Thermon Caloritech EX Series Installation, Operation & Maintenance Instructions Manual

Circulation Heaters
EX Series
ISO 9001
Installation, Operation, & Maintenance Instructions
For CE/ATEX and IECEx Models. Models with
Increased Safety (Type eb) Protection Method
Special Notes
CAUTION
CAUTION
CAUTION. This document presents the minimum requirement pertaining
to the installation, operation, and maintenance of the respective
equipment as required by the manufacturer only. Any additional
considerations, including but not limited to any design consideration,
in-service inspection, and fitness-for-service assessment for all pressure
boundary components to meet any safety principles and local jurisdictional
regulatory requirements, shall be the responsibility of the user.
ELECTRIC SHOCK HAZARD. All electric heating equipment installations
must be performed by qualified personnel in accordance with the local
electrical codes and standards and must be effectively grounded to
eliminate shock hazard.
FIRE/EXPLOSION HAZARD FOR EXPLOSIVE ATMOSPHERE HEATERS.
WARNING
This heater shall be used with protection controls as follows:
Liquid Immersion Applications
a.
Liquid level control to maintain all the heating elements totally
immersed at all times, in conjunction with temperature controls to limit
the liquid temperature below the maximum allowable process design
temperature.
b.
Terminal box internal surface temperature control to limit the surface
temperature of the terminal box
c.
Heater flange surface temperature control to limit the surface
temperature of the flange.
d.
Heating elements sheath temperature controls to limit to the maximum
allowable sheath design temperature
e.
Earth fault or earth leakage current protection device to protect against
arcing and sparking during an earth fault.
Gaseous and/or vapour phase immersion applications
a.
Heating elements sheath temperature controls to limit to the maximum
allowable sheath design temperature.
b.
Terminal box internal surface temperature control to limit the surface
temperature of the terminal box
c.
Heater flange surface temperature control to limit the surface
temperature of the flange.
d.
Earth fault or earth leakage current protection device to protect against
arcing and sparking during an earth fault.
THS3002-1220 Printed in Canada
WARNING
WARNING
Fire/Explosion Hazard. Do not exceed the ratings of the flange as listed in
ANSI BI6.5. In case of code stamped of registered heater, do not exceed
the rating as stated in the data report and/or registration documents. Do
not operate the heater in the presence of combustible gases, vapours,
dusts or fibres unless the heater is specifically marked for the hazardous
location and heater operating temperature does not exceed the
temperature code rating. Corrosion of the sheath could result in a ground
fault which, depending upon the fluid being heated, could cause a fire or
an explosion.
Fire Hazard. If a thermostat is provided, it is designed for temperature
control service only. Since the thermostat does not fail safe, it should not
be used for temperature limiting duty. Wiring to this device is the users'
responsibility.
Heaters are capable of developing high temperatures, therefore extreme
care should be taken to:
a.
Use explosion-proof terminal enclosures in explosive atmospheres.
b.
Maintain distance between heater and combustible materials.

The heater must be installed and operated in accordance with the following
specific conditions of use:
2
1.
The heater shall be installed with electrical safety devices as described in the Installation, Operating and
Maintenance manual and in accordance with local codes and standards.
2.
It is the user’s responsibility to connect the installed temperature sensors to safety devices as defined in
IEC 60079-0, that are fail-safe and can only be reset manually. The temperature monitoring circuit shall
be set according to the controller set point label on the equipment and used to disconnect the supply
when operated.
3.
Anti-condensation heater, if used, shall be prevented from operating while the immersion heater is in
operation.
4.
The temperature classification of the heater is based on the complete immersion of the heater elements
in either a fluid or gas. Depending on the use of the heater, a flow or liquid level device must be used to
ensure immersion in the process medium. Refer to the Installation, Operating and Maintenance manual
for details.
5.
The heater must be installed in accordance within the operating parameters taken from the nameplate,
caution labels, instruction manual and condition of use documentation.
6.
An electrical protection device must be installed to protect against earth related faults in accordance
with the Installation, Operating and Maintenance manual.
TABLE OF CONTENTS
A. Diagrams.............................................4
B. Description.........................................6
C. Installation..........................................7
D. Operation............................................8
E. Maintenance......................................9

3
A.
DIAGRAMS
Immersion Heater - Round Box (IP66) Stilted
TERMINAL BOX TEMPERATURE SENSOR
(THERMOCOUPLE OR RTD)
ELEMENT SUPPORT
(KEEPER)
SHEATH TEMPERATURE SENSOR
(THERMOCOUPLE OR RTD)
INCREASED SAFETY
TERMINAL BOX - ROUND
(RATED IP66) AVAILABLE IN
PAINTED STEEL OR STAINLESS STEEL
INCREASED SAFETY
TERMINAL BLOCKS
WIRING CONNECTION HUBS
(METRIC OR IMPERIAL)
HEATING ELEMENT
HEATER FLANGE
-
ANSI B16.5/16.47, DIN, JIS, CUSTOM
-
AVAILABLE IN CARBON STEEL, STAINLESS
-
STEEL, INCOLOY, INCONEL, OTHERS
-
AVAILABLE IN STEEL, STAINLESS
-
STEEL, INCOLOY, INCONEL, OTHERS
Figure 1
Electrical Ratings: Voltages up to 690 Vac, 1 or 3 PH., Wattages Up To 4,000KW, 50 or 60Hz
Ambient Temperature Rating: -60 °C to +80 °C
Markings: IECEx Ex eb IIC Gb, T1 to T6
ATEX
II 2 G Ex eb IIC TI TO T6 Gb
Mounting Orientation: Horizontal or Vertical
Immersion Heater - Round Box (IP66) Stilted
TERMINAL BOX TEMPERATURE SENSOR
(THERMOCOUPLE OR RTD)
TERMINAL BOX SENSOR
(THERMOCOUPLE OR RTD)
FLANGE TEMPERATURE SENSOR
(THERMOCOUPLE OR RTD)
SHEATH TEMPERATURE SENSOR
ELEMENT SUPPORT (THERMOCOUPLE OR RTD)
(KEEPER)
INCREASED SAFETY
TERMINAL BLOCKS
WIRING CONNECTION HUBS
(METRIC OR IMPERIAL)
INCREASED SAFETY
TERMINAL BOX - ROUND
(RATED IP66) AVAILABLE IN
PAINTED STEEL OR STAINLESS STEEL
HEATING ELEMENT
- AVAILABLE IN STEEL, STAINLESS
HEATER FLANGE
- STEEL, INCOLOY, INCONEL, OTHERS
- ANSI B16.5/16.47, DIN, JIS, CUSTOM
Diagrams
- AVAILABLE IN CARBON STEEL, STAINLESS
4
- STEEL, INCOLOY, INCONEL, OTHERS
Electrical Ratings: Voltages up to 690 Vac, 1 or 3 PH., Wattages Up To 4,000KW, 50 or 60Hz
Ambient Temperature Rating: -60 °C to +80 °C
Markings: IECEx Ex eb IIC Gb, T1 to T6
ATEX
II 2 G Ex eb IIC TI TO T6 Gb
Mounting Orientation: Horizontal or Vertical
Figure 2
Immersion Heater - Square or Rectangular Box (IP64) - Stilted
FLANGE TEMPERATURE SENSOR
(THERMOCOUPLE OR RTD)
ELEMENT SUPPORT
(KEEPER)
SHEATH TEMPERATURE SENSOR
(THERMOCOUPLE OR RTD)
TERMINAL BOX TEMPERATURE SENSOR
(THERMOCOUPLE OR RTD)
INCREASED SAFETY
TERMINAL BLOCKS
HEATING ELEMENT
WIRING CONNECTION HUBS
(METRIC OR IMPERIAL)
INCREASED SAFETY
TERMINAL BOX - SQUARE OR RECTANGULAR
(RATED IP64) AVAILABLE IN
PAINTED STEEL OR STAINLESS STEEL
CAN BE ROTATED
- AVAILABLE IN STEEL, STAINLESS
- STEEL, INCOLOY, INCONEL, OTHERS
HEATER FLANGE
STILTED TERMINAL BOX
TO REDUCE TEMPERATURES
AT ELECTRICAL
CONNECTIONS
-
ANSI B16.5/16.47, DIN, JIS, CUSTOM
-
AVAILABLE IN CARBON STEEL, STAINLESS
-
STEEL, INCOLOY, INCONEL, OTHERS
Electrical Ratings: Voltages up to 690 Vac, 1 or 3 PH., Wattages Up To 4,000KW, 50 OR 60Hz
Ambient Temperature Rating: -60 °C to +80 °C
Markings: IECEx Ex eb IIC Gb, T1 to T6
ATEX
II 2 G Ex eb IIC TI TO T6 Gb
Mounting Orientation: Horizontal or Vertical
Figure 3
Round Box
Stilted
Diagrams
5
B.
1.
DESCRIPTION
Circulation heaters for liquid service are designed for operation
6.
Protect terminals of heating elements from drippings,
condensation, fumes, spray or any other substance which
could result in element contamination.
7.
When melting solids by direct immersion, a surface vent
should be provided to allow gases to escape. Operate the
heater on ½ voltage until melted material completely
covers the heating elements. Heaters used for this purpose
may require special design features. Check factory for
recommendations.
8.
For
only while completely full with liquids. Never allow the heating
elements to be exposed while energized or failure will result.
CAUTION
CAUTION Use the heater only in liquids
and at pressures for which it was designed
(unless specifically designed for non-liquid
applications). Normally copper sheath is
recommended in water, steel or alloy sheath
in oil, and the appropriate alloy sheath for
heating chemical solutions. Check factory for
recommendations.
and/or IECEx Certification:
II 2 G Ex eb IIC T6...TI Gb
WARNING DO NOT insulate over the heater
flange, stilted area and terminal enclosure.
WARNING
2.
3.
4.
Circulation heaters for gas service are designed to operate
under the design pressure and design temperature specified
in the pressure vessel ratings. High limit sensing devices
(thermocouples/RTD) provide means of control for the
maximum allowable temperature to operate the heater
below design conditions. Never operate the heaters beyond
limit temperatures specified in the heaters drawings. Never
operate the heater without a high temperature limits.
Circulation heaters are welded pressure vessels with inlet and
outlet connections to allow fluid/gas flow and heat transfer to
a customer flud.
Where gasket is required, user must ensure that gasket
surface is clean and dry before installing heater.
In accordance with:
EN IEC 60079-0:2018
IEC 60079-0:2017
EN 60079-7-2017
IEC 60079-7-2017
2813
2721 PLYMOUTH DR. OAKVILLE, ON. CANADA
CAT. NO.
PART NO.
TYPE
S.O. NO.
DATE
CSANe 20ATEX3165X
EX eb IIC T*** Gb
IECEx CSA 19.0013X
Ex eb IIC Gb T***
VAC
PH.
CLASS
CLASS
IP RATING ****
AMBIENT TEMP.
Description
6
The terminals must be protected at all times from moisture
or vapour. In explosive atmospheres, explosion resistant
terminal housings must be used. In outdoor locations,
moisture resistant housings are required. It is recommended
to use a drip loop to prevent moisture from entering the
terminal box via the wire or cable.
ZONE
GR.
ZONE
TEMP.
CODE
PROCESS TEMP. MAX.
-60° TO 80°C
-76° TO 176°F
°C
°F
MADE IN CANADA
THERMON HEATING SYSTEMS, INC.
www.thermon.com
O
5.
Hz
KW
HAZARDOUS LOCATION
22506-01
C.
INSTALLATION
CAUTION
CAUTION
WARNING
WARNING
CAUTION
WARNING
1.
CAUTION Heaters with overtemperature
devices require specific installation orientation.
Overtemperature devices are required to be
installed in accordance with local codes and
standards and be designed to de-energize the
heater on an overtemperature event.
Electric Shock Hazard Disconnect all power
before installing or servicing the heater.
Failure to do so could result in personal injury
and/or property damage. All maintenance
and installation should be done by qualified
personnel in compliance with local codes.
Fire or Shock Hazard Moisture accumulation on
the dielectric material of the elements, sheath
corrosion or overtemperature on the heaters
could cause a fault to ground generating
arcing and molten metal. Install proper ground
fault protections to prevent personal injury or
property damage.
WARNING The end user is responsible for the
proper integration of the electrical systems,
including protections, backups, and controls.
CAUTION For explosive atmospheres an
approved liquid level and/ or temperature
limiting control must be used to de-energize
in the event of system malfunction. Unless
otherwise specified, use supply wire suitable
for 90°C min.
CAUTION
6.
When insulation is supplied, special care must be taken while
handling the heater for installations. Failure to do this could
compromise the integrity of the metal jacket covering the
insulating material.
7.
Check supply voltage for compliance with heater nameplate
voltage. DO NOT connect the heater to a voltage source
other than listed on the heater nameplate.
8.
If the heater is immersed in liquid, a level control switch
or overtemperature sensing device affixed to the
uppermost heating element is required. Check factory for
recommendations.
9.
If the heater is installed in a pressurized system, a safety relief
valve must be used to prevent a hazardous pressure buildup.
10.
For heaters installed in pressurized system, proper bolting
hardware must be used that is suitable for the pressures
and temperatures of the equipement. Use the appropraite
gasket for the pressure and temperature; torque the bolts on
an even clockwise or counter clockwise pattern. Refer to the
heater drawings for details.
11.
Heaters with explosion resistant terminal housings must only
be used in locations for which the heaters are certified.
WARNING Creepage and clearance for
electrical connections to the heater must be
maintained in accordance with local codes and
standards for IECEx and ATEX Increased Safety
installations.
•
Check heater nameplate information for approval code.
•
Never energize an explosion resistant heater unless the
terminal housing cover is properly tightened.
•
An immersion heater for explosive atmospheres is
approved for use only if an approved liquid level
control and/or temperature limiting device is used to
de-energize the heater under low liquid conditions.
Unpack and check heater for any damage that may have
been caused during shipping.
12.
Remove any dessucant material in the electrical box.
3.
Check that all terminal connections are tight.
4.
Provide adequate space for vertical or horizontal installation.
With horizontal mounting, inlet and outlet must be directed
upwards at 90° from the horizontal.
5.
Ensure that the circulation heater vessel is properly mounted
on a solid steel or concrete base. For heater removal and
maintenance purposes, user must allow sufficient clearance
in the surrounding area of the circulation heater.
On ATEX/CE certified heaters which are being installed in the
EU, the installation of heater shall be in accordance with the
requirements of the local jurisdiction.
CAUTION
WARNING
CAUTION Exposed heater surfaces could be at
elevated temperatures that can cause fire or
bodily harm.
WARNING Do not set the overtemperature
protection device above the setpoint indicated
on the heater nameplate. Refer to the heater
drawings for more information.
Installation
2.
CAUTION Use copper conductors only
with sufficient current carrying capacity for
the heater circuit load and in accordance
with the local electrical code. Check the
heater nameplate for minimum conductor
temperature rating. Temperature deration
factors must be applied for heaters operating
above 30°C (86°F).
7
13.
Temperature sensors supplied are required to be used with
an overtemperature protection device in order to maintain
the Temperature Code (T-Code) of the heater.
14.
Mounting of the heater must follow the design specifications
of the heater. Failure to follow this could result in equipment
failure or malfunction.
15.
In order to allow for expansion and contraction the use of
lockwashers when mounting is not recommended. Apply
maximum torque necessary to contain the equipment but
still allow for expansion.
16.
Heater nozzles are not intended to be used as pipe supports.
User must ensure that inlet and outlet pipes are properly
supported.
17.
Heater must be properly vented or purged depending on
the application. For liquid heater, user must take special care
with piping arrangements to prevent air pockets which can
causes heater failure or damage.
18.
When using circulation heaters in pressurized systems,
user must install the appropriate relief valve at the outlet
of the heater to allow the thermal fluid expansions due to
blockages.
19.
DO NOT install a shutoff of any kind between the pressure
relief valve and the heater. DO NOT install a shutoff on the
discharge pipe between the relief valve and atmosphere.
special care must be taken on all flanged gasket surfaces to
prevent potential scratching.
21.
Electrical terminal box must be properly closed and sealed
prior to start of operation. Box cover must be properly placed
and tightened. Unused conduit entries must be sealed with
suitable plugs.
22. The circulation heater and system must be flushed/purged
prior to start of operation to remove any contaminants that
could have been introduced during installation.
23. On ATEX / CE certified heater which are being installed in the
EU, the installation of the heater shall be in accordance with
the requirements of the local jurisdiction.
24. The heaters must be protected against abnormal earth
fault and earth leakage current. Depending on the electrical
power system, the following protection device must be
installed with the heater.
TT and TN Systems:
A residual current protection device with a trip setting not
exceeding 100mA. The residual current protection device
shall disconnect power supply to the heater when residual
current above the trip setting has been detected.
IT Systems:
An insulation monitoring device designed to trip when the
insulation between any phase of the electrical power supply
to ground is less than 50Ω/V.
20. When handling or performing maintenance on the heater
D.
CAUTION
WARNING
Installation / Operation
WARNING
8
WARNING
OPERATION
RISK OF EXPLOSION Do not operate heater at
voltages higher than the rating specified on the
nameplate. Failure to do this will cause elevated
temperatures.
WARNING Prior to operation an insulation
resistance check must be performed. Heater
with values less than 500,000 ohms should
follow a drying process. Please contact factory
for details on procedure if heater is under
500,000 ohms
FIRE HAZARD Heater should be submersed
in the fluid for proper operation and to avoid
element overheating that could result in fire or
damage of the heater.
WARNING When operating the heaters in
a closed system or vessel, system designers
must ensure that proper controls are used
to maintain the temperature and pressure at
normal levels.
WARNING
WARNING Low megohm on heating elements
with epoxy or hermetic seals cannot be
serviced in the field. Typical resistance values
when sealed are 1000 MΩ or greater.
1.
Check that all connections are tight.
2.
If a thermostat is provided, verify that it is operating properly
by cycling it and verifying cutout.
3.
Perform an IR test prior to energization and verify that levels
are acceptable (500,000 ohms min).
4.
Energize the heater and check for signs of hotspots in the
electrical connections or vessel.
5.
Retorque all bolted fitting connections and all electrical
connections after 10 cycles.
6.
For adequate operation, always maintain the circulation
heater with the minimum design flow conditions for which
the heater was designed.
7.
For liquid service, always maintain the heater completely
immersed influid at all times or element failure may result.
E.
MAINTENANCE
WARNING
WARNING
NOTE*:
WARNING Disconnect all power before servicing
the heater or heated equipment. Failure to do so
could result in personal injury and/or property
damage. All maintenance and installation should
be done by qualified personnel in compliance
with local codes.
3.
Remove the immersion heater periodically to inspect for
corrosion, sludge build-up and for scale removal. Do not
continue to use a heater showing visible signs of damage.
4.
Periodically check for leaks and torque all bolted
connections.
WARNING Overtemperature devcices in the
heating bundles are specifically located based
on the process and heater design. Rotation of the
bundles should be avoided without consulting
with the manufacturer.
5.
If a heater element is damaged (sheath rupture or electrical)
user must consult factory for further advice.
6.
Heater output can be verified by loop current draw or
resistance check. If heater is not operating properly, user
must verify resistance, IR resistance to check integrity of
heater elements.
7.
All returning product to the factory must be totally clean
and a copy of the MSDS of the process fluid / gas must
accompany the product.
The orientation of the flange or pipe plug relative to
the vessel before removal. Use a reference mark on the
immersion heater and vessel or draw a quick sketch
showing the conduit connection orientation, to ensure
propoer orientation when re-installing.
1.
Heaters stored for prolonged periods may absorb moisture.
Using a 500V DC megger (insulation resistance tester) check
the value of the insulation resistance to ground for each
circuit. Initial readings of over 500,000 ohms to ground are
normally acceptable. Should lower readings be observed,
check factory for instructions.
2.
Periodically check electrical connections for tightness
and check wire insulation for any damage and replace if
necessary.
Maintenance
9
NOTES
NOTES
PLEASE ADHERE TO INSTRUCTIONS IN THIS MANUAL
Failure to do so may be dangerous and may
void certain provisions of your warranty.
For further assistance, please call 24hr hotline: 1-877-325-3473 (U.S.A. and Canada)
Please have model and serial numbers available before calling.
WARRANTY: Under normal use the Company warrants to
No warranty applies to paint finishes except for manufacturing
the purchaser that defects in material or workmanship will be
defects apparent within 30 days from the date of installation.
repaired or replaced without charge for a period of 18 months
The Company neither assumes nor authorizes any person to assume
from date of shipment, or 12 months from the start date of
for it any other obligation or liability in connection with the
operation, whichever expires first. Any claim for warranty
must be reported to the sales office where the product was
purchased for authorized repair or replacement within the
Company has been paid by the Purchaser in full accordance with
Subject to State or Provincial law to the contrary, the
the terms and conditions of the contract.
Company will not be responsible for any expense for
installation, removal from service, transportation, or damages
of any type whatsoever, including damages arising from lack
of use, business interruptions, or incidental or consequential
damages.
The Company cannot anticipate or control the conditions of
product usage and therefore accepts no responsibility for
the safe application and suitability of its products when used
alone or in combination with other products. Tests for the
The Purchaser agrees that the Company makes no warranty or
guarantee, express, implied or statutory, (including any warranty
of merchantability or warranty of fitness for a particular purpose)
written or oral, of the Article or incidental labour, except as is
expressed or contained in the agreement herein.
LIABILITY: Technical data contained in the catalog or
on the website is subject to change without notice. The
Company reserves the right to make dimensional and other
design changes as required. The Purchaser acknowledges
safe application and suitability of the products are the sole
the Company shall not be obligated to modify those articles
responsibility of the user.
This warranty will be void if, in the judgment of the Company,
the damage, failure or defect is the result of:
manufactured before the formulation of the changes in design
or improvements of the products by the Company.
The Company shall not be liable to compensate or indemnify
Vibration, radiation, erosion, corrosion, process
the Purchaser, end user or any other party against any actions,
contamination, abnormal process conditions,
temperature and pressures, unusual surges or pulsation,
fouling, ordinary wear and tear, lack of maintenance,
•
The Purchaser agrees that all warranty work required after the
initial commissioning of the product will be provided only if the
terms of this warranty.
•
product(s).
claims, liabilities, injury, loss, loss of use, loss of business,
damages, indirect or consequential damages, demands,
incorrectly applied utilities such as voltage, air,
penalties, fines, expenses (including legal expenses), costs,
gas, water, and others or any combination of the
obligations and causes of action of any kind arising wholly or
aforementioned causes not specifically allowed for in
partly from negligence or omission of the user or the misuse,
the design conditions or,
incorrect application, unsafe application, incorrect storage and
Any act or omission by the Purchaser, its agents, servants
handling, incorrect installation, lack of maintenance, improper
or independent contractors which for greater certainty,
maintenance or improper operation of products furnished by the
but not so as to limit the generality of the foregoing,
Company.
includes physical, chemical or mechanical abuse,
accident, improper installation of the product, improper
storage and handling of the product, improper application
or the misalignment of parts.
Edmonton
1-780-466-3178
F 780-468-5904
5918 Roper Road
Alberta, Canada T6B 3E1
Oakville
1-800-410-3131
1-905-829-4422
F 905-829-4430
Orillia
1-877-325-3473
1-705-325-3473
F 705-325-2106
Houston
1-800-654-2583
1-713-433-2600
F 713-433-4541
Denver
1-855-244-3128
1-303-979-7339
F 303-979-7350