CALORIQUE THERMOLAR THS-206 User manual

Fhermofar® Fank Temperature
Maintenance tem




Confinn system voltage before con-
neding the system lo powersupply. Do
not conned systems to any vohoge
other than that for which they were
designed.
Systems
operated ol higher than
designed
vohoge pose o risk of eledric
shock and/or fire.
Systems
operated ol lower than
designed vohoge may not maintain
temperature which could resub in loss
of or damage lo conlenls.
INTRODUQION
The CalorJQue Thermolar® Tank Temperature Maintenance System
is a low heat-density warming system designed to safely and effi-
ciently maintain the contents temperature of any tank. Ideal for pro-
cess control, adhesive storage (etc.) the THERMOLAR system provides
uniform heat that won't scorch tank contents.
Note
TheThennolorSystem is designed for temperature maintenance only and typically will
not provide sufficient heal lo significantly raise the temperature of tonk 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 violation of the system warranty and voids 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 CALOR/QUE
Cross check all parts with the System Components List to ensure that
all parts are included and in good condition before beginning instal-
lation. Quanti1ies and/or lengths are included in the System
Components List.
The following specifications are generic to the Thermolar system.
Complete specifica1ions for the par1icular system being installed are
included on the System Components List.
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:
THS-206:
120 Vac
240 Vac

CalorIQ.Je Thermolar hea1ing elements are factory assembled with
an integral ground shield, adhesive backing and moisture-proof
electrical connections.
Width:
Maximum Temperature:
Lead Length:
PARTS -INSTALLER SUPPLIED
..,,.
11 inches/280 mm
Do not expose any Thermolar
heating element to tempera-
tures in excess of
l 80°F/82°C. See pages 7 and
8 for maximum exposure
temperatures of standard
tank types.
8
feet/3.5 m
Standard grade duct tape (or equivalent) rated for at least
170"F/7 6°C.
,__Calle
Used to run electrical power from branch circuit box to the control
unit. The type and length are determined by local code and individ-
ual requiremen1s of the installation.
,_
General electrician's tools, including screwdriver, linesmans pliers,
wire cutter/stripper, etc.
,_,,,__
Thermal insulation of the type and thickness noted on the System
Componen1s List
must be installed on the tank to ensure proper and
safe opera1ion.
&
Do not cut or otherwise
alter
the Thennolor heat-
ing elements
I

2
G,arif Onnlnellf ,,,_diea
Fuse or circuit breaker rated for at least 120% of 1he system
amperage rating.
,,_,,,,.,__
The power supply must include a fault detector suitable for equip-
ment protec1ion. This may be integral wi1h 1he overcurrent protec-
tion.
INSTALLATION
Note
For best resuffs, insulate underneath the tonk If the underside will not be oc.oessible ofter
installation
cl the Thermolorsy$fem, then in$foll insulation prior lo final placement of the
tonk. Insulating underneath the tonk will help ovoid excessive heat loss, reducing operat-
ing expense
and the risk cl damage lo sensitive contents.
CONTROL UNIT
1. Determine the locution of the control unit.
• II the control unit will be positionm remotely from the tonk, skip to the next section,
Heating Elements.
• Attoching the control un~ hmpororily to the tonk woll ot this lime will oid in oligning
the heoting elements so thot the power cords will reoch the controller.
• lnstolling the control unit ot 4¥e level will moke completion ond operolion eosier.
2. Slide the strop through the slots providm on the bock of the control unit.
3. Run the strop oround the tonk ond slip the free end into the budde.
4. Pos~ion the box obout 4 feet/1.2 m from the bottom of the tonk ond lighten the strop to hold ii
in ploce.

HEATING ELEMENTS
Note
Do not install heating elements when the oir ond/or tonk temperature is below
35°Fn°c. Below thistemperature the adhesive bocking initially moy not slick properly.
Once
the healing elemenls hove been secured in place for oJ least 24 hours, tempera-
tures
ol or below 35 °F/2°C will nol adversely offed the adhesive.
1. Altom heoting eltmmts to the tonk sidewoll using the odhesive bocking provided. Hold the
elements in pos~ion Ihm, working oround the tonk, pe~ the r~eose poper from them ond
press light~ into pos~ion.
Note
Press the elements lightly in place ol this time in case they need lo be reposi-
tioned later.
Note
The heating elements ore most effedive when placed os close to the boltom of
the tonk os possible. Thiswill allow wormer material to flow upward, promoting
convedion rurrents ond
more even internal healing.
2. Repeot step l lor eoch hmting element.
Note
If ony heating elements need lo be moved, do so before the adhesive sets up.
Aller o short time
the heating elements con nol be removed without seriously
damaging them.
3. Once oll of the elements ore in ploce proper~, firmly press the elmJmt/odhesive into ploce
securing the elmJmls to the tonk.
4. Seol the edges of eoch elmJent with dud lope. This will ensure thot insulotion does not come
between the ~emenls ond the tonk woll which could impede heot flow into the tonk.
3
&~
Do not install
..& the elements
'ID ~v~r mon:,voys,
'1 fillings, pipes,
ribs, channels, insulolion
or anything
other than the smoolh tonk wall itself.
Ensurethat
the entire element will be
in smooth, dired oontod with the sur-
face d
the tonk.
overlap
the
&~
Do not fold or
(." heating ele-
ments

4 
 


  

 
  
  
Note
  a     

 
 
    
 
Note
       
   
      
 

ELECTRICAL CONNECTIONS
1. Meosure ond record the resislonce of eoch heoting element.
Record the meosured resislonces on the lobel on the bock of the control unit foce plote.
2. Route oll wiring to the control unit os shown in the following figure.
5
&Metal tonks must
be prop-
erly grounded before oper-
ating the system.
& ¾ ~:::~:!:;
~~wires over
healing elements. The 01/er-limil $en-
sor wire may be run over the healing
element
lo which ii is attached, but
only for
the shortest dist once possible.
Input Power
NOTE
When routing the wiring, include the small "J" curves lo the lowest point of each wire.
This will help lo ensure lhol any waler that penelroles the insulation does not reach
the healing elements.
3. Secure oll wiring in ploce to the side of the tonk using dud lope.
4. Conned eoch hmting element ond the thermo-sensors to the oppropriote terminol connections
of the control unit occording to the following diogrom.
Note
Cut wires lo length, os necessary.
S. Run power supply coble from the circuit breoker box to the control unit ond moke the connec-
tions to the power supply connedors inside the control unit.
Note
Local codes may require the U$e of on intermediary jundion/switch box.
ffi
Some thermo-sensors
cables may include o
ground wire. Do not con-
ned lhermo-. sensor ground
wires
lo the common line voltage
ground.
&Milke
sure that power is
turned off before working
with
the input power coble.
&~
Do not tum on
~
power lo the
ii 11 system unless
"! 'I there is con-
6. Altom remote olorms, a opplicoble, lo the remote olorm reloy points (shown on the wiring tents in the tonk
diogrom on the nB(f poge).
• Two alarm relays are provided that operate in the event that
either tempera1ure set for over-limit or low-limit is reached.
•
Note that the alarm relays do not generate an alarm signal.
External
power for the alarms must be provided.
• 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.

6 1
8888 )
Over Limit Sensor
rInput Power
Maintenance Sensor
INSULATION
Insulate the tank using the type and thickness insula1ion 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.
Note
Make sure that the control unit cover issecurely in plooe before insulation is applied lo
the tonk lo ensure that no insulation gets into the oonlrol una itself.
Note
If using blown-on insulation, creole o dam around the control unit cover lo ensure that
a
may be removed to allow for progmmming and the indicator lights to be seen.
OPEUTI0N
PROGRAMMING
The programmable controller provides four different user-settable
parameters
Maintenance Temperature:
Differential:
Over-Limit Temperature:
Low-Limit Temperature:
The
desired conten1s temperature.
The precision of temperature control.
The highest temperature that the
heating elemen1s, the tank conten1s or
the tank i1self should reach.
The
lowest allowable contents
temperature.

[ 8.8.8.8 .]
0 0 0
:-)
Jf " Jl H H
Heater Circuits Active
0
ltii!nH..attr
Rd,y
• 3+1 ! ·); t?sl
I
I=+ ~bdel:( 1
Tank Temperature Maintenance System .._ __ _,
CAUTION
U-1c jnc Vott~c Conductcr:: Arc E:cp:iccd
\A/her n-e racep1Me lsf1em:inc ' /
The over-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 over-limit temperature is reached, power to
all elements will be shut off.
Note
The c.ontrol unit will normally be preprogrammed with the temperaturesspecified
when
the system was ordered. Before operating the system, confirm the temperature
programming.
To set temperatures:
1. Press the Scroll button one or more times until the desired lundion setting LED ism.
The LCD disploy now indicotes the current fund ion setting.
2. Use the .6. ond "Y buttons to set the temperoture higher or lowe- thon the currmt setting.
See the following se:tion, Operating Temperatures, for o list of occeptoble te-nperotures.
Note
Set the over-lima temperature at least l O'F/5°C higher than the maintenance
ternperature.
3. Press the Scroll button one or more limes to e~her highlight onother fund ion or until oll lunc-
lion lights ore out, which returns the control unit to ope-oting mode.
MAXIMUM OPERATING TEMPERATURES
Metal Tanks
Maintenance Temperature:
Over Limit Temperature:
Low Limit Temperature:
Crosslinked Jl'ofyefflyfene Tanks
Maintenance Temperature:
Over Limit Temperature:
Low Limit Temperature:
up to 160"F/70°C
up to 170"F/75°C
up to 155°F/65°C
up to 130"F/55°C
up to 140"F/60°C
up to 125°F/50°C
7
ffi
When programming the
oontrol una is complete,
ensure that all fundion
lights
ore out. When the
system is in programming mode (when
one of the fundion lights islij) the
heating elements will still operate but
there is o possibility that the program-
ming may
be changed inadvertently.
&~
~:~::::~d
(.' lures noted at
left.
Temperature settings above
those listed
may result in damage lo the Thermolor
system,
the tonk ond/o.- the tonk con-
tents.
&
~
Ensure that the
t temperature
of
ll the contents
~ 'I being loaded
into o tonk does not exceed the maxi-
mum temperature setting
os noted at
left.

8
MAXIMUM OPERATING TEMPERATURES (continued)
linear Polyethylene Tanks
Maintenance Temperature:
Over Limit Temperature:
Low
Limit Temperature:
OPERATION
up to 120'F/50°C
up to 130'F/55°C
up to 115°F/45°C
Under normal operating condi1ions, no adjustment is necessary. It is
suggested that the liquid level within the tank be maintained to at
least the level of the highest hea1ing element. This will ensure that
each heating element is operating at its peak efficiency.
TEMPERATURE ALARMS
User intervention may be required if either the over-limit or low-limit
alarm lights are illuminated or if remote alarms (if installed) are ac1i-
vated.
Under these circumstances, check for the following indica-
tions:
Note
In normal operation, the over-limit temperature alarm and relay may occasionally be
adivotecl If the over-limit alarm and relay remain on for more than 5 minutes at a
time remedial
adion should be followed.
• Does the system or exterior of the tank look damaged in any
way?
Determine the extent of the damage and contact CalorJQ.Je
technical
support at [phone] for possible correc1ive
action.
•
Are the hea1ing elements damaged?
To determine if the elements have been damaged:
1. Remove the ~stem from power.
2. Disconnect mch heoting element from the terminol strip in the control unit.
3. II possible, visuol~ inspect eoch element for obvious domoge.
4. Using on ocwrote ohm or multimeter, determine the resistom:e of eoch element. These rmdings
should be bttween the following ( depending on vohoge):