User manual CALORIQUE THERMOLAR TANK WARMING SYSTEM

[. . . ] Complete specifications for the particular system being installed are included on the System Components List. Control Unit 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 Heating Elements 1 Calorique Thermolar heating elements are factory assembled with an integral ground shield, adhesive backing and moisture-proof electrical connections. Width: Maximum Temperature: 11 inches/280 mm Do not expose any Thermolar heating element to temperatures in excess of 180°F/82°C. See pages 7 and 8 for maximum exposure temperatures of standard tank types. [. . . ] This will ensure that insulation does not come between the elements and the tank wall which could impede heat flow into the tank. INSTALLATION Do not install the elements over manways, fittings, pipes, ribs, channels, insulation or anything other than the smooth tank wall itself. Ensure that the entire element will be in smooth, direct contact with the surface of the tank. 4 THERMO-SENSORS 1. Using duct tape, attach the Over Limit thermo-sensor (marked with red) to the central area of the upper-most heating element. Locate the sensor approximately 1-1/2 ft/450 mm from the cord end of the heating element. Using duct tape, attach the Maintenance thermo-sensor directly to the tank wall approximately 6 inches/150 mm from the bottom-most heating element. 2. Over Limit Sensor Maintenance Sensor INSTALLATION CONTROL UNIT -- ON TANK WALL If the control unit is located on the tank itself, finish tightening the strap so that the box is secured in place. Note Make sure that the strap does not cross any heating elements, power cords or thermosensor leads. CONTROL UNIT -- REMOTE LOCATION If the control unit is located remotely from the tank, attach the control unit, using standard electrical practices, to any suitable surface, pole, etc. Note Standard lead lengths on the thermo-sensors and heating elements are 20 ft/6 m and 8 ft/2. 5 m respectively. When locating the control unit, ensure that the thermo-sensor wires and heating element power cords are not stretched taut and do not cross over the heating elements. ELECTRICAL CONNECTIONS 1. Measure and record the resistance of each heating element. Record the measured resistances on the label on the back of the control unit face plate. Route all wiring to the control unit as shown in the following figure. 5 Metal tanks must be properly grounded before operating the system. Do not run power cords or thermosensor wires over heating elements. The over-limit sensor wire may be run over the heating element to which it is attached, but only for the shortest distance possible. Input Power NOTE When routing the wiring, include the small "J" curves to the lowest point of each wire. This will help to ensure that any water that penetrates the insulation does not reach the heating elements. 3. 4. Secure all wiring in place to the side of the tank using duct tape. Connect each heating element and the thermo-sensors to the appropriate terminal connections of the control unit according to the following diagram. Note Cut wires to length, as necessary. Make sure that power is turned off before working with the input power cable. Do not turn on power to the system unless there is contents in the tank. 5. Run power supply cable from the circuit breaker box to the control unit and make the connections to the power supply connectors inside the control unit. Note Local codes may require the use of an intermediary junction/switch box. 6. Attach remote alarms, if applicable, to the remote alarm relay points (shown on the wiring diagram on the next page). · Two alarm relays are provided that operate in the event that either temperature 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. [. . . ] If no: either fill the tank or shut off the heating system until the tank has been filled. If yes: check to see if the 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 the material has a low viscosity (like water), proceed to the next troubleshooting question. 9 · · Is there material in the tank? [. . . ]