Chromalox PD444-2 User's Manual
Contents
1. individual elements o a Representative wiring diagrams for heaters with Single use fuse F or Resetable fuse RF Single phase heater circuit using a SPST thermostat Line Voltage and or current do not exceed thermostat or thermal fuse rating Figure 3 Ground O i Ja Pia o d _ ooo _Fused Thermostat Disconnect Customer Supplied Thermal Fuse Figure 3 One Single phase heater or 3 single phase heaters equal in size and each having a thermal fuse wired as a 3 phase heater circuit using a DPST thermostat Line voltage and current do not exceed thermostat or thermal fuse s rating Figure 4 Dotted line and L3 indicates 3 phase connections Ground O Fused Thermostat Thermal Fuses Disconne Customer Supplied Black AVAA V gt Heater Figure 4 Single phase or 3 phase heater circuit Line voltage and or current exceeds thermostat or thermal fuses ratings Figure 5 Dotted line and L3 indicates 3 phase connections Black lo Black _ lo i rv J rr rl gt wd Black O Fused Disconne TR ol2 O i L1 Customer Supplied Thermostat Magnetic Contactor Thermal Fuses Figure 5 Ferrule Nut Conduit Insert een C E sno Sealing Insert 1 Cut conduit Slide nut and sealing insert onto2. Construction Characteristics A High quality resistance wire held in place by compacted mag nesium oxide in stainless steel sheath and Teflon covered Low watt density Grounded construction Over temperature protection Epoxy filled vapor tight plastic terminal enclosure prevents entry of contaminants Flexible conduit 3 long with 6 leadwire extension is stan dard AWARNING 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 essen tial agaw Teflon is a registered trademark of DuPont Co INSTALLATION AWARNING 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 by a qualified person in accor dance with the National Electrical Code NFPA 70 1 Before installing the type GTF heater inspect it for possible dam age which may have occurred during shipment Also check to insure that the line voltage is the same as that stamped on the nameplate 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 AWARNING FIRE HAZARD If the heater is no
3. Chromalox Installation Instructions SERVICE REFERENCE omsong4 sen GTF _____ REFERENCE Supersedes PD444 1 PD444 2 161 562652 001 Date DECEMBER 2004 Chromalox Type GXF GTF GTFL Series Grounded Teflon Immersion Heaters GXF GXFL it i M GTF6 GENERAL AWARNING FIRE EXPLOSION HAZARD This heater is not intended for use in hazardous atmospheres where flammable vapors gases liquids or other com bustible atmospheres are present as defined in the National Electrical Code Failure to comply can result in explosion or fire Chromalox type GTF series of Teflon over the side immer sion heaters are especially suited for most plating tank and other corrosive solutions It is inert to acid baths anodizing and picking operations up to 212 F solution temperatures AWARNING Sheath corrosion can result in a ground fault which depending upon the solution being heated can cause an explosion or fire IMPORTANT t is the responsibility of the pur chaser of the heater to make the ultimate choice of sheath material based upon his knowledge of the chemical composition of the corrosive solu tion character of the materials entering the solu tion and controls which he maintains on the process Chromalox cannot warrant any electric immersion heater against failure by sheath corrosion if such failure is the result of operating conditions beyond our control 2010 Chromalox Inc 1 Heater
4. cable to this product at http Awww chromalox com customer service policies termsofsale aspx Chromalox PRECISION HEAT AND CONTROL 2150 N RULON WHITE BLVD OGDEN UT 84404 Phone 1 800 368 2493 www chromalox com TA Q0 EF Litho in U S A
5. e If the removed Thermal fuse is dry proceed by using it as a guide to cut and strip the wires of the new Thermal fuse Re connect the Thermal fuse leads to the extension leads using the original wire nuts Re insert the Thermal fuse into the well making sure it is fully seated to the bottom of the well 8 Re seal using the original sealing putty or an RTV type sealant 9 Replace the head cover return the heater to the tank 10 Turn the power back on ds m Thermal Fuse Temperature System Be sure and satisfied that your process bath tanks are as well protected as possible from tank leaks excessive evaporation tank refill failures and worker error Grounded Electric Immersion Heaters are practical efficient and safe when used properly and installed in tanks that have proper solution levels Good ventilation trained operators and safeguards such as liquid level controls and Thermal fuse over temperature sensors Thermal fuse systems help reduce the hazards created by low liquid levels and when properly seated and wired they will cut off the power to the heaters thus avoiding the extreme tempera tures resulting if solution levels are low enough to expose heater hot zones Single Use Fuse F Sensor consists of a one time thermal fuse sensor which is standard on all GTF over the side heaters The F thermal fuse is wired in series with the controller To operate properly the fuse mu
6. st be fully seated to the bottom of the thermowell tube When the fuse blows shut off the main power to the heater remove the spent fuse and install the new fuse Refill the tank to the proper level prior to turning power back on Replacement thermal devices must be purchased from Chromalox Resettable Fuse RF Sensor consists of a Bi metallic thermostatic sensor an audi ble alarm alarm relay and reset button The RF System operates on the same principle as the F except that the sensor does not blow It operates as a Bi metal lic thermostat which opens and sounds the alarm The reset but ton must be pushed to re activate the heater and control after the solution level in the tank has been raised to the proper level AWARNING FIRE SHOCK HAZARD Before replacing fuse make sure the cause of the failure has been detected and corrected THERMAL FUSE INSTALLATION REPLACEMENT con t Thermal Fuse Replacement Protection Devices FT Std Teflon Heaters RFT L Shaped Teflon Heaters F Amp Capacity 25 Amps RF Amp Capacity 5 Amps Blank low Temp 180 F Low temp most common for this style heater RF sensors require additional Control Components which include a Relay Audible Alarm and Manual Reset Pushbutton Specify 120 or 240V when ordering For process temperatures above 180 F consult factory Limited Warranty Please refer to the Chromalox limited warranty appli
7. t properly sub merged the heating elements will overheat and could result in a fire or damaged equipment a 3 Where work will pass over or near equipment additional protec tion such as a guard may be needed 4 In an electroplating operation the heaters are not under any cir cumstance to be placed between the electrodes and the work 5 A drip loop is recommended to minimize passage of moisture along wiring into terminal box and connections AWARNING FIRE HAZARD Since heaters are capable of devel oping high temperatures extreme care should be taken to A Avoid contact between heater and combustible material B Keep combustible materials far enough away to be free of the effects of high temperatures WIRING AWARNING ELECTRIC SHOCK HAZARD Any installation involving electric heaters must be performed by a qualified person and must be effectively grounded in accordance with the National Electrical Code to eliminate shock hazard 1 Electrical wiring to heater must be installed in accordance with the National Electrical Code and local electrical codes by a quali fied person When element wattages are not equal heaters must not be con nected in series Under no condition should the conduit be cut shorter or fumes will enter the cable and will be drawn into the heater and condense inside The wiring will then be attacked and will shorten heater life Tamperproof wiring epoxy imbedded prevents field rewire of
8. the conduit 2 Screw the ferrule insert into one end of the flexible conduit 3 Seat the ferrule insert inside of the body seat the sealing insert and hand tighten the cap onto the body 4 Repeat steps thru 3 above for the other end of the conduit after pulling the wires 5 If the fitting is used in a threaded hole first thread the body into the hole then follow steps 1 thru 3 6 If the fitting is used thru an opening use the locknut and plastic washer to fasten it Opening for 1 2 NPT thread is 7 8 OPERATION 1 Do not operate heater at voltages in excess of that stamped on the heater since excess voltage will shorten heater life Always maintain a minimum of 2 of solution above the heated portion of the element to prevent exposure of the effective heated length If the heater is not properly submerged it may overheat and shorten heater life Do not operate heater if dry 3 Sludge should not be allowed to build up to the point where it contacts heater as this can lead to premature heater failure Heater must not be operated in sludge 4 In an electroplating operation the heaters are not under any cir cumstances to be placed between the electrodes and the work 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 by a qualified per son in accordance
9. with the National Electrical Code NFPA 70 1 Heaters should be checked periodically for coating and corrosion buildup and cleaned if necessary 2 Tank should be checked regularly for sediment around the end of heater as this sediment can act as an insulation and shorten heater life 3 Note Before Teflon heater is removed from solution it should be allowed to cool from 15 to 20 minutes THERMAL FUSE INSTALLATION REPLACEMENT 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 by a qualified per son in accordance with the National Electrical Code NFPA 70 The Thermal fuse device must be properly installed and these procedures followed or heater failure or fire may result A liquid level control is a must as an additional safety feature to help minimize the possibility of fire 1 Make sure all electrical power to the heater is shut off 2 Unscrew the head cover Remove the wire nuts from the fuse leads and save for re use Remove the Sealing Putty and pull the Thermal fuse out of its well Clean the putty out of the well and save for re use Check the Thermal fuse and the inside of the well to see if it is wet If wet inside dry out well Immerse the tube into the solu tion If moisture appears again inside the well DO NOT use the heater Call the factory for further advic
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