Chromalox POO401-9 User manual

DIVISION 4 SECTION GEN
SALES
REFERENCE
DATE
SERVICE REFERENCE
Installation Instructions
POO401-9
161-053241-001
DECEMBER, 2008
(Supersedes POO401-8)
Chromalox
®
© 2010 Chromalox, Inc.
General Recommendations
on the Use of Electric Heating Elements
Safety Guidelines
The safety and performance of this heater is dependent upon prop-
er handling, installation, control and maintenance. Since we cannot
anticipate all conditions under which this information and heater, or
this heater in combination with other manufacturer’s products may be
used, it is advised that you conduct your own tests to determine the
safety and suitability of this heater in combination with other products
in your application.
The Safety Alert Symbol: is found throughout these installa-
tion instructions to identify potential hazards that can result in person-
al injury. The seriousness of the potential risk is identified by one of
these three words:
– will result in serious injury or death.
– could result in serious injury or death.
– may result in minor or moderate injury.
Read and follow these instructions to minimize risks of electric
shock or fire. Save these instructions for future reference.
The electric heating element(s) supplied herein are of rugged con-
struction and if properly installed, operated and maintained, are
designed for long life and dependable, trouble-free service.
The system designer is responsible for the safety
of this equipment and should install adequate
back-up controls and safety devices with their
electric heating equipment. Where the conse-
quences of failure could result in personal injury or
property damage, back-up controls are essential.
GENERAL
INSTALLATION
!
!
DANGER
ELECTRIC SHOCK HAZARD. Disconnect all power
before installing or servicing heater. Failure to do
so could result in personal injury or property dam-
age. Heater must be installed by a qualified person
in accordance with the National Electrical Code,
NFPA 70.
ELECTRIC SHOCK HAZARD. Any installation involv-
ing electric heaters must be performed by a quali-
fied person and must be effectively grounded in
accordance with the National Electrical Code to
eliminate shock hazard.
FIRE/EXPLOSION HAZARD . Since electric heaters are capa-
ble of developing high temperatures, extreme care should be
taken to:
A. Avoid mounting heaters in an environment containing
combustible liquids, gases or vapors.
B. Avoid contact between heaters and combustible materials.
C. Keep combustible materials far enough away to be free of
the effects of high temperatures.
Failure to comply could result in personal injury or property
damage.
High heating efficiency, low sheath temperatures, and long heater
life result when electric heaters are properly installed.
1. Heater mounting must allow for heater expansion without sacri-
ficing heat transfer efficiency.
2. Electric heaters should not be bent or deformed because heater
insulation can be damaged, leading to electrical problems and a
short heater life.
3. Clamp-on heaters should be securely clamped to clean, smooth,
metal surfaces. No insulation should contact sheath.
4. Cartridge heaters, when inserted, should be provided with snug fit-
ting holes. Use heat transfer and release compound as required.

FIRE HAZARD. Failure to comply with the following
could result in personal injury or property damage.
A. Do not operate heaters at voltages in excess of that marked on
heater since excess voltage can shorten heater life.
B. Do not operate heaters under conditions that result in sheath
temperatures higher than the recommended maximum since
excess temperatures can cause premature failure and fire.
Generally, sheath materials are limited to the following maximum
temperatures.
The table above applies to ring, tubular and cartridge element as well
as most strip elements.
A. Chrome Steel Finned Strips — 950˚F.
Heaters should not be operated in environments with factors that
can destroy the integrity of electrical insulation inside the heater. The
following contaminants and others can create current leakage (shock)
hazards, permanent heater damage, or cause heater failure and there-
fore, should be avoided.
A. Water or water vapors C. Corrosive liquids and vapors
B. Grease, oil or oil vapors D. Noxious or reactive gases
Low Megohm Condition — The refractory material used in elec-
tric heaters may absorb moisture during transit, storage or when sub-
ject to humid environments that will reduce the cold insulation resis-
tance (low megohm). Low megohm may result in a high leakage cur-
rent to ground and nuisance trips of ground fault protection equip-
ment. Normally, the megohm value increases after heat-up. Typical
insulation values are 5 megohm or greater on complete assemblies or
20 megohm on individual unsealed elements. It is recommended that
heaters with 1 megohm or less be dried out before applying full power.
If dried properly, low megohm will not effect heater life or efficiency.
To correct a low megohm condition, remove terminal enclosure
cover, gaskets, and terminal hardware. Bake heaters in an oven at 300
to 500˚F for several hours or preferably overnight.
An alternate procedure is to cycle the heater in 10 to 15 minute
periods at low voltage until megohm values are normal. Sheath tem-
peratures should not exceed 350˚F.
NOTE: Low megohm on heating elements with epoxy or hermetic
seals cannot be serviced in the field. Typical resistance
values when sealed are 200 megohm or greater.
FIRE OR SHOCK HAZARD. Moisture accumulation in
the element refractory material, element over-tem-
perature, or sheath corrosion can cause ground fault
to the element sheath, generating arcing and molten
metal. Install Ground Fault Protection to prevent
property damage.
103 GAMMA DRIVE, PITTSBURGH, PA 15238
Phone: [phone] www.chromalox.com
OPERATION
Sheath Material Maximum Sheath Temperatures
Copper 350˚F
Iron or Steel 750˚F
Chrome or Stainless Steel 1200˚F
INCOLOY®1500˚F
MONEL®900˚F
WIRING
HAZARD OF ELECTRIC SHOCK. Any installation
involving electric heaters must be effectively ground-
ed in accordance with the National Electrical Code to
eliminate shock hazard.
1. Electric wiring to heating elements must be installed by a quali-
fied person in accordance with the National Electrical Code or
local electrical codes.
2. Type and temperature rating of wire should be suitable for appli-
cation.
Limited Warranty:
Please refer to the Chromalox limited warranty applicable to this product at
http://www.chromalox.com/customer-service/policies/termsofsale.aspx.