INSTALLATION, OPERATING AND MAINTENANCE …

1 installation , OPERATING &. MAINTENANCE INSTRUCTIONS FOR 870. SERIES INDUSTRIAL control panels . GENERAL. HEATREX Industrial control panels are designed to provide Temperature regulating devices, temperature limiting years of trouble free operation if properly installed and controls, and low liquid level controls are recommended for maintained. Please read and follow these instructions for use with electric heaters to control the heating process and installing and maintaining the control Panel. safeguard the heater from excessive temperatures that can cause damage. Also, damage to fluid could occur if the Industrial control panels can be provided for use with heater is allowed to exceed the maximum film temperature various electric heating equipment to interlock safety recommended by the manufacturer. devices and to control a process at a desired setpoint temperature. HEATREX Industrial control panels can be specially designed for use in hazardous areas as specified in Article Refer to the appropriate installation , Operation, and 500 through 516 of the National Electrical Code.

2 Refer to MAINTENANCE Instructions for any heater provided with this the control Panel nameplate for classification of the heater control Panel. provided. See section below labeled Hazardous Areas for specific requirements. CAUTION. Failure to follow HEATREX recommendations could For additional electric heater product offerings, refer to result in premature failure and/or serious equipment HEATREX catalog literature on Process Heating such as damage. Circulation Heaters, Immersion Heaters, or Tubular Heating Elements. TYPICAL CONTROLS. Refer to the wiring diagram included with this instruction sheet for equipment included with the control panel. See individual manufacturer data sheets or IOM's for Typical control Circuit Equipment: additional information on components listed below. control Transformer provides 120 VAC power for control Typical Power Circuit Equipment: circuit. Disconnect Switch removes line voltage from the control Process Temperature Controller receives a temperature panel for servicing and MAINTENANCE .

3 Signal from a process sensor or remote input and adjusts heater output to maintain required temperature setpoint. Fusing or Circuit Breaker protects wiring and controls from excessive current due to short circuit or overload. control Circuit Switch pilot device allows the control circuit to be disabled while the main disconnect is on. This allows Power Contactor magnetic definite purpose device power to the process controller for configuration and setup. interlocked with the control circuit to isolate incoming power from the load for ON-OFF control methods or as a safety. High Limit Controller over-temperature protection that breaks the control circuit when measured process or SCR Power Controller accepts signal from Process element sheath temperature exceeds setpoint. Typically Temperature Controller and proportions heater output (also provided with manual reset. see Electronic Multi-Stage Sequencer).

4 control Relay defines control logic by interlocking safety Electronic Multi-Stage Sequencer (as alternate to SCR) - devices to the heater power or can provide remote alarm provides power proportional to a 4-20mA signal from a indication to the customer. process temperature controller by pulling in multiple heater stages as required. Panel Heater provided when required for panels installed outdoors in cold climates, to keep temperature of control o components above 32 F. 1. installation . Do not weld to control Panel to avoid damage to electronic CAUTION components. HEATREX recommends installation be performed by qualified personnel familiar with the National Electrical Electrical Instructions Code and all local codes and standards. It is the responsibility of the installer to verify the safety and The potentially high OPERATING and ambient temperatures of suitability of the installation electric heaters used with industrial control panels require field wiring to the heater be carefully matched to the application, to avoid serious injury or damage to the WARNING equipment.

5 The wiring must be de-rated for the expected DO NOT mount control panels in an atmosphere heater terminal box temperature. Refer to the National containing combustible gases, vapors, dusts, or fibers Electrical Code. unless properly marked as suitable for the condition. Refer to section below for special instructions for Hazardous The size and type of incoming and interconnecting field Areas. wiring will depend upon terminal box or panel temperature, heater current draw per conductor, number of conductors WARNING per conduit, and wire insulation rating. The control panel Hazardous voltages are present in this equipment. Lock temperature can be assumed to be 130oF max. Refer to out and tag the branch circuit disconnect switch before the appropriate IOM for the estimated heater terminal box working on this control Panel. temperature. Field supplied conductors must be sized for at least 125% of the circuit current.

6 Handling and Storage To calculate the circuit current (in amps): Care must be taken to avoid damage to the control Panel during storage and handling. Single phase KW x 1000. Line current Line Voltage Protect the control Panel from weather damage during storage. It is recommended to store the control Panel in a Three phase KW x 1000. cool dry area when possible. Ensure all openings are tightly Line current x Line Voltage sealed if stored outdoors. Refer to the wiring diagram included with this instruction Mechanical Instructions sheet for wiring recommendations. An additional copy is provided inside the panel. Review the field wiring Site Selection requirements carefully. Select instrument wiring to properly match the required signal. Shielded cable is recommended Review the NEMA Type rating of the control Panel noted for low voltage and thermocouple signals to minimize 60Hz on the nameplate.

7 Do not install a control Panel in an area noise. Shields must be grounded at one end only to inconsistent with its rating. prevent a ground loop. Allow sufficient free space around panel installation site. Where thermocouple extension wire is required between the Working space for panel MAINTENANCE should be at least the heater and panel, verify it is connected with proper polarity, width of the panel or 30 inches, whichever is greater. as shown on the wiring diagram. Failure to do so may Height must be the height of the panel or 6' 6 , whichever is result in an uncontrolled heater. Keep in mind that the Red . greater. The depth in front of the panel shall not be less wire is negative for type J and K thermocouples. Refer to than 3 feet. In all cases, the working space shall permit at the wiring diagram for the required wire type. The least a 90 degree opening of the equipment doors or hinged maximum loop resistance allowed is 100 ohms to avoid panels (per NEC Article ).

8 Measurement error. Leave a minimum of 6 clearance to any SCR heat sinks Any remote interlock, such as a flow switch or remote shut- mounted through the side of panels to allow proper cooling. down, may be interlocked with the heater by removing and replacing the jumper typically provided at terminal block Mounting labeled C1-C2 with the interlock dry contact. control panels are provided with either wall or floor Wiring to the panel should be permanently installed in mounting. Mount the panel with structural quality bolts metallic or non-metallic electrical grade conduit in matching the size of the holes provided in the mounting accordance with all applicable electrical codes, and should feet. 2. include a grounding conductor if non-metallic conduit is leakage, (shock) hazards, permanent damage, or failure to used. the control Panel and should be avoided. Field supply wiring must be rated for 600 Vac.

9 Use copper conductors. CAUTION. The electrical installation should include a service When performing Dielectric or Meg Ohm tests, remove disconnect switch in sight of the panel and heater, as well transformer primary fusing to isolate control circuit as branch circuit over-current protection and over- electronic equipment. Failure to do so may result in temperature protection, if not provided with the panel. damage to the control components. WARNING It is recommended to perform an insulation resistance test Retighten all electrical connections that may have to the power circuit prior to energizing the equipment, to loosened during shipment. Failure to do so may result confirm the electric heater is not wet. Test in-between all in damage to the control Panel or risk of fire. de-energized power components. If the value is less than 1 Meg Ohm using a 500 Vdc or similar tester, refer to Confirm all unused conduit holes in the panel are sealed MAINTENANCE and Troubleshooting sections.

10 With plugs suitable for the environment. If the user prefers a dielectric test to confirm wiring Attach a ground conductor to the mounting lug provided, or insulation, test the power circuit at no more than two times by other appropriate means, per NEC Article 250. the rated voltage plus 1000 volts after isolating the transformer. If the control circuit is tested, remove control Be sure the panel doors are properly closed and sealed to boards from any SCR's, pull out process controller, remove ensure personnel protection. Also, contaminants can create secondary ground(s), and disconnect any High Limit Controllers. Test control circuit at 1200V max. OPERATION. Cautions and Setup HEATREX recommends that all safety interlocks be tested during initial startup to ensure they properly disable the CAUTION heater. After 10 days of operation, retighten all electrical Equipment should be operated by qualified personnel connections.