Tutco SureHeat Max Air F074723 User manual

OPERATING MANUAL
Max Air Heater
FOR SAFETY AND LONG HEATER LIFE,
CAREFULLY READ THIS MANUAL BEFORE USE.

THANK YOU FOR CHOOSING THE MAX AIR HEATER
TUTCO MAX AIR HEATER
The Max provides a compact, efficient heater for heating air or inert gases up to 1400°F/760°C.
The Max comes in various power ratings ranging from 6kW to 36kW. Two (2) type “K” thermo-
couples with a convenient terminal block are included for ease of wiring. One thermocouple
measures inlet air temperature (S1) and other can be used for exit/process air temperature (S2).
When powered and controlled with the Max Control Panel (sold separately) you are provided a
convenient, cost effective solution for safely controlling the AC power to your Max. If operated
correctly, the heater will operate continuously for 5000 hours or longer.
SPECIFICATIONS
Maximum Inlet Air Pressure 80 PSI (5.52 BAR)
Maximum Inlet Air Temperature 200°F (93°C)
Maximum Exit Air Temperature 1200°F (650°C) for 6kW to 10kW
1400°F (760°C) for 18kW to 36kW
Minimum Airflow (Recommended) 12 SCFM (340 SLPM)
Exit Air Connection: 1-1/2” FNPT
Inlet Air Connection: 1-1/4” FNPT
Safety Approvals: CE, UL Recognized, CSA
Control/Limit Sensors: Type “K” isolated, ungrounded, exposed junction TCs:
S1 measures inlet temperature
S2 measures exit temperature
GENERAL INFORMATION
Environmental Conditions:
Ambient Temperature 32°F to 104°F (0°C to 40°C)
Humidity 0% to 95% R.H.
Ventilation:
Use in a well-ventilated area away from excess dust, dirt, and moisture.
Cleaning:
With unit OFF and unplugged, exterior surfaces may be wiped clean using a dry, lint-free cloth.
Protective Earthing:
Each heater comes with a convenient grounding stud and hardware located at the inlet of the
heater for protective means of earthing.
2

WARNINGS!
TUTCO SureHeat Process Air Heaters contain high watt-density elements and must be
controlled carefully to prevent element failure.
IMPORTANT: Be sure to read and understand this operating manual before turning the
system ON. Follow all checklists shown in the manual. Failure to do so can cause a heat-
er failure and may void warranty.
ONLY qualified individuals should install and service this heater and related controls.
Do not hesitate to contact TUTCO SureHeat with any questions
Phone: [phone]
E-Mail: [email protected]
ELECTRICAL SHOCK HAZARD!
Follow all applicable electrical codes and use proper wiring.
BURN/FIRE/EXPLOSION HAZARD!
For use with Air or Inert Gases Only -
Do not use with or near explosive or reactive gases.
Avoid contact with the surface of the heater especially the air exit-end during or soon
after operation. Depending on the installation location customer may need to install
protective screen or guard to prevent injury to personnel and comply with OSHA code.
DO NOT USE NEAR VOLATILE OR COMBUSTIBLE MATERIALS.
3

4
PRECAUTIONS
1. Use filtered air. Avoid grease, oil, or oil vapors, corrosive or reactive gases which will
damage heater.
Note: When using compressed air a pressure reduction valve and an oil & water separation unit
should be installed to avoid contaminating the heater and reducing heater life.
2. Operate at safe voltages as shown on the Performance Curves (see page 11). Excess voltage
will cause premature failure. (See Proper Temperature Controller Setup on Page 7 for details.)
3. Using the Max heater with the recommended MAX panels provides improved performance
and protection from loss of airflow. It is highly recommended that the S1 thermocouple supplied
with the heater be used with a temperature limiting board to protect against low/no airflow
(TUTCO SureHeat Part #074835 – set to 300°F/150°C). (See Page 9 for proper wiring)
• If using other forms of control you must always have sufficient airflow through the
heater before applying power. Otherwise element will overheat very quickly, and
burn out.
4. If using a process air temperature thermocouple other then the supplied S2 thermocouple it
is highly recommended that the S2 thermocouple be used with a temperature limiting board to
protect against over temperature protection (TUTCO SureHeat Part #F074835 – set to 1205°F
(652°C) for 6 & 10kW units and 1405°F (763°C) for 18, 30 & 36kW units).
5. If using closed-loop control, use a temperature controller with a fast sampling period (<500ms)
and minimal overshoot.
6. Sudden applications of power can damage heater. To avoid this:
ALWAYS:
a. Return set-point temperature to ambient (70ºF/20ºC) after use.
b. Use a controlled ramp to set-point. (See Proper Temperature Controller Setup on
Page 7 for details.)

HEATER MODEL AND PARTS LIST
F074723 6.0kW 240 – 1Ø 50/60Hz 25.0 12 12 F075526, F078135
F074724 6.0kW 240 – 3Ø 50/60Hz 14.5 12 12 F078135
F074725 6.0kW 380 – 3Ø 50/60Hz 9.1 12 12 F078216
F074726 6.0kW 480 – 3Ø 50/60Hz 7.2 12 12
F078135
F074727 10.0kW 240 – 1Ø 50/60Hz 41.7 10 10 F075526
F074728 10.0kW 240 – 3Ø 50/60Hz 24.1 12 12
F078135, F078136
F074729 10.0kW 380 – 3Ø 50/60Hz 15.2 12 12 F078216, F078136
F074731 10.0kW 480 – 3Ø 50/60Hz 12.0 12 12 F078135
F074732 18.0kW 240 – 3Ø 50/60Hz 43.4 8 10 F078136
F074733 18.0kW 380 – 3Ø 50/60Hz 27.4 10 12 F078217
F074734 18.0kW 480 – 3Ø 50/60Hz 21.7 12 12
F078135
F074735 30.0kW 380 – 3Ø 50/60Hz 45.6 8 8 F078217
F074736 36.0kW 480 – 3Ø 50/60Hz 43.4 8 10 F078136
* Follow applicable electrical codes during installation
5
Part
Number
Maximum
Wattage
Maximum
Voltage
Maximum
Amperage
Suggested
wire size for
60°C cable*
Suggested
wire size for
60°C cable*
Compatible
controllers

DIMENSIONS/MOUNTING
NOTE: The inlet side of the heater is located where the leads/power feedthrus come out of the housing. Failure to install
the heater in its proper orientation can result in heater damage and is not covered under the manufacturer’s warranty.
6
S1+
S2+
S2-
S1-
#10-32
SCREWS
Warning: Avoid Damage to Housing
3/8” NPT (Sensor): 4 ft-lb
3/4” NPT (Power): 25 ft-lb
1-1/4” NPT (Air): 7 ft-lb
(Excessive force will crack housing and void warranty
)
1.90
[48.1]
1.88
[47.8]
3.51
[98.2]
4.75
[120.6]
4.45
[113.0]
1/4-20
MTG HOLES
SENSOR WIRE PORT
3/8” NPT
AIR INLET PORT
1 1/4” NPT
POWER WIRE PORT
3/4” NPT
16.00* [406.4]
12.49* [317.2]
12.21* [310.2]
2.00
[50.8]
AIR EXIT PORT
1 1/2” NPT
1/4-20
MTG HOLES
FLOW
Ø4.00
[101.6]
2.49
[63.2]
2.38
[60.3]
3.50
[88.9]
Ø
*Installation Notes:
• 18kW, 30kW and 36kW heater is 16” (406.4mm) long
• 6kW and 10kW heater is 12” (304.8mm) long
• Difference is 4” (101.6mm) shorter nozzle tube
NOTE: The inlet side of the heater is located where the leads/power feedthrus come out of the housing. Failure to install
the heater in its proper orientation can result in heater damage and is not covered under the manufacturer’s warranty.

POWER TEMPERATURE CONTROLLER
4 Start the heater with a 0º (F or C) Set-Point (SV): This will ensure the output signal to the power
control starts off low (0% output) before the contactor is engaged and immediately applying
full power.
4 Use proper closed loop control (PID) settings. TUTCO SureHeat typically uses the following PID;
Proportional (P), Integral (I) and Derivative (D); settings as a starting point for stable temperature
control. Some manual tuning may be required for more precise control.
Description: Range: Default:
• (P) roportional 90-250 160
• (I) ntegral 8-20 9
• (D) erivative 0-2 2
• Scan/Refresh Rate < 500mSec 200mSec
4 Incorporate a Ramp Rate for the start-up of the heater. The slower the ramp to the final set-point
the less temperature overshoot the system will incur and other related problems the system will
have. Typically; TUTCO SureHeat heaters should be ramped up over a period of several minutes.
The following are recommended ramp rates based on final temperature. (For custom ramp rates
consult with factory)
Set-Point Temperature Ramp per Minute
• Up to 600ºF (up to 300ºC) 360ºF (150ºC)
• 601-1000ºF (301-500ºC) 240ºF (100ºC)
• 1001-1400ºF (501-760ºC) 120ºF (50ºC)
OPTIONAL:
4 Reduce the output of the temperature controller. Most temperature controllers default to 100%
output as its high limit value. This value can be reduced as most air heaters are oversized for the
application and don’t need 100% power to achieve the desired output. Consult with TUTCO
SureHeat technical support.
7

INSTALLATION
8
WIRE HEATER TO CONTROL (G, H1, H2, H3) and (S1, S2)
K” THERMOCOUPLE WIRE must be Te flon Coated and Teflon Insulated, note RED is NEGATIVE ( - ).
• S1 Type “K” Thermocouple Sensor on heater connects to INLET LIMIT controller.
TUTCO SureHeat sets INLET TEMP LIMIT to 300°F/150°C.
• S2 Type “K” Thermocouple Sensor on heater connects to EXIT TEMP controller.
TUTO SureHeat sets EXIT TEMP ALARM at 1405ºF/763ºC.
HEATER TO CONTROL (G, H1, H2, H3) POWER WIRES are standard 8 to 12 Gauge, 4-wire
(H1, H2, H3, Ground) electrical cable.
WIRE CONTROL TO MAIN POWER (L1, L2, L3, GND)
MAIN POWER WIRES are standard AWG #8 to 12 gauge, 4-wire (H1, H2, H3, Ground)
electrical cable.
MAIN POWER WIRE fuses must be sized based on maximum heater current.
(see heater ratings to properly size by applicable electrical codes)
MOUNT AND WIRE HEATER
Mount heater before wiring. Wire according to diagram on Page 9. Follow applicable electrical codes.
1
2
3
WARNING: THE INLET AIR/GAS SIDE OF THE HEATER IS THE PLASTIC HOUSING END WHERE THE POWER
TERMINALS AND THERMOCOUPLE TERMINAL BLOCK IS LOCATED. INSTALLING THE HEATER IN THE WRONG
ORIENTAT ION WILL DAMAGE THE HEAT ER AND CAN CREATE ADDITIONAL HAZARDS AS A RESULT. POWER
CONNECTION WIRE SIZES ARE RECOMMENDED IN THE PRODUCT TABLE ABOVE. THESE ARE RECOMMENDAT IONS
ONLY, AND ALL LOCAL, REGIONAL AND NATIONAL ELECTRICAL CODES SHOULD BE CONSULTED
.
PROPER TORQUE VALVES FOR FITTINGS
WARNING: Avoid Damage to Housing
3/8” NPT (Sensor): 4 ft-lb
3/4” NPT (Power): 25 ft-lb
1-1/4” NPT (Air): 7 ft-lb
(Excessive force will crack housing and void warranty)

9
TYPICAL WIRING
EXIT TEMP
CONTROL
AC
INLET LIMIT
CONTROL
HEATER
POWER
CONTROL
TC–
TC+
TC–
TC+



L1

LH
L1 L2
–

+

+ –
AC

AC
ALARM*
RELAY
DC
OUTPUT RELAY**
+
S2
S2
–
H1 
H2 
G 
+
S1
S1
–




SureHeat®Max 1Ø
EXIT TEMP
CONTROL
AC
INLET LIMIT
CONTROL
HEATER
POWER
CONTROL
TC–
TC+
TC–
TC+


H1

H2

H3


L1

L2

L3
–
+ –
AC

AC
ALARM*
RELAY
DC
OUTPUT
+
S2
S2
–
H3 
H2 
H1 
G 
+
S1
S1
–




SureHeat®Max 3Ø
RELAY**
+
* Exit Temp Alarm Relay to open at 1405ºF
**Inlet Limit Relay to open at 300ºF
Other settings may damage heater and void warranty.
SureHeat®Max Heater
Installation

OPERATION (with Heater)
10
1 2
REFERENCE PERFORMANCE CURVES
Beginning on page 11 prior to operating heater.
CONNECT AIR SOURCE TO HEATER
34
TURN ON AIR
Set pressure or flow to desired operating level.
ENERGIZE MAIN POWER LINE
Via disconnect switch or circuit breaker on control cabinet.
1 2
RETURN SET-POINT TEMPERATURE
Set controller device to ambient (70ºF/20ºC)
TURN OFF MAIN POWER
34
CONTINUE AIR FLOW
Allow air to continue to flow for a minimum of 1 minute
or until exit air temperature is 300°F/150°C or less for
safety. Continue airflow longer as necessary to prevent
burn hazard to personnel.
TURN OFF AIR TO SYSTEM
5
CONTROL AIRFLOW
During operation, with constant airflow, the exit temperature will vary only a few degrees from set point. Although the
heater will not burn out with zero airflow, if the heater is operated in a vertical downward position and an airflow of
12 SCFM or less is run through the heater, the inlet temperature of the heater will exceed 300°F/150°C and the low
limit controller will begin to limit power to the heater.
6
CLOSED OR OPEN-LOOP SYSTEM
If using a closed loop system, turn on power to the temperature and power controller, then set the desired temperature
on the temperature controller. If using an open loop system, increase power to the heater through the power controller
until the desired temperature is attained.
START-UP
SHUT-DOWN
X
X
º

11
PERFORMANCE CURVES
The attached performance curves show exit air temperatures at different airflows and voltages.
Pressure readings (longer dashed lines) are measured at the inlet to the heater with no entrance or
exit restrictions.
MAX MAXIMUM PERFORMANCE CURVE
Temperature measured by the internal S2 “K” thermocouple
Minimum recommended airflow is 12 SCFM (340 SLPM)
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*

'
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
12
MAX PERFORMANCE CURVE – 6kW
MAX PERFORMANCE CURVE – 10kW
Solid lines indicate safe, normal-life operating conditions. The shorter dash lines indicate marginal, shorter-life operating
conditions leading to premature burnout. With a known flow (or pressure) at the heater entrance, follow the flow (or pres-
sure) line across until it meets the desired temperature curve. Drop a line straight down to intersect the x-axis. This point,
along the “Heater volts – true RMS” axis, represents the voltage required to generate the desired exit air temperature.

13
'
Q
MAX PERFORMANCE CURVE – 18kW
MAX PERFORMANCE CURVE – 36kW

14
TROUBLESHOOTING AND HEATER REPLACEMENT
1. Note that “TYPICAL” Element Life is APPROXIMATELY 5000 hours. This is based on heater
element operating at or below temperatures shown on PERFORMANCE CURVE(S). In addition
to normal end of life, elements can fail due to mechanical damage, or problems with the control
system.
2. If an element has failed prematurely, it should be inspected by SureHeat to determine the cause
of the element failure.
3. When replacing or troubleshooting heaters, turn off power to the system and be sure to follow
lock-out/tag-out procedures.
a. For Troubleshooting Heater
i.) Use multi-meter to check continuity between:
1. Power terminals: H1-H2, H2-H3, and H1-H3
2. Thermocouples: Positive (+ yellow) to Negative (- red)
ii.) If there is continuity on all above tests, check system wiring:
1. Crossed thermocouple wires.
2. Reversed thermocouple wire polarity – Note: RED is NEGATIVE ( - ).
3. Verify inlet air temperature is below set point on INLET
TEMPERATURE controller.
iii.) If there is no continuity on any test, then contact your local TUTCO SureHeat
representative for assistance.
4. Remove entire heater assembly from system. Internal components are typically not replaceable.
5. Reconnect thermocouples, power and ground wires for new/replacement heater.
6. Attach any covers and operate heater per operating manual.

15
LIMITED WARRANTY
TUTCO SureHeat warrants that all products to be delivered hereunder will be free from defects in
material and workmanship at the time of delivery. TUTCO SureHeat’s obligation under this warranty
shall be limited to (at its option) repairing, replacing, or granting a credit at the prices invoiced at the
time of shipment for any of said products. This warranty shall not apply to any such products which
shall have been repaired or altered, except by TUTCO SureHeat, or which shall have been subjected.
TUTCO SureHeat shall be liable under this warranty only if (A) TUTCO SureHeat receives notice of
the alleged defect within sixty (60) days after the date of shipment; (B) the adjustment procedure
hereinafter provided is followed, and (C) such products are, to TUTCO SureHeat’s satisfaction,
determined to be defective.
THE WARRANTY SET FORTH IN THE PRECEDING PARAGRAPH IS EXCLUSIVE AND IN LIEU OF
ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, ANY
IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE OR OF MERCHANTABILITY.
The information contained in this manual is based on data considered to be true and accurate.
Reasonable precautions for accuracy has been taken in the preparation of this manual, however
TUTCO SureHeat assumes no responsibility for any omissions or errors, nor assumes any liability
for damages that may result from the use of the product in accordance with the information
contained in this manual.
Please direct all warranty/repair requests or inquiries to the place of purchase, and provide the
following information, in writing:
(A) Order number under which products were shipped
(B) Model/Serial Number of product
(C) Reason for rejection
PRODUCTS CAN NOT BE RETURNED TO TUTCO SUREHEAT WITHOUT AUTHORIZATION.
Replacement, repair, or credit for products found to be defective will be made by the place of pur-
chase. All products found to be not defective will be returned to the Buyer; transportation charges
collect or stored at Buyers expense.

Electric Industrial Air Heaters for
Demanding High-Temperature Applications
The technical data and specifications supplied in this operating manual are subject to
change without prior notice. Contact TUTCO SureHeat for additional assistance.
800-258-8290
[email protected] or[email protected]
22 Industrial Drive Exeter, NH 03833 USA
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