Tutco SureHeat SKORPION Series User manual

SKORPION™ Process Air Heater
Safety
SHOCK HAZARD!
Only qualified individuals should install this heater and related controls.
Follow all applicable electrical codes and use proper wiring.
BURN HAZARD!
Avoid contact with the heater nozzle during or soon after operation.
EXPLOSION HAZARD!
Heater produces extremely high temperatures. Do not use in
hazardous environments, and/or near explosive or reactive gases,
or combustible materials.
OOPPERERATATININGGINSTRUCTIONS
2/6/2018
SKORPION™ Process Air Heater

Description
The SKORPION™ Process Air Heater from Tutco SureHeat represents the perfect
combination of power,size, reliability and control inAir Heating technology.
The SKORPION™ Process Air Heater produces air temperatures from 1200°F (650°C) (120V
version) to 1400°F (760°C) (230V version). A closed-loop PID temperature control system
ensures precise control of your process.
If used correctly, anelement life of5000 hours or greater can be expected.
Limited Warranty
Tutco SureHeat Products Inc. (“OSPI”) warrants that this Product will be free of defects in material and
workmanship for a period of two (2) years from date of purchase. Buyer’s sole remedy, and Tutco
SureHeat obligation, under this warranty is limited to (at Tutco SureHeat option) repairing or replacing
any non-conforming Product or granting a credit to Buyer for the Product. A replacement Product
assumes the remaining warranty of the original Product. This warranty shall not apply to any Product
that has been repaired or altered, except by Tutco SureHeat, or that has been subjected to abuse or
mishandling. Tutco SureHeat express warranty applies only when the Product is properly operated in
accordance with specifications and instructions.
THE FOREGOING CONSTITUTES THE SOLE AND EXCLUSIVE REMEDY OF BUYER.
OSPI DISCLAIMS ALL OTHER REPRESENTATIONS AND WARRANTIES, EXPRESS OR IMPLIED,
WITH RESPECT TO THE PRODUCT, INCLUDING THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL OSPI BE
LIABLE FOR ANY SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING LOST
PROFITS OR REVENUES OR ANY OTHER COSTS OR DAMAGES. SOME STATES DO NOT ALLOW
LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS AND/OR DO NOT ALLOW THE
EXCLUSION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS
AND EXCLUSIONS MAY NOT APPLY.
To obtain service under this warranty, contact the place of purchase within two (2) years following date of
purchase. The following information must be provided in writing:
(i) Order number under which the Product was shipped;
(ii) Model/Serial Number; and
(iii) Reason for rejection.
Failure to follow this procedure shall void the warranty.
Tutco SureHeat reserves the right (i) toexamine the failed Product todetermine the cause of failure and
patterns of usage and (ii) tobe the sole judge as to whether the Product isdefective and covered under this
warranty.
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.
Tutco SureHeat
129 Portsmouth Avenue
Exeter, NH 03833 USA
800-258-8290
[email protected]
www.tutcosureheat.com 1

Heater Models and Parts List
SKORPION™ AIR HEATERS REPLACEMENT PARTS
*SKORPION Models without Blower are supplied with a 1” NPT adaptor plate for separate
air source connection (<5 PSI).
Complete Unit with Blower
Heating
Element Temp Control SSR Power Control Blower 1” NPT
adaptor
plate
Nozzle
Tube
F075615 1.5kW 120V~ 1 Ø 12.5A F205526 F205499 F205486 F205513 N/A F205494
F075616 3.0kW 230V~ 1 Ø 13A F205502 F205499 F205486 F205512 N/A F205494
F076008 4.5kW 230V~ 1 Ø 20A F205614 F205499 F205486 F205604 N/A F205494
Complete Unit without Blower*
F075869 1.5kW 120V~ 1 Ø 12.5A F205526 F205499 F205486 N/A F205549 F205494
F075835 3.0kW 230V~ 1 Ø 13A F205526 F205499 F205486 N/A F205549 F205494
F076029 4.5kW 230V ~ 1 Ø 20A F205614 F205499 F205486 N/A F205549 F205494
ACCESSORIES
F075744 High Flow Nozzle 21mm (1”) diameter
F075745 Standard Flare 150mm x 12mm (6”x0.5”)
F075746 Wide Flare 300mm x 4mm (12”x 0.16”)
2

General Information
Environmental Conditions
Ambient Temperature 0°C to 38°C (32°F to 100°F)
Humidity 0% to 90% R.H.
Ambient Pressure 0.8 to 1.2 Bar (11.8 psia to 17.6 psia)
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 damp cloth.
Attaching 230V (European style) plugs
(see diagram):
NOTE: Useplug appropriate for local area and codes.
Only qualified personnel should perform wiring.
Overcurrent protection should be provided external
to the heater unitwithin plug type shown or similar fusing.
Protective Earthing
The yellow and green ground wire in the power cable is attached directly to the aluminum
base plate inside the heater via a dedicated screw terminal. Additional protective earthing
can be attached to the aluminum base plate if desired.
Basic Operation
1. Turn SKORPION air heater ON using two switches:
1.1. Switch S1 (blower) sends power to the blower and to heater switch S2.
1.2. Switch S2 (heater) sends power to the heater control circuit.
1.3. Note, for heater safety, S2 (heater) cannot turn ON without S1 (blower) ON.
2. Adjust airflow via a rotational air damper at the blower inlet.
3. Adjust temperature set point with the UP/DOWN arrows on the temperature controller.
Heater will ramp to temperature.
3.1. The process temperature is measured with an internal type “K” thermocouple located at
the end of an element inside the stainless housing.
4. When turning the heater off the heater power (S2) may be turned off and the blower (S1)
left on to cool the heater housing assembly. This is suggested to prevent burn injury of
personnel around the heater but is not necessary for safety of the heater element.
3

Detailed Operation
•Heater Voltage is regulated by a Solid State Relay (SSR), which is turned ON and OFF
rapidly according to the temperature controller DC OUT signal. A “zero cross” type SSR
is used to minimize electrical noise.
•Heater Element is protected with a resistive photo detector and a thermal resistor
(thermistor) mounted at the heater inlet. These sensors are connected in parallel with the
DC input signal going to the SSR.
oIf the element overheats (bright orange color) the photo detector resistance
decreases which reduces the control signal which, in turn, limits power to the
heater.
oIf the air temperature in the housing reaches an unsafe level, the thermistor
resistance decreases which reduces the control signal, which in turn, limits power
to the heater.
oA small fixed resistor in series with the control signal sets element and air
temperature limits.
•The large black dots on the wiring diagram represent connections that are made on the
internal terminal strip. The terminal strip allows the customer easy access to remove and
replace the heater element and blower if necessary.
4

Performance
Heater Model 1.5kW 120V 3.0kW 230V 4.5kW 230V Without
blower*
MAXIMUM AIR TEMP
with exit restriction
Open ended/flare 1000°F
(540°C) 1400°F (760°C) 1400°F (760°C) *see note
High flow nozzle 1300°F
(730°C) 1400°F (760°C) 1400°F (760°C) *see note
MAXIMUM FLOW RATE
no restriction, 60Hz power.
At 20°C (68°F) 25 SCFM
(708 SLPM) 25 SCFM (708 SLPM) 45 SCFM (1274 SLPM) *see note
At 750°C (1400°F) 12 SCFM
(340 SLPM) 12 SCFM (340 SLPM) 22 SCFM (623 SLPM) *see note
* FOR SKORPION models without Blower (external air source):
A) The maximum temperature capability ofheater will depend entirely on the airflow rate
produced by external airsource. Higher airflow rates than those produced by the standard
SKORPION blower will yield lower maximum temperatures.
B) External airsupply must be turned ON prior to turning heater ON
C) For best flow conditions, use min. ”NPT size incoming air line.
D) Do not exceed 5 psi (.34 BAR) or airleaks will be noticeable in the heater.
5

Replacement Procedures
I. Replacing the Heating Element
1. Turn heater/blower switches OFF, and disconnect from power source.
2. Use a flat screwdriver to remove (pry open) the wiring cover under the stainless nozzle
tube.
3. Remove the stainless nozzle by removing the two mounting screws, and the thru-bolt
which passes through the plastic support tower and threads into the nozzle flange.
4. Disconnect the KTC+ (Yellow), KTC- (Red), HTR1, HTR2 connections from the wiring
terminal as shown. Total of four wires.
5. Remove the old element, pulling the KTC and HTR wires through the plastic support
tower.
6. Install new element by reversing steps 2-5.
II. Replacing the Temperature Controller
1. Turn heater/blower switches OFF, and disconnect from power source.
2. Remove the four screws which secure the black plastic top cover plate.
3. Remove the four screws which attach the aluminum base plate to the main heater plastic
structure.
4. With the top cover plate and the aluminum plate removed, you now have access to the
top and bottom mounting tabs on the temperature controller.
5. While lifting the top and bottom white plastic mounting tabs, gently push the temperature
controller halfway out of the faceplate.
6. Using masking tape or other method, mark each wire going to the back of the controller
with a number 1-9, corresponding to its terminal location. This is CRITICAL to ensure
proper wiring to the new controller.
7. Using a small screwdriver, loosen and remove the wires from the terminals at the rear of
the temperature controller.
8. Remove temperature controller completely from the faceplate.
9. Install new temperature controller halfway into faceplate.
10. Reconnect the wires according to the terminal number and ID marking from step #4.
11. Press controller into faceplate while engaging the white mounting tab securely.
12. Replace the black plastic top cover plate and reattach mounting screws.
6

III. Replacing the Power Controller
NOTE: Thermally conductive compound (“heat sink grease”) is required to mount new SSR.
1. Turn heater/blower switches OFF, and disconnect from power source.
2. Remove the four screws which secure the black plastic top cover plate.
3. Remove the four wires connecting to the four terminals on the solid state relay. Be sure
to mark the wires clearly for re-installation.
4. Remove the two screws holding the Solid State Relay from the aluminum base plate and
remove the SSR.
5. Carefully wipe off the old white heat sink putty from the base plate and apply new heat
sink putty on the back of the new SSR.
6. Mount SSR onto aluminum base plate with the mounting screws and reconnect wires.
7. Replace the black plastic top cover plate and reattach mounting screws.
IV. Replacing the Blower
1. Turn heater/blower switches OFF, and disconnect from power source.
2. Use a flat screwdriver to remove (pry open) the wiring cover under the stainless nozzle
tube.
3. Remove the blower by removing the three mounting bolts. One of these bolts passes
through the plastic support tower and threads into the nozzle flange.
4. Disconnect the GND, FAN1, and FAN2 connections from the wiring terminal as shown.
Total of three wires.
5. Remove the blower, GND, FAN1, FAN2 wires through the plastic support tower.
6. Install new blower by reversing steps 2-5.
7

SKORPION™ (1.5kW/3.0kW)
8

SKORPION™ (4.5kW)
9

SKORPION™ Without Blower (1.5kW/3.0kW/4.5kW)
10

Tutco SureHeat
129 Portsmouth Avenue
Exeter, NH 03833 USA
Tel: [phone]
[email protected]
www.tutcosureheat.com