Chromalox Water Heater PD444 2 User Manual

®
Chromalox  
SERVICE REFERENCE  
Installation Instructions  
DIVISION  
SALES  
4
SECTION GTF  
REFERENCE (Supersedes PD444-1)  
PD444-2  
161-562652-001  
DATE  
DECEMBER, 2004  
®
Chromalox Type GXF/GTF/GTFL Series  
®
Grounded Teflon Immersion Heaters  
GXF/GXFL  
GTF  
GTFL3  
GTF6  
GENERAL  
1. Heater Construction Characteristics  
A. High quality resistance wire held in place by compacted mag-  
nesium oxide in stainless steel sheath and Teflon® covered.  
B. Low watt density.  
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.  
Chromalox type GTF series of Teflon® over-the-side immer-  
sion heaters are especially suited for most plating tank and other  
corrosive solutions. It is inert to acid baths, anodizing and picking  
operations up to 212˚F solution temperatures.  
C. Grounded construction.  
D. Over-temperature protection.  
E. Epoxy filled, vapor tight, plastic terminal enclosure prevents  
entry of contaminants.  
F. Flexible conduit 3’ long with 6” leadwire extension is stan-  
dard.  
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.  
Sheath corrosion can result in a ground fault  
which, depending upon the solution being heated,  
can cause an explosion or fire.  
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  
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.  
© 2010 Chromalox, Inc.  
Download from Www.Somanuals.com. All Manuals Search And Download*.Teflon® is a registered trademark of DuPont Co.  
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.  
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  
and shorten heater life. Do not operate heater if dry.  
4. In an electroplating operation the heaters are not, under any cir-  
cumstances, to be placed between the electrodes and the work.  
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 end  
of heater as this sediment can act as an insulation and shorten  
heater life.  
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.  
3. Note: Before Teflon heater is removed from solution, it should be  
allowed to cool from 15 to 20 minutes.  
THERMAL FUSE INSTALLATION/REPLACEMENT  
proper solution levels. Good ventilation, trained operators and  
safeguards such as liquid level controls and Thermal fuse over-  
temperature 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) —  
Sensor consists of a one-time thermal fuse sensor which is  
standard on all GTF over-the-side heaters.  
A liquid level control is a must as an additional safety feature  
to help minimize the possibility of fire.  
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®.  
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.  
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.  
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.  
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 —  
FIRE/SHOCK HAZARD: Before replacing fuse,  
make sure the cause of the “failure” has been  
detected and corrected.  
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  
 
THERMAL FUSE INSTALLATION/REPLACEMENT (con’t.)  
Thermal Fuse Replacement Protection Devices  
Model Number  
Used On  
FT  
RFT  
Std. Teflon® Heaters  
FLT  
RFLT  
L- Shaped Teflon® Heaters  
F Amp Capacity - 25 Amps; RF Amp Capacity - 5 Amps;  
Blank (low) Temp = 180˚F  
Low 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 240V when ordering.  
For process temperatures above 180˚F, consult factory.  
Limited Warranty:  
Please refer to the Chromalox limited warranty applicable to this product at  
2150 N. RULON WHITE BLVD., OGDEN, UT 84404  
Phone: 1-800-368-2493  
 
TA - Q0 - EF  
Litho in U.S.A.  

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