Chromalox Electric Heater GS User Manual

®
Chromalox  
SERVICE REFERENCE  
Installation Instructions  
DIVISION  
4
SECTION GS, GT  
SALES  
REFERENCE  
PD442-2  
(Supersedes PD442-1)  
161-562650-001  
DATE  
DECEMBER, 2004  
Chromalox Type GS and GT Series  
Over-The-Side Immersion Heaters  
GSL3 or GTL3  
GS or GT  
GENERAL  
the chemical composition of the corrosive solu-  
tion, character of the materials entering the solu-  
tion, and controls which he maintains on the  
process. Chromalox cannot warrant any electric immersion  
heater against failure by sheath corrosion if such failure is the result  
of operating conditions beyond our control.  
FIRE/EXPLOSION HAZARD: This heater is not  
intended for use in hazardous atmospheres where  
flammable vapors, gases, liquids, or other com-  
bustible atmospheres are present as defined in  
the National Electrical Code. Failure to comply can  
result in explosion or fire.  
1. Heater Construction Characteristics  
A. High quality resistance wire held in place by ceramic core and  
magnesium oxide in various sheath materials.  
Chromalox type GS and GT over-the-side immersion heaters  
are designed primarily for corrosive baths and available in a vari-  
ety of sheath materials. 316 stainless steel and titanium sheets are  
standard.  
B. Medium and low watt densities.  
C. Epoxy filled cavity to prevent entry of contaminants.  
D. Over-temperature protection.  
E. Flexible conduit 3’ long with 6” leadwire extension.  
Sheath corrosion can result in a ground fault  
which, depending upon the solution being heated,  
can cause an explosion or fire  
The system designer is responsible for the safety  
of this equipment and should install adequate  
back-up controls and safety devices with their  
electric heating equipment. Where the conse-  
quences of failure could result in personal injury  
or property damage, back-up controls are essen-  
tial.  
IMPORTANT: It is the responsibility of the pur-  
chaser of the heater to make the ultimate choice  
of sheath material based upon his knowledge of  
© 2010 Chromalox, Inc.  
 
OPERATION  
1. Do not operate heater at voltages in excess of that stamped on the  
3. Sludge should not be allowed to build-up to the point where it  
contacts heater, as this can lead to premature heater failure.  
Sludge legs are standard on L-shaped heaters. Heater must not be  
operated in sludge.  
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,  
create a hazard of fire and shorten heater life. Do not operate  
heater if dry.  
MAINTENANCE  
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 ele-  
ments, as sediment can act as an insulator and shorten heater life.  
3. Check for loose terminal connections.  
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.  
4. If corrosion or moisture is indicated in the terminal housing,  
check the conduit layout to correct the conditions that allow cor-  
rosion or moisture to enter the terminal housing.  
THERMAL FUSE INSTALLATION/REPLACEMENT  
Grounded Electric Immersion Heaters are practical, efficient  
and safe when used properly and installed in tanks that have prop-  
er solution levels, good ventilation, trained operators and safe-  
guards such as liquid level controls and Thermal fuse over-tem-  
perature sensors.  
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.  
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.  
The Thermal fuse device must be properly installed and these  
procedures followed or heater failure or fire may result.  
Single Use Fuse (F) —  
A liquid level control is a must as an additional safety feature  
to help minimize the possibility of fire.  
Sensor consists of a one-time thermal fuse which is standard  
on all GS and GT over-the-side heaters.  
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.  
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 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.  
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.  
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.  
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.  
FIRE/SHOCK HAZARD: Before replacing fuse,  
make sure the cause of the “failure” has been  
detected and corrected.  
 
THERMAL FUSE INSTALLATION/REPLACEMENT (con’t.)  
Thermal Fuse Replacement Protection Devices  
Model Number  
Used On  
F, FM, FH  
RF, RFM, RFH  
Standard OTS Heater  
FL, FLM, FLH  
RFL, RFLM, RFLH  
L-Shaped OTS Heater  
F Amp Capacity - 25 Amps; RF Amp Capacity - 5 Amps;  
Blank (low) Temp = 180˚F; M (Medium) Temp - 230˚F; H (High) Temp = 300˚F.  
(Max Process Temperature)  
Medium temp. most common for this style heater.  
RF sensors require additional control components which include a Relay,  
Audible Alarm, and Manual Reset Pushbutton.  
Specify 120 or 240 V when ordering.  
Limited Warranty:  
Please refer to the Chromalox limited warranty applicable to this product at  
TA - Q0 - EF  
Litho in U.S.A.  
2150 N. RULON WHITE BLVD., OGDEN, UT 84404  
Phone: 1-800-368-2493  
 

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