CALORIQUE THERMOLAR THS-106 User manual

Thermolar®Tank Temperature
Maintenance System
Installation & Operation Manual for Systems Employing
THS-106 or THS-206 Electronic Controller
Precise, efficient temperature maintenance for all types of metal and plastic tanks

INTRODUCTION
The Calorique Thermolar® Tank Temperature Maintenance System is
a low heat-density warming system designed to safely and efficiently
maintain the contents temperature of any tank. Ideal for process
control, adhesi e storage (etc.) the THERMOLAR system pro ides uni-
form heat that won’t scorch tank contents.
When installed and operated in accordance with these instructions,
the Thermolar system complies with National Electrical Code article
427. Failure to install and operate this system in accordance with
the manufacturer’s instructions may result in an unsafe condition
and constitutes a iolation of the system warranty and oids that
warranty. Note that the system must be installed on a branch circuit
that is protected by a fault detector that is suitable for equipment
protection.
PARTS & SPECIFICATIONS
PARTS — SUPPLIED BY CALORIQUE
Cross check all parts with the System Components List to ensure that
all parts are included and in good condition before beginning instal-
lation. Quantities and/or lengths are included in the System
Components List.
The following specifications are generic to the Thermolar system.
Complete specifications for the particular system being installed are
included on the System Components List.
CCoonnttrrooll UUnniitt
Included with the control unit are a strap for attaching it to the tank
and two remote thermo-sensors with 20 foot/6 m leads.
Voltage: THS-106: 120 Vac
THS-206: 240 Vac
INTRODUCTION
Confirm system oltage before con-
necting the system to power supply. Do
not connect systems to any oltage
other than that for which they were
designed.
Systems operated at higher than
designed oltage pose a risk of electric
shock and/or fire.
Systems operated at lower than
designed oltage may not maintain
temperature which could result in loss
of or damage to contents.
Note
The Thermolar System is designed for temperature maintenance only and typically will
not pro ide sufficient heat to significantly raise the temperature of tank contents.

HHeeaattiinngg EElleemmeennttss
Calorique Thermolar heating elements are factory assembled with
an integral ground shield, adhesi e backing and moisture-proof
electrical connections.
Width: 11 inches/280 mm
Maximum Temperature: Do not expose any Thermolar
heating element to tempera-
tures in excess of
180°F/82°C. See pages 7 and
8 for maximum exposure
temperatures of standard
tank types.
Lead Length: 8 feet/3.5 m
PARTS — INSTALLER SUPPLIED
DDuucctt TTaappee
Standard grade duct tape (or equi alent) rated for at least
170°F/76°C.
PPoowweerr CCaabbllee
Used to run electrical power from branch circuit box to the control
unit. The type and length are determined by local code and indi id-
ual requirements of the installation.
TToooollss
General electrician’s tools, including screwdri er, linesmans pliers,
wire cutter/stripper, etc.
IInnssuullaattiioonn
Thermal insulation of the type and thickness noted on the System
Components List must be installed on the tank to ensure proper and
safe operation.
Do not cut or otherwise
alter the Thermolar heating
elements.
1
PARTS & SPECIFICATIONS

INSTALLATION
CCiirrccuuiitt OOvveerrccuurrrreenntt PPrrootteeccttiioonn
Fuse or circuit breaker rated for at least 120% of the system
amperage rating.
FFaauulltt PPrrootteeccttiioonn
The power supply must include a fault detector suitable for equip-
ment protection. This may be integral with the o ercurrent protec-
tion.
INSTALLATION
CONTROL UNIT
1 Determine the location of the control unit
•If the control unit will be positioned remotely from the tank, skip to the next section,
Heating Elements
•Attaching the control unit temporarily to the tank wall at this time will aid in aligning
the heating elements so that the power cords will reach the controller
•Installing the control unit at eye level will make completion and operation easier
2 Slide the strap through the slots provided on the back of the control unit
3 Run the strap around the tank and slip the free end into the buckle
4 Position the box about 4 feet/1 2 m from the bottom of the tank and tighten the strap to hold it
in place
Note
For best results, insulate underneath the tank. If the underside will not be accessible after
installation of the Thermolar system, then install insulation prior to final placement of the
tank. Insulating underneath the tank will help a oid excessi e heat loss, reducing operat-
ing expense and the risk of damage to sensiti e contents.
2

INSTALLATION
HEATING ELEMENTS
1 Attach heating elements to the tank sidewall using the adhesive backing provided Hold the
elements in position then, working around the tank, peel the release paper from them and
press lightly into position
2 Repeat step 1 for each heating element
3 Once all of the elements are in place properly, firmly press the element/adhesive into place
securing the elements to the tank
4 Seal the edges of each element with duct tape This will ensure that insulation does not come
between the elements and the tank wall which could impede heat flow into the tank
Do not install the
elements o er
manways, fittings,
pipes, ribs, chan-
nels, insulation or anything other than
the smooth tank wall itself. Ensure that
the entire element will be in smooth,
direct contact with the surface of the
tank.
Do not fold or
o erlap the heat-
ing elements.
Note
Press the elements lightly in place at this time in case they need to be reposi-
tioned later.
Note
The heating elements are most effecti e when placed as close to the bottom of
the tank as possible. This will allow warmer material to flow upward, promoting
con ection currents and more e en internal heating.
Note
If any heating elements need to be mo ed, do so before the adhesi e sets up.
After a short time the heating elements can not be remo ed without seriously
damaging them.
Note
Do not install heating elements when the air and/or tank temperature is below
35°F/2°C. Below this temperature the adhesi e backing initially may not stick properly.
Once the heating elements ha e been secured in place for at least 24 hours, tempera-
tures at or below 35°F/2°C will not ad ersely affect the adhesi e.
3

INSTALLATION
THERMO-SENSORS
1 Using duct tape, attach the Over Limit thermo-sensor (marked with red) to the central area of
the upper-most heating element Locate the sensor approximately 1-1/2 ft/450 mm from the
cord end of the heating element
2 Using duct tape, attach the Maintenance thermo-sensor directly to the tank wall approximately
6 inches/150 mm from the bottom-most heating element
CONTROL UNIT — ON TANK WALL
If the control unit is located on the tank itself, finish tightening the
strap so that the box is secured in place.
CONTROL UNIT — REMOTE LOCATION
If the control unit is located remotely from the tank, attach the con-
trol unit, using standard electrical practices, to any suitable surface,
pole, etc.
Note
Make sure that the strap does not cross any heating elements, power cords or thermo-
sensor leads.
Note
Standard lead lengths on the thermo-sensors and heating elements are 20 ft/6 m and
8 ft/2.5 m respecti ely. When locating the control unit, ensure that the thermo-sensor
wires and heating element power cords are not stretched taut and do not cross o er
the heating elements.
4
Over Limit Sensor
Over Limit Sensor
Maintenance Sensor
Maintenance Sensor

INSTALLATION
ELECTRICAL CONNECTIONS
1 Measure and record the resistance of each heating element
Record the measured resistances on the label on the back of the control unit face plate
2 Route all wiring to the control unit as shown in the following figure
3 Secure all wiring in place to the side of the tank using duct tape
4 Connect each heating element and the thermo-sensors to the appropriate terminal connections
of the control unit according to the following diagram
5 Run power supply cable from the circuit breaker box to the control unit and make the connec-
tions to the power supply connectors inside the control unit
6 Attach remote alarms, if applicable, to the remote alarm relay points (shown on the wiring
diagram on the next page)
•Two alarm relays are pro ided that operate in the e ent that
either temperature set for o er-limit or low-limit is reached.
•Note that the alarm relays do not generate an alarm signal.
External power for the alarms must be pro ided.
•Each relay terminal offers the option of a normally open
(NO) or normally closed (NC) switch. Do not use both set-
tings for the same relay terminal.
Some thermo-sensors cables
may include a ground wire.
Do not connect thermo-sen-
sor ground wires to the com-
mon line oltage ground.
Make sure that power is
turned off before working
with the input power cable.
Do not turn on
power to the sys-
tem unless there
is contents in the
tank.
Note
Cut wires to length, as necessary.
Note
Local codes may require the use of an intermediary junction/switch box.
5
Metal tanks must be properly
grounded before operating
the system.
Do not run power
cords or thermo-
sensor wires o er
heating elements.
The o er-limit sensor wire may be run
o er the heating element to which it is
attached, but only for the shortest dis-
tance possible.
NOTE
When routing the wiring, include the small “J” cur es to the lowest point of each wire.
This will help to ensure that any water that penetrates the insulation does not reach
the heating elements.
Input Power

INSULATION
Insulate the tank using the type and thickness insulation indicated
on the System Component List. This insulation factor has been used
to calculate the heating load required by the system: using less insu-
lation may result in contents damage.
OPERATION
PROGRAMMING
The programmable controller pro ides four different user-settable
parameters
Maintenance Temperature: The desired contents temperature.
Differential: The precision of temperature control.
O er-Limit Temperature: The highest temperature that the
heating elements, the tank contents or
the tank itself should reach.
Low-Limit Temperature: The lowest allowable contents
temperature.
OPERATION
6
Note
Make sure that the control unit co er is securely in place before insulation is applied to
the tank to ensure that no insulation gets into the control unit itself.
Note
If using blown-on insulation, create a dam around the control unit co er to ensure that
it may be remo ed to allow for programming and the indicator lights to be seen.
Input Power
Maintenance Sensor
Over Limit Sensor

OPERATION
The o er-limit and low-limit temperatures are used in conjunction
with the on-board indicator lights and/or remote alarms to indicate
a fault situation. If the o er-limit temperature is reached, power to
all elements will be shut off.
To set temperatures:
1 Press the Scroll button one or more times until the desired function setting LED is lit
The LCD display now indicates the current function setting
2 Use the Land Mbuttons to set the temperature higher or lower than the current setting
See the following section, Operating Temperatures, for a list of acceptable temperatures
3 Press the Scroll button one or more times to either highlight another function or until all func-
tion lights are out, which returns the control unit to operating mode
MAXIMUM OPERATING TEMPERATURES
Metal Tanks
Maintenance Temperature: up to 160°F/70°C
O er Limit Temperature: up to 170°F/75°C
Low Limit Temperature: up to 155°F/65°C
Crosslinked Pol eth lene Tanks
Maintenance Temperature: up to 130°F/55°C
O er Limit Temperature: up to 140°F/60°C
Low Limit Temperature: up to 125°F/50°C
When programming the con-
trol unit is complete, ensure
that all function lights are
out. When the system is in
programming mode (when one of the
function lights is lit) the heating ele-
ments will still operate but there is a
possibility that the programming may
be changed inad ertently.
Do not exceed
the temperatures
noted at left.
Temperature set-
tings abo e those listed may result in
damage to the Thermolar system, the
tank and/or the tank contents.
Ensure that the
temperature of
the contents
being loaded into
a tank does not exceed the maximum
temperature setting as noted at left.
Note
The control unit will normally be preprogrammed with the temperatures specified
when the system was ordered. Before operating the system, confirm the temperature
programming.
Note
Set the o er-limit temperature at least 10°F/5°C higher than the maintenance
temperature.
7

MAXIMUM OPERATING TEMPERATURES (continued)
Linear Pol eth lene Tanks
Maintenance Temperature: up to 120°F/50°C
O er Limit Temperature: up to 130°F/55°C
Low Limit Temperature: up to 115°F/45°C
OPERATION
Under normal operating conditions, no adjustment is necessary. It is
suggested that the liquid le el within the tank be maintained to at
least the le el of the highest heating element. This will ensure that
each heating element is operating at its peak efficiency.
TEMPERATURE ALARMS
User inter ention may be required if either the o er-limit or low-limit
alarm lights are illuminated or if remote alarms (if installed) are acti-
ated. Under these circumstances, check for the following indica-
tions:
•Does the system or exterior of the tank look damaged in any
way?
Determine the extent of the damage and contact Calorique
technical support at [phone] for possible correcti e
action.
•Are the heating elements damaged?
To determine if the elements ha e been damaged:
1 Remove the system from power
2 Disconnect each heating element from the terminal strip in the control unit
3 If possible, visually inspect each element for obvious damage
4 Using an accurate ohm or multimeter, determine the resistance of each element These readings
should be between the following (depending on voltage):
OPERATION
8
Note
In normal operation, the o er-limit temperature alarm and relay may occasionally be
acti ated. If the o er-limit alarm and relay remain on for more than 5 minutes at a
time remedial action should be followed.

OPERATION
15840
high resistance (120 volt elements) = ————————
rated heat output in watts
13680
low resistance (120 volt elements) = ————————
rated heat output in watts
63360
high resistance (240 volt elements) = ————————
rated heat output in watts
54720
low resistance (240 volt elements) = ————————
rated heat output in watts
The number of watts is given on the System Components List
If the resistance reading does not fall within the above numbers, contact Calorique technical
support at [phone] for remedies
•Is the input oltage to the heating elements correct?
•The design oltage is clearly marked on the faceplate of the
control unit. Operating heating elements at greater than
their design oltage can cause o erheating of the elements
and tank contents. Operating elements at lower than their
design oltage may result in insufficient heat output to
properly maintain contents temperature.
•If the input oltage is not correct: disconnect the system
from power and contact Calorique technical support.
•Is there material in the tank?
•An empty tank, or a tank with a contents le el below the
le el of the heating elements will, in a short time, result in
an o er-temperature situation.
•If no: either fill the tank or shut off the heating system until
the tank has been filled.
•If yes: check to see if the material is thick and sludge-like. If
it is, then mechanical agitation (mixing) may be required to
ensure that heat is e enly distributed through the contents.
If the material has a low iscosity (like water), proceed to
the next troubleshooting question.
•Is each heating element operating?
Check the Heater Circuits Acti e indicator lights. When the Main
Heater Relay light is illuminated, each heater circuit light should
also be lit (unless there is no heating element attached to the
particular circuit). Ensure that any non-operating element is cor-
rectly wired into the control unit. If it is (they are): contact
Calorique technical support.
•If the abo e remedies do not fix the problem, call Calorique
technical support at [phone] for additional help.
9

Caloriq e Ltd.
2380 Cranberry Highway
West Wareham, MA 02576, USA
[phone] • [phone] fax
Copyright © 1997-2003 Calorique, Ltd.
All Rights Reser ed. Printed in USA
CM2001 — 2003-04