McElroy A227001 User manual

Instruction Sheet: 43800101 1
2"- 4" Heater Rebuild Kits
A
227001, A227002, A438001, A438002
06/16/21 REV. C
Overview
This instruction sheet describes the steps necessary to rebuild the heating and control system of 2" – 4"
heaters. It will convert them from a thermoswitch to electronic controls located inside the handle with a knob
for setting the temperature and a heating indicator light.
This instruction sheet covers 4 kits (2" & 4" and 120 Volts & 240 Volts) for rebuilding the following 8 different
heaters.
Old New
214901 214905 2mlmc Sidewall & Socket 100-120V Htr Assy
214902 214906 2mlmc Sidewall & Socket 200-240V Htr Assy
215501 215505 2mlmc Bp 100-120V, 50/60 Htr Assy
215502 215506 2mlmc Bp 200-240V, 50/60 Htr Assy
424308 424315 14mlmc Sidewall & Socket 100-120V htr Assy
424309 424316 14mlmc Sidewall & Socket 200-240V htr Assy
424304 424317 14pb Bp 100-120V, 50/60 Htr Assy
424305 424318 14pb Bp 200-240V, 50/60 Htr Assy
Heater Conversion Kits:
Contents of A227001 2" Heater Handle/Controller Rebuild Kit, 120V
Qty Item Description
1 214701 Mlmc Htr Cover Plate Gasket
1 8163114 Model 215505 Part No Label
1 8163112 Model 214905 Part No Label
1 MAH00036 #6-32ncx3/8lg self tapping screw
2 MAH00055 1/4-20nc X 1"Lg SHCS SS
1 227001 2" Heater Handle/Controller
Rebuild Assembly, 120V
1 43800101 Instruction Sheet (this paper)
1 MJL00057 # 7 (.201) Drill bit
Contents of A227002 2" Heater Handle/Controller Rebuild Kit, 240V
Qty Item Description
1 214701 Mlmc Htr Cover Plate Gasket
1 8163107 Model 215506 Part No Label
1 8163113 Model 214906 Part No Label
1 MAH00036 #6-32ncx3/8lg self tapping screw
2 MAH00055 1/4-20nc X 1"Lg SHCS SS
1 227002 2" Heater Handle/Controller
Rebuild Assembly, 240V
1 43800101 Instruction Sheet (this paper)
1 MJL00057 # 7 (.201) Drill bit
PH02751-12-04
PH02751-12-04
PH02749-12-04

Instruction Sheet: 43800101 2
2"- 4" Heater Rebuild Kits
A
227001, A227002, A438001, A438002
06/16/21 REV. C
Contents of A438001 4" Heater Handle/Controller Rebuild Kit, 120V
Qty Item Description
1 436301 Cover Plate Gasket
1 8163108 Model 424315 Part No Label
1 8163110 Model 424317 Part No Label
1 MAH00036 #6-32ncx3/8lg self tapping screw
2 MAH00055 1/4-20nc X 1"Lg SHCS SS
1 438001 4" Heater Handle/Controller
Rebuild Assembly, 120V
1 43800101 Instruction Sheet (this paper)
1 MJL00057 # 7 (.201) Drill bit
Contents of A438002 4" Heater Handle/Controller Rebuild Kit, 240V
Qty Item Description
1 436301 Cover Plate Gasket
1 8163109 Model 424316 Part No Label
1 8163111 Model 424318 Part No Label
1 MAH00036 #6-32ncx3/8lg self tapping screw
2 MAH00055 1/4-20nc X 1"Lg SHCS SS
1 438002 4" Heater Handle/Controller
Rebuild Assembly, 240V
1 43800101 Instruction Sheet (this paper)
1 MJL00057 # 7 (.201) Drill bit
Tool list for 2" – 4":
3/16" hex wrench
5/64" hex L-key
channel lock pliers
medium width tip flat screw driver
3/16" diameter x 5" long punch or rod
hammer
Drill Press (required for proper alignment and depth)
Step 1
Unplug the heater and let it cool to room temperature. Protect the
butt plates from abrasion during this rebuild. Remove the 2 screws
attaching the heater handle with a 3/16" hex wrench. Discard the
screws. Unscrew the thermometer and pull the handle away from
the body. Keep the thermometer, its guard, and the stripper bar.
TX02040-07-16-02
PH02750-12-04
PH02353-07-02
PH02750-12-04
PH02338-07-02

Instruction Sheet:
43800101 3
2"- 4" Heater Rebuild Kits
A
227001, A227002, A438001, A438002
06/16/21 REV. C
Step 2
Unscrew the ground wire and discard the screw. Pull out
both heater cartridges and the thermoswitch. If they are
stuck use a 3/16" diameter x 5" long punch to knock them
out from the bottom. Discard the old handle assembly,
gasket and power cord.
TX02041-07-16-02
Step 3
If the heater body already has the hole called out in the
diagrams, skip to Step 4.
Otherwise, use a drill press and provided drill bit to drill a
hole in the heater body in the location shown in the
diagrams and the depth listed below. A Drill Press is
required for this operation to ensure proper position and
depth.
3" for the 2" and 4" heater bodies.
TX02362-12-20-04
PH02345-07-02, PH02344-07-02
PH02759-12-20-04
PH02760-12-20-04

Instruction Sheet: 43800101 4
2"- 4" Heater Rebuild Kits
A
227001, A227002, A438001, A438002
06/16/21 REV. C
PH02752-12-04
Step 4
Put the cartridge heaters and RTD through the slot in the
gasket. Align the handle with the body so that the
thermometer holes in the body, gasket and handle line up.
Slide the heater cartridges into the outer holes and the RTD
into the drilled hole in the body. Make sure the cartridges
are all the way in, at least flush with the bottom of the body
recess.
TX02043-07-16-02
Step 5
Clean area around the screw hole to ensure good electrical
connection.
Attach the ground wire to the heater body with the #6-32
screw.
Step 6
Put the handle on the top of the body while pushing the RTD
as deep as it will go down in its hole. The wires to the
cartridge heaters will fold into the recess. Loosely bolt on
the new handle/controller assy with the thermometer guard
and stripper bar using the (2) 1/4-20 socket head
capscrews. If available, apply high temperature anti-seize
compound (not included in the kit) to the screw threads.
Install the thermometer and then tighten the two socket
head capscrews using a 3/16” hex wrench.
TX02044-07-16-02
Step 7
Several Part Number Labels may be included in the kit.
Choose the one that matches the heater size, voltage and
configuration. Affix it to the back of the handle. Be sure it is
turned the same way as the MMI logo on the handle.
Discard the remaining Part Number labels.
TX02045-07-16-02
PH02754-12-04
PH02753-12-04

Instruction Sheet:
43800101 5
2"- 4" Heater Rebuild Kits
A
227001, A227002, A438001, A438002
06/16/21 REV. C
Step 8
The Ground Bonding Test determines whether the safety ground
circuit of the heater can adequately handle fault current.
By using a Multi-Meter under ohms measure, connect the black
lead to the plug ground pin and the red lead to the heater body.
In no case shall the resistance exceed 1 ohm.
If the resistance exceed 1 ohm, open the heater body and inspect
if the ground cable is properly connected and its screw is tight
enough.
Step 9
Put the heater in the bag frame assembly, set the knob to 500F
and plug the cord into power. The red indicator light on the
temperature dial should glow steadily. If it flashes a signal
repeatedly, an error has occurred. Count the flash sequence and
unplug the heater. Call McElroy Technical Service at 918-836-
8611 for more information.
TX02046-07-16-02
Step 10
The knob should be calibrated to agree with the surface
temperature as measured with a pyrometer. Let the heater come
to temperature (indicator light cycling on and off slowly). If the butt
plate temperature measurement is not 500F then hold the knob still
and loosen its set screw with a 5/64" hex L-key. Turn the loose
knob to the measured temperature and tighten the screw (do not
over tighten). Turn tightened knob to 500F and measure the
temperature after the heater light has cycled a few times.
TX02047-07-16-02
Step 11
For parts information, refer to the assembly drawing listed on the
heater handle part number label. The drawing can be viewed and
printed via the Internet at McElroy Manufacturing Inc’s web site:
www.mcelroy.com.
TX02048-07-16-02
PH02748-12-04
PH02346-07-02
PH02755-12-04

INSTRUCTION SHEET REVISION HISTORY LISTING
PART NO: 43800101
DESCRIPTION: 2”-4” HEATER REBUILD KITS
ORIGINATOR: CHECK: APPRV’D: RELEASED: 12/04
CHK/APR REV DATE BY DESCRIPTION OF REVISION
LTD A 04/30/12 FTS ADDED STEP 5 AND 8. EMPHASIZING GROUND CABLE INSTALLATION AND
GROUND BOND TESTING.
SRB/JBC B 8/23/18 RLT REVISED TO UPDATE SHEETS TO MEET CURRENT McELROY STANDARDS.
MRH/BWJ C 6/16/21 MRH REVISED TO REPLACE MAH00052 WITH MAH00055 TO INCREASE THREAD
ENGAGEMENT AND HELP PREVENT THREAD DEFORMATION.