User manual CALORIQUE THERMOLAR TANK WARMING SYSTEM

[. . . ] 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. 8 feet/3. 5 m Do not cut or otherwise alter the Thermolar heating elements. Lead Length: PARTS -- INSTALLER SUPPLIED Duct Tape Standard grade duct tape (or equivalent) rated for at least 170°F/76°C. Power Cable Used to run electrical power from branch circuit box to the control unit. The type and length are determined by local code and individual requirements of the installation. Tools General electrician's tools, including screwdriver, linesmans pliers, wire cutter/stripper, etc. Insulation Thermal insulation of the type and thickness noted on the System Components List must be installed on the tank to ensure proper and safe operation. PARTS & SPECIFICATIONS 2 Circuit Overcurrent Protection Fuse or circuit breaker rated for at least 120% of the system amperage rating. Fault Protection The power supply must include a fault detector suitable for equipment protection. [. . . ] 4. Once all of the elements are in place properly, firmly press the element/adhesive into place securing the elements to the tank. 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. 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. 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. Each relay terminal offers the option of a normally open (NO) or normally closed (NC) switch. Do not use both settings for the same relay terminal. INSTALLATION Some thermo-sensors cables may include a ground wire. Do not connect thermo-sensor ground wires to the common line voltage ground. 6 Over Limit Sensor Input Power Maintenance Sensor INSULATION Insulate the tank using the type and thickness insulation indicated on the System Component List. [. . . ] If the input voltage is not correct: disconnect the system from power and contact Calorique technical support. An empty tank, or a tank with a contents level below the level of the heating elements will, in a short time, result in an over-temperature situation. If no: either fill the tank or shut off the heating system until the tank has been filled. If it is, then mechanical agitation (mixing) may be required to ensure that heat is evenly distributed through the contents. [. . . ]