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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 per-
son in accordance with the National Electrical
Code, NFPA 70.
The Thermal fuse device must be properly installed and these
procedures followed or heater failure or fire may result.
A liquid level control is a must as an additional safety feature
to help minimize the possibility of fire.
1. Make sure all electrical power to the heater is shut-off.
2. Unscrew the head cover. Remove the wire nuts from the fuse
leads and save for re-use.
3. Remove the “Sealing Putty” and pull the Thermal fuse out of its
well. Clean the “putty” out of the well and save for re-use.
4. Check the Thermal fuse and the inside of the well to see if it is
wet. If wet inside, dry out well. Immerse the tube into the solu-
tion. If moisture appears again inside the well DO NOT use the
heater! Call the factory for further advice.
5. If the removed Thermal fuse is dry, proceed by using it as a guide
to cut and strip the wires of the new Thermal fuse.
6. Re-connect the Thermal fuse leads to the extension leads using
the original wire nuts.
7. Re-insert the Thermal fuse into the well making sure it is “fully
seated” to the bottom of the well.
8. Re-seal using the original “sealing putty” or an RTV type sealant.
9. Replace the head cover, return the heater to the tank.
10. Turn the power back on.
Thermal Fuse Temperature System —
Be sure and satisfied that your process bath tanks are as well
protected as possible from tank leaks, excessive evaporation, tank
refill failures, and worker error.
Grounded Electric Immersion Heaters are practical, efficient
and safe when used properly and installed in tanks that have
proper solution levels. Good ventilation, trained operators and
safeguards such as liquid level controls and Thermal fuse over-
temperature sensors.
Thermal fuse systems help reduce the hazards created by low
liquid levels and when properly seated and wired, they will cut
off the power to the heaters, thus avoiding the extreme tempera-
tures resulting if solution levels are low enough to expose heater
hot zones.
Single Use Fuse (F) —
Sensor consists of a one-time thermal fuse sensor which is
standard on all GTF over-the-side heaters.
The F thermal fuse is wired in series with the controller. To
operate properly the fuse must be fully seated to the bottom of the
thermowell tube. When the fuse “blows”, shut off the main power
to the heater, remove the spent fuse and install the new fuse.
Refill the tank to the proper level prior to turning power back on.
Replacement thermal devices must be purchased from
Chromalox
®
.
Resettable Fuse (RF) —
Sensor consists of a Bi-metallic thermostatic sensor, an audi-
ble alarm, alarm relay, and reset button.
The RF System operates on the same principle as the F
except that the sensor does not “blow”. It operates as a Bi-metal-
lic thermostat which “opens” and sounds the alarm. The reset but-
ton must be pushed to re-activate the heater and control, after the
solution level in the tank has been raised to the proper level.
FIRE/SHOCK HAZARD: Before replacing fuse,
make sure the cause of the “failure” has been
detected and corrected.
OPERATION
1. Do not operate heater at voltages in excess of that stamped on the
heater since excess voltage will shorten heater life.
2. Always maintain a minimum of 2” of solution above the heated
portion of the element to prevent exposure of the effective heated
length. If the heater is not properly submerged, it may overheat
and shorten heater life. Do not operate heater if dry.
3. Sludge should not be allowed to build-up to the point where it
contacts heater as this can lead to premature heater failure.
Heater must not be operated in sludge.
4. In an electroplating operation the heaters are not, under any cir-
cumstances, to be placed between the electrodes and the work.
MAINTENANCE
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 per-
son in accordance with the National Electrical
Code, NFPA 70.
1. Heaters should be checked periodically for coating and corrosion
buildup and cleaned if necessary.
2. Tank should be checked regularly for sediment around the end
of heater as this sediment can act as an insulation and shorten
heater life.
3. Note: Before Teflon heater is removed from solution, it should be
allowed to cool from 15 to 20 minutes.
THERMAL FUSE INSTALLATION/REPLACEMENT