LTFX Installation Manual - Chromalox Precision Heat and Control

LTFXElectric TankImmersion HeatersInstallation Instructions1PN403-4161-049178-101July 2013

LTFXElectric Tank Immersion Heater Installation InstructionsGeneralThe Chromalox Electric Tank Immersion Heater, ModelLTFX, is an engineered, pretested package designed togive years of virtually maintenance free service and it isshipped ready for installation into a storage tank. LTFXprovides low watt-density heating over a large heatingsurface with precise temperature control for suchmaterials as asphalt, fuel oil, pitch and tar, liquid sugar,lube oils, linseed oil, biodiesel, glycerin, ethanol andmany other heat sensitive compounds.The open coil heating elements (OCE) are housed ineither 2” or 3” Schedule 40 carbon or stainless steelpipes, which are welded into the 150# ANSI flange.Once the Unitary Immersion Heater is mated to yourtank, the heating elements may be removed and replacedwithout draining the tank.Since excessive temperatures may permanently damagethe heater and cause premature failure, the use oftemperature controls, limiting controls, and liquid levelsensors are required.The system designer is responsible for thesafety of this equipment and should install adequateback-up controls and safety deviceswith their electric heating equipment. Wherethe consequences of failure could result in personalinjury or property damage, back-up controlsare essential.InstallationFIRE OR EXPLOSION HAZARD: The tank mustbe purged of all flammable vapors prior to cuttingor welding.High heating efficiency, low element temperatures, andlonger heater life are achieved when the unit is properlyinstalled.1. To avoid chipping or cracking, precaution should betaken while unpacking, handling, and installing theceramic insulators. Heaters with damaged insulatorsshould be returned to the factory for repair orreplacement. Contact your local sales office for returnauthorization.2. The LTFX unit must not be mounted in the verticalposition as the resistance wire on the OCE elementcan sag, thus causing uneven heating or short circuit.Unit should be installed in a horizontal positionwith the thermowell on top only.FIRE OR EXPLOSION HAZARD: Mount the heaterin a level, horizontal orientation only. Allother orientations may result in property damageor personal injury.3. IMPORTANT: Mount heater in the tank so the liquidlevel will always be above the effective heated portionof the heater. Provide expansion tank if necessary.4. Select a location for this installation according tothe following guidelines: (refer to Figure 1)A. Heating elements are removable through the terminalenclosure however adequate room mustbe provided for this purpose. The removal lengthof the OCE heating element is 3 feet since thecenter section may be bent on a 12” radius. OCEelements should only be bent in a vertical planewith ground strap on the bottom.B. The neck on the tank’s mating flange should beof adequate length to accommodate tank insulationand flange bolting.5. Tube supports (internal to the tank) should beplaced approximately three feet from the ‘wet-side’of the LTFX flange to ensure gasket sealing integrity.Additional tube supports can then be spaced on 10foot centers. Do not anchor the heater tubes to thesupports, as the tubes must be allowed to expand.6. To ensure proper sealing, a material appropriategasket needs to be installed between the matingflanges. The mating flanges should then be securedby tightening the bolting according to TEMA Standards.7. A tank suction pipe should be mounted at least 2”above the level of the heaters. A separate line canbe provided to drain tank after heaters have beende-energized.2

Allow for TankInsulation and Bolting36” Min. ElementRemoval DistanceFluidLevelOpen-Coil ElementsModel LTFXFigure 1WiringELECTRIC SHOCK HAZARD. Disconnect allpower before installing or servicing heater.Failure to do so could result in personal injuryor property damage. Heater must be installedor serviced by a qualified person in accordancewith applicable National Electric Codes, NFPA70 and/or International Electric codes.ELECTRIC SHOCK HAZARD. Any installationinvolving electric heaters must be performedby a qualified person and must be effectivelygrounded in accordance with applicable NationalElectric Codes and/or International ElectricCodes to eliminate shock hazard.The system designer is responsible for thesafety of this equipment and should install adequateback-up controls and safety deviceswith their electric heating equipment. Wherethe consequences of failure could result in personalinjury or property damage, back-up controlsare essential.1. Electrical wiring to heating elements must be sizedand installed in accordance with applicable NationalElectric Codes, International Electric Codes and/orand applicable local codes by a qualified person asdefined by the code.2. Temperatures at the heater terminals will require theuse of manganese nickel or equivalent temperaturelead wire. (Type TGS, TGT, or TGGT are recommended.)Wiring Entrance Locations - MoistureResistant Housing Only (E4 Option)The Moisture Resistant (E4) Housing offers severalconvenient options for conduit wiring & location. Thehousing is equipped with two removable service entranceplates for installation of wiring. Any or all of thesix sides can be used for wiring locations. Refer to explodedview drawing. The housing can also be rotated(by removal from flange) to allow for more positionpossibilities. To install service entrance holes, simplyremove the side Allen screws and use the centeringdepression to drill the appropriate size hole. Reinstallthe gasket(s), if applicable, and service entrance platesby tightening the Allen head screws to 4-5 in/lbs. The‘Octobox’ style of housing can be removed for ease ofaccess to element bussing or to better locate the powerconduit(s) entry point. To accomplish, simply removethe Allen-head screws on the outside of the housing.3

When reinstalling, be sure to properly align gasket, ifapplicable, and tighten to 40-50 in/lbs.Tip for Reinstalling Gaskets:Place allen head screws through metal covers andgentle push gasket hole over the threaded screw. Thiswill allow the gasket to stay in place while tighteningthe cover.Table A – E4 Wiring InformationHeater kW Volts PhaseTotalAmpsCircuitsLTFX-125-004E4 4 480 3 4.8 1LTFX-128-008E4 8 480 3 9.6 1LTFX-1212-012E4 12 480 3 14.5 1LTFX-2212-024E4 24 480 3 28.9 1LTFX-3212-036E4 36 480 3 43.4 1LTFX-2325-060E4 60 480 3 72.3 1LTFX-3325-090E4 90 480 3 108.4 3LTFX-4325-120E4 120 480 3 144.5 2LTFX-6325-180E4 180 480 3 216.8 3LTFX-8325-240E4 240 480 3 289.0 4Wiring Entrance Locations - ExplosionResistant Housing Only (E2 Option)The Explosion Resistant (E2) Housing features dedicatedconduit connection sizes and locations for eitherNPT installation of conduit or Metric cable glands. Incomingwiring must be suitable for a maximum terminalenclosure temperature of 158˚F (70˚C). Wiring installationmust be in accordance with Hazardous Arearequirements. The use of EYS seals or rigid conduitmay be required. Please consult with the local inspectionauthority.Maximum TemperaturesSafe operation in a hazardous location requires themaximum operating temperatures of all exposed surfacesof the heater including temperatures on the outsideof the vessel, piping, flanges, screw plugs, enclosuresand other heat conducting parts be limited. Theflammable liquids, vapors or gases present determinethe maximum surface temperature permitted in anyhazardous location. The end user or purchaser of theelectric heating equipment is responsible for determiningthe proper classification of an area and for providingChromalox with hazardous area specifications andrequirements for proper equipment design. (NEC andIEC provide guidelines for evaluating and classifyinghazardous locations.)An approved liquid level control or overtemperaturecontrol must be installed to deenergizethe heater if the liquid level drops below thetop of the heater.Maximum fluid temperature per following table:Temperature ClassT1 (450˚C)T2 (300˚C)T3 (200˚C)T4 (135˚C)T5 (100˚C)T6 (85˚C)Maximum Fluid Temperature440˚C290˚C195˚C130˚C95˚C80˚CThe external surfaces of the heater must not exceedthe marked fluid temperature. An over-temperaturecontrol should be used if there is a possibility of theheater’s external surface temperature exceeding thefluid temperature.4

Table B – E2 Wiring InformationHeater kW Volts PhaseTotalAmpsCircuitsLTFX-125-004E2 4 480 3 4.8 1LTFX-128-008E2 8 480 3 9.6 1LTFX-1212-012E2 12 480 3 14.5 1LTFX-3210-024E2 24 480 3 28.9 1LTFX-3215-036E2 36 480 3 43.4 1LTFX-3225-060E2 60 480 3 72.3 1LTFX-4225-090E2 90 480 3 108.4 2LTFX-8215-120E2 120 480 3 144.5 2LTFX-9220-180E2 180 480 3 216.8 3LTFX-12225-240E2 240 480 3 289.0 4Explosion Resistant Housing Conduit Entry TableFlangeSize(In.)Standard ConstructionConduit/Cable EntriesPer EnclosureOptional ConstructionConduit/Cable EntriesPer Enclosure3/4” NPT 1-1/2”NPT M20 M404 & 5 1 1 1 16 1 1 1 18 1 2 1 210 1 2 1 212 1 2 1 214 1 3 1 316 1 3 1 318 1 4 1 4Note: A minimum of 5 full threads must be engaged on all cableand conduit entries.Third Party CertificationsE4 Moisture Resistant Enclosure CertificationsNorthAmericanDesignations(s)CanadianDesignation(s)EuropeanDesignation(s)InternationalDesignation(s)Rating NEMA 4 NEMA 4 IP66 IP66Agency(s)ManufacturersDeclarationManufacturersDeclarationE2 Explosion Resistant Enclosure CertificationsRatingNorth AmericanDesignations(s)ExplosionResistantCanadianDesignation(s)ExplosionResistantEuropeanDesignation(s)ExplosionResistantInternationalDesignation(s)ExplosionResistantAgency(s) CSAus CSA ATEX IECExRatings Class I, Div. 1Groups B, C & DClass II, Div. 1Groups E, F & GClass I Zone 1AEx dIIB + H2 GbT1 to T6Class I, Div. 1Groups B, C & DClass II, Div. 1Groups E, F & GClass I Zone 1Ex dIIB + H2 GbT1 to T6-50˚C < Ta < +60˚C0359II 2 GEx d IIB+H2 GbT1 to T6IP66Ex d IIB+H2 GbT1 to T6IP66*Note: Temps over T3 (200˚C) require stand-offs for third-party listing. Refer to IECEx andATEX certificates for stand-off dimensions.5

OperationFIRE OR EXPLOSION HAZARD. To avoid possibledamage to the heater, do not energize untilthe tank is filled with fluid. Recommended fluidlevel is 2” above the heater tube or pipe.FIRE or EXPLOSION HAZARD. Do not open enclosurewhen energized. Do not open enclosurewhen an explosive gas atmosphere is present.1. Do not operate heaters at voltages in excess of thatstamped on the heater, since excess voltage willshorten heater life.2. Heaters should not be operated in environmentswith factors that can destroy the electrical insulatingcharacteristics of the ceramic insulators. Foreigncontaminants can create leakage (shock) hazards,permanent heater damage, or cause heater failureand therefore should be avoided.For initial operation and tuning the control scheme:1. Turn the master circuit breaker off and open thecontrol box door.2. Set the indicating temperature control at the desiredtemperature and the over-temperature cutoutat 50°F above this temperature.3. Interlock the liquid level control with the cutout device.4. Close the control box door and turn the circuitbreaker on. To energize the heater circuits, turn theon-off selector switch to the “on” position.MaintenanceFIRE or EXPLOSION HAZARD. Do not open enclosurewhen energized. Do not open enclosurewhen an explosive gas atmosphere is present.ELECTRIC SHOCK HAZARD. Disconnect allpower before installing or servicing heater.Failure to do so could result in personal injuryor property damage. Heater must be installedor serviced by a qualified person in accordancewith applicable National Electric Codes, NFPA70, and/or International Electric Codes.1. Make certain both the terminals and the ceramicinsulators are free from contact with oil, liquid, orother foreign matter. NOTE: Chromalox cannot beresponsible for failures or damage caused by contaminationon the ceramic insulators. Make certainthe heaters are not exposed to contaminants.2. Check electrical connections at heater terminalsand tighten if necessary. This will help avoid hot terminalswhich may destroy wire insulation or heaterterminals3. Check overheat operation to assure heater protection.Element Replacement - Moisture Resistant HousingOnly (E4 Option)1. To remove the OCE heating elements, first turn thecircuit breaker to the off position.2. Next remove the housing lid, element wiring andthe element mounting screw. Now pull the elementstraight out of the heating tube. NOTE: OCE elementsshould only be bent in a vertical plane withground strap on the bottom.3. When removing the heating elements, make certain thatthe terminals and the ceramic insulators do not contactoil or any other liquid foreign matter. Note: Chromaloxcannot be responsible for failures or damage causedby contamination on the ceramic insulators.4. Installation is the reverse of the above.Element Replacement - Hazardous Locations,Explosion Resistant Housing Only (E2 option)1. To remove the OCE heating assembly, first turn thecircuit breaker to the off position.2. Next remove the housing lid, element wiring, and8mm bolting around the element flamepath module.If bolts must be replaced, use a minimum of grade10.9. If needed, (2) 1/4-20x2” bolts may be used tobreak loose the module from the flange. Turn boltsevenly until module is free. The flamepath module willbe re-used, so disconnect the heating element fromthe module pins. Now pull the element assembly outof the heating tube. NOTE: OCE elements shouldonly be bent in a vertical plane with ground strap onthe bottom.3. When removing the heating elements, make certain thatthe terminals and the ceramic insulators do not contactoil or any other liquid foreign matter. Note: Chromaloxcannot be responsible for failures or damage causedby contamination on the ceramic insulators.6

4. Inspect the element assembly flange and matingsurface for any debris, oils, or contamination.NOTE: Surfaces must be in suitable condition to ensureproper hazardous rating.5. Wire connection to OCE heating element shouldbe made using ring connectors. Wire connection toflamepath module must be made with crimp-stylebarrel connectors. If wires between flamepath moduleand OCE element need to be replaced, the wiresshould be rated for a minimum of 250˚C. It is alsorequired to cover the barrel connector, wire and ringconnector with electrical sleeving to prevent unwantedgrounding. Connect the new element to theflame path module by wiring connection(s) to theOCE element and slide the OCE element into tube.6. Connect the new element to the flamepath moduleand slide into tube. Flamepath module bolting mustbe tightened to 26 ft/lbs. of torque.7. Reattach element wiring. When reinstalling housinglid, be sure to properly align gasket, and tightenhousing bolts to 26 ft/lbs.Renewal Parts IdentificationTable C – E4 Housing Renewal Parts IdentificationHeater Model kW Volts PhaseImmersionLength In.(mm)ANSIFlange SizeNumberof TubesNominalTube Dia.(In)Replacement OCEModel No.LTFX-125-004E4 4 480 3 60 (1,524) 4" - 150# 1 2” OCE-05040-2-483LTFX-128-008E4 8 480 3 96 (2,438) 4" - 150# 1 2” OCE-06080-2-483LTFX-1212-012E4 12 480 3 144 (3,658) 4" - 150# 1 2” OCE-12120-2-483LTFX-2212-024E4 24 480 3 144 (3,658) 6" - 150# 2 2” OCE-12120-2-483LTFX-3212-036E4 36 480 3 144 (3,658) 6" - 150# 3 2” OCE-12120-2-483LTFX-2325-060E4 60 480 3 300 (7,620) 8" - 150# 2 3” OCE-25300-3-483LTFX-3325-090E4 90 480 3 300 (7,620) 10" - 150# 3 3” OCE-25300-3-483LTFX-4325-120E4 120 480 3 300 (7,620) 10" - 150# 4 3” OCE-25300-3-483LTFX-6325-180E4 180 480 3 300 (7,620) 12" - 150# 6 3” OCE-25300-3-483LTFX-8325-240E4 240 480 3 300 (7,620) 14" - 150# 8 3” OCE-25300-3-483Table D – E2 Housing Renewal Parts IdentificationHeater Model kW Volts PhaseImmersionLength In.(mm)ANSIFlange SizeNumberof TubesNominalTube Dia.(In)Replacement OCEModel No.LTFX-125-004E2 4 480 3 66 (1,676) 4" - 150# 1 2” OCE-06040-2-483LTFX-128-008E2 8 480 3 96 (2,438) 4" - 150# 1 2” OCE-06080-2-483LTFX-1212-012E2 12 480 3 144 (3,658) 4" - 150# 1 2” OCE-06080-2-483LTFX-3210-024E2 24 480 3 120 (3,048) 8" - 150# 3 2” OCE-06080-2-483LTFX-3215-036E2 36 480 3 180 (4,572) 8" - 150# 3 2” OCE-06080-2-483LTFX-3225-060E2 60 480 3 300 (7,620) 8" - 150# 3 2” OCE-25200-2-4803LTFX-4225-090E2 90 480 3 300 (7,620) 10" - 150# 4 2” OCE-25225-2-4803LTFX-8215-120E2 120 480 3 180 (4,572) 12" - 150# 8 2” OCE-15150-2-4803LTFX-9220-180E2 180 480 3 240 (6,096) 14" - 150# 9 2” OCE-25200-2-4803LTFX-12225-240E2 240 480 3 300 (7,620) 14" - 150# 12 2” OCE-25200-2-48037

Limited Warranty:Please refer to the Chromalox limited warranty applicable to this product athttp://www.chromalox.com/customer-service/policies/termsofsale.aspx.2150 N. RULON WHITE BLVD., OGDEN, UT 84404Phone: 1-800-368-2493 www.chromalox.com© 2013 Chromalox, Inc.8