Installation, Operation, and Maintenance Instructions
1.0 Handling
1.1 Unpack and handle with care to avoid damage to heater and
components
1.2 Make sure heater is protected from contamination during
storage. A dry environment if preferred.
1.3 Refer to Application Data link for additional information
related to heater system design and selection.
2.0 Safety
2.1 WARNING: Make sure power supply is turned off before
installation or service of electric heater to prevent electrical
shock or damage to equipment.
2.2 WARNING: Circuit should have separate disconnect means
which shall be capable of being locked in the open position
and also in sight from the heater.
2.3 WARNING: Wiring must conform to the National Electric
Code and Local Regulations and should be performed by a
a qualified electrician. Make sure wiring is of a suitable
temperature rating, amperage rating, and the location.
2.4 WARNING: When servicing, handle with caution, the heater
surface may be hot.
2.5 WARNING: Do not install heater into a medium or an
environment that could result in an explosion, fire, or
hazardous condition. Contact Vulcan regarding heaters that
are specifically designed for hazardous locations.
3.0 Installation and Operation
3.1 Caution: Make sure the heater supply voltage is the same
as the rated heater voltage.
3.2 Caution: Heater should be properly grounded to prevent
electrical shock hazard
3.3 Caution: Do not support or suspend heater from termination
or wiring
3.4 A common cause of heater failure is contamination of the
the internal heater components through the termination end
of the heater. Make sure the heater is protected from
contamination in the final application.
3.5 Make sure heater termination is not exposed to water or
other liquids. Make sure that no dripping from
condensation on cold water pipes or other sources can fall
on any exposed electrical wiring connections or components.
3.6. Terminations should be properly tightened and connected
to hook-up wiring. A loose connection will result in over-
heating at the connection and could lead to premature
failure. Where possible, use a wrench or pliers to prevent
twisting of the terminals during installation.
3.7 It is good practice to avoid routing of thermocouples with
power wiring. Use separate conduit. Thermocouples,
thermostat capillary tubes, and wiring should be kept clear
of heater terminals by distance or appropriate insulation.
3.8 Most Circulation heaters are designed for heating of
a liquid. Circulation heater must be installed in system so
that the vessel is filled with liquid at all times during
operation. Care should be taken to avoid air entrapment
or pockets within vessel. Make sure installation allows
free circulation through exchanger. Reduced flow will
reduce heater life, may degrade fluid being heated, and
may result in poor temperature control.
3.9 Most Circulation heaters can be mounted vertically or
horizontally. If mounting vertically- make sure terminal
enclosure is at the top. If mounting horizontally- make sure
the outlet coupling is located at the highest point to ensure
that no air is trapped in the vessel.
3.10 Unit should be bolted to a suitable mounting bracket by use
of the vessel mounting brackets provided. (included on
2-1/2" Pipe Size models and larger)
3.11 Make sure all mating inlet and outlet joints are properly
tightened and checked for leaks.
3.12 System should include a flow switch, low liquid level cut-off
switch, over temperature switch, or other safety device
(depending on type of system). Heater tubes designed for
direct immersion will fail if operated in air and may cause
other system damage.
3.13 Circulating or forced flow systems must have unrestricted
flow to ensure proper control performance, heater life, and
system integrity.
3.14 Heater wiring should be performed per diagram supplied with
unit or refer to our following website page for common circuits:
Common_Wring.pdf
3.15 Do not exceed 105% of rated voltage. Higher voltages result
in higher wattage output which could damage the heater,
system, or medium heated.
3.16 Units equipped with a thermostat-
3.16.1 Do not exceed amperage rating of thermostat.
3.16.2 Thermostats are designed for heater control only
and are not intended for use as a direct control of
motors, pumps, or other devices.
3.16.3 Do not use thermostat as a power disconnection
means for the heater assembly.
3.17 Check for proper installation of conduits and covers to ensure
terminal box protection. Make sure gaskets seat properly on
units equipped with moisture resistant terminal boxes.
4.0 Maintenance
4.1 For most applications, no heater maintenance is required.
4.2 Disconnect line switch prior to any testing or work on the
heater
4.3 Check heater terminations after the initial 8 hours and tighten
any loose terminal and jumper connections.
4.4 Recheck wiring periodically to ensure wiring has not become
damaged, worn, or loose due to vibration or other application
related conditions. Tighten, repair, or replace as needed.
4.5 Heater tubes should be checked periodically for scaling or
mineral deposits on heater tubes and cleaned as required.
5.0 Trouble Shooting
5.1 WARNING: Disconnect power supply to heater(s) before
performing any trouble shooting procedures.
5.2 Check supply voltage to heater to ensure there is power.
5.3 Check wiring circuit- make sure heater is properly wired and
all supporting controls, relays, contactors, and other circuit
related switches are also properly wired and functional.
5.4 Check heater(s)- No heat due to a heater failure is generally
due to an open heater circuit. Check heater resistance across
both terminals or leads. A reading of infinity (no continuity)
indicates an open circuit within the element and the heater
must be replaced.
5.5 Longer than normal heat up time for units with more than one
heating element may be the result of an individual heating
element failure.
5.6 Poor temperature control is often the result of improper
circulation of the medium being heated or improper positioning
of the temperature sensors relative to the heater tubes.
Increased circulation of medium over the heater or relocating
the temperature sensor usually improves temperature control
