen Head screws through metal covers and gentle push gasket hole over the threaded screw This will allow the gas ket to stay in place while tightening the cover Wiring Entrance Locations Explosion Resistant Housing Only E2 Option The Explosion Resistant E2 Housing features dedicated conduit connection sizes and locations for NPT installation of con duit Wiring installation must be in accordance with Hazardous Area requirements The use of EYS seals or rigid conduit may be required Please consult with the local inspection authority Maximum Temperatures Safe operation in a hazardous location requires the maximum operating temperatures of all exposed surfaces of the heater including temperatures on the outside of the vessel piping flanges screw plugs enclosures and other heat conducting parts be limited The flammable liquids vapors or gases present determine the maximum surface temperature permitted in any hazardous location The end user or purchaser of the elect
7. lation involv ing electric heaters must be performed by a quali fied person and must be effectively grounded in accordance with the National Electrical Code to eliminate shock hazard 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 conse quences of failure could result in personal injury or property damage back up controls are essential 1 Electrical wiring to heating elements must be sized and installed in accordance with the National Electric Code and applicable local codes by a qualified person as defined in the NEC 2 Temperatures at the heater terminals will require the use of man ganese nickel or equivalent temperature lead wire Type TGS TGT or TGGT are recommended WIRING cont d Wiring Entrance Locations Moisure Resistant Housing Only E4 Option The Moisture Resistant E4 Housing offers several conve nient options for conduit wiring amp location The housing is equipped with two removable service entrance plates for installa tion of wiring Any or all of the six sides can be used for wiring locations Refer to exploded view drawing The housing can also be rotated by removal from flange to allow for more position possibilities To install service entrance holes simply remove the side Allen screws and use the centering depression to drill the appropriate size hole Reinstall th
8. ment wiring and the element mount ing screw Now pull the element straight out of the heating tube NOTE OCE elements should only be bent in a vertical plane with ground strap on the bottom 3 When removing the heating elements make certain that the terminals and the ceramic insulators do not contact oil or any other liquid foreign matter NOTE Chromalox cannot be responsible for failures or dam age caused by contamination on the ceramic insulators 4 Installation is the reverse of the above Element Replacement Hazardous Locations Explosion Resistant Housing Only E2 option 1 To remove the OCE heating assembly first turn the circuit breaker to the off position 2 Next remove the housing lid element wiring and 5 16 bolting around the element flamepath module If needed 2 1 4 20x2 bolts may be used to break loose the module from the flange Turn bolts evenly until module is free The flamepath module will be re used so disconnected the heating element from the module pins Now pull the element assembly out of the heating tube NOTE OCE elements should only be bent in a vertical plane with ground strap on the bottom 3 When removing the heating elements make certain that the terminals and the ceramic insulators do not contact oil or any other liquid foreign matter Note Chromalox cannot be responsible for failures or damage caused by contamination on the ceramic insulators 4 Inspect the element assembly flange an
9. n may be bent on a 12 radius OCE elements should only be bent in a vertical plane with ground strap on the bottom B The neck on the tank s mating flange should be of adequate length to accommodate tank insulation and flange bolting 5 Tube supports internal to the tank should be placed approximately three feet from the wet side of the LTFX flange to ensure gasket seal ing integrity Additional tube supports can then be spaced on 10 foot centers Do not anchor the heater tubes to the supports as the tubes must be allowed to expand 6 To ensure proper sealing a material appropriate gasket needs to be installed between the mating flanges The mating flanges should then be secured by tightening the bolting according to TEMA Standards 7 A tank suction pipe should be mounted at least 2 above the level of the heaters A separate line can be provided to drain tank after heaters have been de energized Allow for Tank Insulation and Bolting 36 Min Element x s Removal Distance Fluid Level Open Coil Elements Model LTFX Tank Figure 1 WIRING AWARNING AWARNING WARNING 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 or ser viced by a qualified person in accordance with the National Electrical Code NFPA 70 AWARNING ELECTRIC SHOCK HAZARD Any instal
10. ric heating equip ment is responsible for determining the proper classification of an area and for providing Chromalox with hazardous area specifica tions and requirements for proper equipment design NEC and IEC provide guidelines for evaluating and classifying hazardous locations An approved liquid level control or overtemperature control must be installed to deenergize the heater if the liquid level drops below the top of the heater Table A E4 Wiring Information Heater Volts Phase Total Amps Circuits LTFX 125 004E4 K w w o a wlnv w Table B E2 Wiring Information Heater Circuits LTFX 125 004E2 LTFX 128 008E2 Total T 3 3 3 3 3 3 3 3 g ma mn s la l la OPERATION FIRE HAZARD To avoid possible damage to the heater do not energize until the tank is filled with fluid Recommended fluid level is 2 above the heater tube or pipe 1 Do not operate heaters at voltages in excess of that stamped on the heater since excess voltage will shorten heater life 2 Heaters should not be operated in environments with factors that can destroy the electrical insulating characteristics of the ceramic insulators Foreign contaminants can create leakage shock haz ards permanent heater damage or cause heater failure and there fore should be avoided For initial operation
11. tall adequate back up controls and safety devices with their electric heating equipment Where the conse quences of failure could result in personal injury or property damage back up controls are essential INSTALLATION AWARNING DANGER Hazard of Explosion or Fire The tank must be purged of all flammable vapors prior to cutting or welding High heating efficiency low element temperatures and longer heater life are achieved when the unit is properly installed 1 To avoid chipping or cracking precaution should be taken while unpacking handling and installing the ceramic insulators Heaters with damaged insulators should be returned to the factory for repair or replacement Contact your local sales office for return authorization 2 The LTFX unit must not be mounted in the vertical position as the resistance wire on the OCE element can sag thus causing uneven heat ing or short circuit Unit should be installed in a horizontal position with the thermowell on top only 3 IMPORTANT Mount heater in the tank so the liquid level will always be above the effective heated portion of the heater Provide expansion tank if necessary 4 Select a location for this installation according to the following guide lines refer to Figure 1 A Heating elements are removable through the terminal enclosure however adequate room must be provided for this purpose The removal length of the OCE heating element is 3 feet since the cen ter sectio
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