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

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

(508)

291-4224

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):

15&10

high

resistonce

(120

volt

elemmts)

=

-------

roted

heot

output

in

wotts

13680

low

resistonce

(120

volt

elements)

roted

heot

output

in

wotts

63360

high

resistonce

(240

volt

elemmts)

=

-------

roted

heot

output

in

wotts

54720

low

resistonce

(240

volt

elements)

=

-------

roted

heot

output

in

wotts

The

numb11

of

wotts

is

givm

on

the

System

Components

List.

If

the

resistonce

1111ding

does

not

foll

within

the

obove

numbers,

contod

ColorIQue

techni-

col

support

of

(

SOB)

291-4

224

for

remedies.

• Is

the

input

voltage

to

the

heating

elemen1s correct?

•

The

design

voltage

is

clearly

marked

on

the

faceplate

of

the

control

unit.

Opera1ing hea1ing

elements

at

greater

than

their

design

voltage

can cause

overheating

of

the

elements

and

tank

conten1s. Opera1ing

elements

at

lower

than

their

design

voltage

may

result

in

insufficient

heat

output

to

properly

maintain

contents

temperafure.

•

If

1he

input

voltage

is

not

correct:

disconnect

the

system

from

power

and

contact

CalorIQue

technical support.

• Is

there

material

in

1he

tank?

• An emp1y

tank,

or

a

tank

with

a contents level

below

the

level

of

the

hea1ing

elements

will,

in

a

short

time,

result

in

an

over-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

1he

material

is

thick

and

sludge-like.

If

it

is,

then

mechanical

agitation

(mixing)

may

be

required

to

ensure

that

heat

is

evenly

distributed

through

the

contents.

If

1he

material

has

a

low

viscosi1y

0ike

water),

proceed

to

the

ques1ion.

• Is each

heating

element

operating?

Check

the

Heater

Circuits

Ac1ive

indicator

ligh1s.

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

par1icular circuit). Ensure

that

any

non-operating

element

is

cor-

rec1ly

wired

into

1he con1rol

unit.

If

it

is

(1hey are):

contact

CalorIQue

technical support.

•

If

the

above

remedies

do

not

fix

the

problem,

call

CalorIQue

technical

support

at

(508) 291-4224

for

addi1ional

help.

9

Calor/Que

Ltd.

2380

Cranberry Highway

West Wareham,

MA

02576,

USA

(508)

291-4224

• (508)

291-2299

fax

-2000

CalorJQue, Ltd.

All Rights

Reserved.

Printed in

USA

CM2001

-

2000-12

CALORIQUE THERMOLAR THS-206 User manual

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