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 Over The Side heaters are designed for direct immersion into
a liquid. Heater tubes must be installed into the system so
that the tubes are covered by liquid at all times during
operation. Care should be taken to avoid air entrapment
or pockets of overheated fluid around the heater tubes.
3.9 Heaters are designed for placement into tanks with the
heating element portion of the assembly immersed at the
bottom of the tank and the terminal enclosure above the tank.
The heating element tubes (either straight or circular shaped
depending on model) provide the heat.
3.10 Support legs are provided on the heating elements to elevate
the heater off the surface and away from the sludge. Make
sure sludge does not build up around the heater tubes.
3.11 Heater tubes are designed for direct immersion and will fail
if operated in air.
3.12 Heater wiring should be performed per diagram supplied with
unit or refer to our following website page for common circuits:
Common_Wiring.pdf
3.13 Do not exceed 105% of rated voltage. Higher voltages result
in higher wattage output which could damage the heater,
system, or medium heated.
3.14 Units equipped with a thermostat-
3.14.1 Do not exceed amperage rating of thermostat.
3.14.2 Thermostats are designed for heater control only and
are not intended for use as a direct control of motors,
pumps, or other devices.
3.14.3 Do not use thermostat as a power disconnection
means for the heater assembly.
3.15 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.
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