Watlow Electric Electric Heater 316 42 5 1 User Manual

WATLOW IND. WATROD Circulation Heater Installation & Maintenance Manual  
I&M NUMBER: 316-42-5-1  
Date: 6/11/2008  
Page: 1  
Rev: 2.00  
________________________________________________________________________________________________________________________________________________________________________________________________________________________  
Pre Installation  
Check to make sure that heater received is the same as that ordered.  
Watlow heaters are built to comply with UL and CSA dielectric requirements, it may be necessary due to  
atmospheric conditions / humidity, to perform a dielectric test prior to startup. (Refer to megohm test  
under Installation section)  
Safety  
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", a safety hazard 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 a low megohm value exists, two alternative methods can be used to remedy the situation. The best  
method is to remove all terminal hardware including thermostat if provided, 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® and steel elements  
and 400°F (204°C) for copper elements. Both of these methods should be performed with the heater out  
of the tank. The orientation of the heater in relation to the tank should be observed in order to reposition  
the heater properly. This is especially important if a high limit thermocouple is provided.  
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 of  
the installation.  
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 RD. n HANNIBAL MO, 63401n PHONE 573-221-2816 n FAX 573-221-3723  
 
WATLOW IND. WATROD Circulation Heater Installation & Maintenance Manual  
I&M NUMBER: 316-42-5-1  
Date: 6/11/2008  
Page: 3  
Rev: 2.00  
________________________________________________________________________________________________________________________________________________________________________________________________________________________  
OUTLET  
INLET  
OUTLET  
OUTLET  
INLET  
OUTLET  
INLET  
INLET  
LIQUID APPLICATION  
AIR / GAS APPLICATION  
Figure # 1  
Figure # 2  
NPSH  
PUMP  
INCORRECT HEATER POSITION - HEATER ABOVE NPSH  
NPSH  
PUMP  
CORRECT HEATER POSITION - HEATER BELOW NPSH  
Figure # 3  
When installing piping connections, care should be taken to avoid supporting the tank by the nozzles.  
Mounting blocks are provided to help prevent this. Provisions for thermal expansion and contraction  
should be considered, slotted bolt holes in one of the mating mounting pads would do adequately.  
Installation of an isolation valve and pressure relief valve is recommended but not provided. Rating of  
valves should not exceed the ANSI class 150 flange rating. Two 1/2" FNPT couplings are provided for  
drainage and installation of valves.  
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  
WATLOW IND.n # 6 INDUSTRIAL LOOP RD. n HANNIBAL MO, 63401n PHONE 573-221-2816 n FAX 573-221-3723  
 
WATLOW IND. WATROD Circulation Heater Installation & Maintenance Manual  
I&M NUMBER: 316-42-5-1  
Date: 6/11/2008  
Page: 4  
Rev: 2.00  
________________________________________________________________________________________________________________________________________________________________________________________________________________________  
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.  
5. 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 electrical code by qualified personnel.  
Consult wiring diagram supplied with the unit for correct feeder or leadwire connections. If wiring  
diagram 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 a  
#10 ring connector(T&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. Some units are  
supplied as dual voltage . Example: 240V / 480V, check wiring diagram supplied with the unit to make  
sure which scheme was used. In most cases (unless specified by customer) units are wired for the  
higher voltage.  
Thermostats can be supplied with circulation heaters. Consult the wiring diagram supplied with the  
heater for the suggested wiring of thermostats. For safe operation of thermostats, consult Installation and  
Maintenance manual for thermostats that is attached.  
Thermostats should not be used as an "OFF" device; the use of a disconnect switch or circuit breaker is  
recommended. The disconnect switch will allow isolation of the heater when maintenance of the heater  
is required.  
Start Up  
Before energizing the heater the following items should have been checked with the heater power  
disconnected:  
1. Electrical termination is tight and wiring is per wiring diagram supplied with heater  
2. Proper disconnecting means and fusing have been installed  
3. The voltage rating of the heater is the same as that being applied  
4. Megohm is within acceptable limits  
5. Proper temperature controls and safety limiting devices are in place  
6. Heater is securely installed in tank header and no leaks are visible  
Before energizing heater, correct fluid flow should be maintained over the heater bundle to ensure that  
heater elements do not overheat and fail.  
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.  
Thermal cycling may cause the gasket or sealed joints to relax causing a leak. On flange units, tighten bolts  
to re-seat gasket. If the leak persists, contact factory for a new gasket. On screw plug units, tighten threaded  
WATLOW IND.n # 6 INDUSTRIAL LOOP RD. n HANNIBAL MO, 63401n PHONE 573-221-2816 n FAX 573-221-3723  
 
WATLOW IND. WATROD Circulation Heater Installation & Maintenance Manual  
I&M NUMBER: 316-42-5-1  
Date: 6/11/2008  
Page: 5  
Rev: 2.00  
________________________________________________________________________________________________________________________________________________________________________________________________________________________  
plug. If leak persists, remove heating unit and add teflon tape or sealing compound to threads and re-install.  
Care should be taken to observe the orientation of the flange or plug to its original position.  
Troubleshooting  
PROBLEM  
Cause / Correction  
No power available to heater  
Check disconnect switch 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  
Fluid not heating to desired  
temperature  
Not enough Kw  
Too much heat loss  
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. Retighten 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  
factory.  
Liquid immersed units should be removed from tank and checked periodically for scale build-up. Clean as  
required. Scale can cause high sheath temperature and result in inefficiency and shortened life. When the  
heater is removed or tightened, take care to orient the heater in the position it was originally  
oriented.  
Replacement Parts  
Reference the Circulation heater part number on the nameplate when ordering replacement parts.  
Recommended spare parts would be : an immersion heater, flange gasket, and thermostat (if supplied).  
WATLOW IND.n # 6 INDUSTRIAL LOOP RD. n HANNIBAL MO, 63401n PHONE 573-221-2816 n FAX 573-221-3723  
 
WATLOW IND. WATROD Circulation Heater Installation & Maintenance Manual  
I&M NUMBER: 316-42-5-1  
Date: 6/11/2008  
Page: 6  
Rev: 2.00  
________________________________________________________________________________________________________________________________________________________________________________________________________________________  
Contact your local Watlow distributor for ordering replacement parts. Check the Yellow Pages under  
"Electrical Heating Elements" in the largest industrial area nearest you.  
Warranty  
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 expeditiously:  
Customer name  
Contact Name  
Part number  
Quantity  
Reason for return  
Application information  
Customer account number  
Phone Number  
P.O. number  
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 573-221-2816 n FAX 573-221-3723  
 
WATLOW IND. WATROD Circulation Heater Installation & Maintenance Manual  
I&M NUMBER: 316-42-5-1  
Date: 6/11/2008  
Page: 7  
Rev: 2.00  
________________________________________________________________________________________________________________________________________________________________________________________________________________________  
REVISIONS  
LEVEL  
1.00  
2.00  
DESCRIPTION  
Created Document  
HAN2838  
INITIALS  
DATE  
TBR  
06-11-08  
WATLOW IND.n # 6 INDUSTRIAL LOOP RD. n HANNIBAL MO, 63401n PHONE 573-221-2816 n FAX 573-221-3723  
 

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