Storage Tank

M-501-T1 099H2-99TEXAS

Serial Number:41099

OPERATION, MAINTENANCE,SAFETY ANd PARTS MANUAL

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E. D. ETNYRE & CO., Oregoh, lll 61 061

ASPHALT STORAGETANKOperation, Safety and Parts Manual

M-501 -T1 099H2-99TEXAS41099

HOWTO ORDER PARTS

To assure prompt delivery when ordering parts, please furnish the following information: 1) Completename and address of consignee. 2) Method of shipmentprefened. 3) Is shipment to be prepaid or collect? 4)Serial numbers of units to which parts apply. 5) Complete part numbers and descriptions. 6) Any specialinstructions.

Specify unit serial number when ordering parts!

WARRANTYE.D. Etnyre & Co. warrants to the original Purchaser, it's new product to be free from defects in material andworkmanship for a period of twelve (12) months after date of delivery to original Purchaser. The obligation ofthe Company is limited to repairing or replacing any defective part retumed to the Company and will not beresponsible for consequential damages or any further loss by reason of such defect.

The company excludes all implied warranties of merchantability and fitness for a particular purpose. There a¡eno warranties, express or implied, which extend beyond the description of the goods contained in this contract.

This warranty does not obligate the Company to bear the cost of machine transportation in connection with thereplacement or repair of defective parts, nor does it guarantee repair or replacement of any parts on whichunauthorized repairs or alterations have been made or for components not manufactured by the Company ex-cept to the extent of the warranty given by thti original Manufacturer.

This warranty does not apply to:

(1) Normal start-up services, normal maiiltenance services or adjustments usually performed bythe selling dealer, factory service representative or customer personnel.

(2) Any product manufactured by E.D. Etnyre & Co. purchased or subjected to rental use.

(3) Any product or part thereof which shows improper operation, improper maintenance, abuse,neglect, damage or modification after shipment from factory.

(4) Any product or part thereof damaged or lost in shipment. Inspection for damage should bemade before acceptance or signing any delivery documents releasing responsibility of the delivering carrier.

This warranty and foregoing obligations are in lieu of all other obligations and liabilities including negligenceand all warranties of merchantability or otherwise, express or implied in fact or by law.

E. D. ETNYRE & CO., Oregon, lllinois 61061 -92781333 South Daysville Road Phone: 8151792-2116 Fax:815-732-T4OO

I

ïABLE of CONTENTS

Reporting Safety DefectsSafety InstructionsGeneral Identifi cation ..........................InsulationElectric HeatersFloat GaugeElectric PowerThermometerPlumbing...Control Box ...........Control Panel InsidePreparation For UseConnecting PowerGeneral Operating InstructionsHeater OperationPump Tank Operating InstructionsFill from Transport TankerUnloading Storage TankCleaning Asphalt PumpRecirculation .............Wiring - Motors Control panel.........Piping, Motor & P200 Pump Installation ................Piping, Motor & P200 pump Installation................Insulation & Heat Shield Installationinsulation & heat shield installationHeater Installation ..

Heater Kit - 28kw/480 Volt ........Pipe-Level Indicator InstallationBituminous Pump P-200Sump Installation - 4"Tank Gauge AssemblyHandrail, Platform And Ladder Assembly ....ManholeAssembly

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45

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78

9...10...11,.. 11

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16

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t9202l22

23

2425

262728

Remote Bulb Temperature Control Appendix ITemperature Controller, Fenwal Appendix IIUnitized Hearer Kir.............. Appendix IIIProcess Heating Co. Warranty Appendix IVControl Panel Wiring Schematic Appendix V

@ copyright 1999 E' D' ETNYRE & co' AII rights reserved. No part of this publication møy be reproduced by any means, electronic or mechanical, wirhoutthe express permission of E. D. ETNYRE & co. The enclosed dmwin[, ,"^ài, the property of E. D. ETNnRÈ a'co. and no part may be copied or usedwithout the express permissíon of E. D. ETNyRE & CO.

2

Reporting Safety DefectsIf you believe that your vehicle has a defect which

could cause a crash, injury or death, you shouldimmediately inform the National Highway TrafficSafety Administration (NHTSA) in addition tonotifying E.D. Etnyre & Co.

If NHTSA receives similar complaints, it mayopen an investigation, Ifit frnds a safety defect existsin a group of vehicles, it may order a recall andremedy campaign. However, NHTSA cannot becomeinvolved in individual problems between you, yourdealer, or E.D. Etnyre & Co.

To contact NHTSA, you may call the Auto SafetyHotline too-free at 1-800-424-9393 (or 366-0123 inthe Washington, D.C. area). Or, you may write to:U.S. Department of Transportation, 'Washington, D.C20696. You may also obtain other information aboutmotor vehicle safety f¡om the Auto Safety Hotline.

E.D. Etnyre & Co., Oregon,Illinois 61061, PhoneArea Code 815/732-2116, Cable Address..EDECO".CALIFORNIA

A woRNrNG

Unsafe operation of equipment may causeinjury or death.Read and understand the manuals beforeoperating or performing maintenance.

A wnRNrNcTo avoid serious injury or death alwayshave shields in place when operating.

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A wnRNlNG

Do not attempt any operation which is notdescribed in the manuals.

Other operations could cause serious injuryor death.

Read, understand and follow the manualswhen operating or performing maintenance.

A IMPORTANT

When filling the storage tank for the firsttime, carefully fill until the material levelraises to the top of the manhole collar. Thiswill cost the interior of the tank with a thinfilm of asphalt that will deter corrosion.

3

SAFETY INSTRUCTIONSSafety warnings have been provided to call attention to any potentially hazardous situation that may causeproperty damage, personal injury or death to the operator or bystanders. Theses safety warnings areidentified by the following warning symbol.

AAAA

The DANGER symbol alerts you to immediate hazards which V/ILL result in servere personalinjury or death.

The WARNING symbol alerts you to hazards which may cause severe personal injury or death.

A CAUTION alerts you to procedures that may result in damage to the equipment if not followedproperly.

An IMPORTANT provides general information that the operator should be aware of when perform-ing an operation.

All of these warnings appear throughout the manual.As with any type of equipment, there are certain hazards associated with improper or careless operation.The ability to read and understand the instructions in this manual should be a required qualification tobecome an operator.

A HoT SURFAcESSince this tank is intended to store hot liquid asphalt, the surfaces of the tank and equipment may behot. All surfaces and equipment should be considered to be hot. Wear insulated gloves and protec-tive clothing to prevent burns. The piping is heated with electric heat tape, it will be hot eventhough it has not been used recently.

A Hor LreurDSThe liquids stored in this tank are hot. The piping and hoses used to transfer the liquids are hot.'Wear insulated gloves, protective clothing and a face shield when transferring hot liquids, or han-dling hot liquid hoses to avoid burns. Stay clear of piping that may contain hot liquids. Leave allvalves closed unless you are performing an operation which requires a valve to be opened. Do notopen valves unless you are prepared for asphalt to flow.

A ELEcTRtcAL sHocKThis equþment is powered by high voltage electricity. To avoid electrical shock causing personalinjury or death, so not attempt to make repairs or adjustments without turning the main power off atthe control panel. Do not attempt to operate this equipment with the control panel door open.

A MoVING PARTSThis equipment contains moving parts, turning shafts, pulleys and belts. Keep all guards in placewhen operating. The agitator is controlled by a timer and may start unexpectedly. To avoid en-tanglement, do not attempt to make repairs or adjustments without turning the main power off at thecontrol panel.

A FALLSTo avoid falls that could result in death or serious injury do not climb over the guard rails on to topof the tank for any reason. Be careful when working on top of the tank to avoid dropping tools orparts that could strike someone on the ground.

4

G EN ERAL I DENTI FICATION

Platform

Manhole

Level lndicator

Tank Gauge

Sump

Strainer

Motor

Heater

Motor

Pump

WashoutVentValve

Fill Line

FILL

€

Valve<#3+

Lifting Eye

Tank Gauge

Lifting Eye

Liquid Level

Tank

Valve#1

Valve#2

Discharge Line

WashouWentValve

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Pump

DISCHARGE

INSULATIONThe tank is covered with fiberglass insulation, four inches thick. The insulation is intended to main-

tain the temperature of the heated asphalt. The insulation is covered with .040 Min. aluminum sheetingfor weather protection.

ELECTRIC HEATERSThe tank is heated with a 28KW Unitized Heater. The heater is located inside the bottom of the tank,

it is controlled by a thermostat located in the control box. A light in the control box door indicates whenthe heater is on.

FLOAT GAUGEThe tank is equipped with a float type level gauge. The white line on the indicator weight aligns the

tank.

ELECTRIC POWERTanks with pumps require 2401480 volt, three phase power, with four wire (neutral wire) system.

Conversion to other voltages is done with wiring inside the control box.

A WARNING

This equipment is powered by highvoltage electricity. Turn main power off atcontrol panel before making repairs oradjustments.

THERMOMETERA dial thermometer is located in a dry well in the side of the tank. The thermometer indicates the

temperature of the asphalt in the tank. The thermometer may be removed from the well with asphalt inthe tank.

A mRNINGAll surfaces and equipment should beconsidered to be hot. Wear insulatedgloves and protective clothing to preventburns.

PLUMBINGThree inch diameter lines run from the bottom of the tank to the pump. The pump is belt driven by a

five horsepower 2401480 volt three phase electric motor. It may be used to pump out of the storage tankinto other small tanks, or used to pump into the storage tank from transport tanks. The system may alsobe used to recirculate the product in the storage tank. All lines are insulated and heated with 115 volt heattape.

6

CONTROL BOXThe control box is located on the side opposite the ladder. In the door of the control box is a master

disconnect or switch which controls power for all of the electrical functions. A heater indicator light isalso located in the door, indicating when the heaters are on. Apump, forward, off, and reverse switch willbe located in the control box door as well. Inside the box are the various fuses and contactors to operate

the electrical equipment. A timer for the agitator and the thermostat for the heaters are located inside the

control box. Also located inside the control box is a 115 volt receptacle (GFI), that may be used forpowering lights or hand tools up to 15 amp capacity.

ONOFF

OPENCOVER

TEMPERATUREGAUGE

WINDOW

LOW LEVEL

I-IEAT ON

HI LIMITPUSHTO RESET

Storage Tank Gontrol PanelOutside View

¡[, onncER

This equipment is powered by high voltage electricity.

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CONTROL PANEL INSIDE

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1. GFCI/Heat Trace Transformer2. Control Power Transformer3. ICE Relay4. Sectional Terminal Block (3-sections)5. Main Tank Temperature Control6. Tank High Limit Temperature Control7. Heat Trace Contactor

9. Heat Trace Fuse Block10. Reversing Motor Start-up Pump12. Motor Protection Reversing Starter14. Tank Heater Fuse Blocks15. Tank Heater Contactors16. GFCI Receptacle17. Heat Trace Temperature Control

I

PREPARATION FOR USE

INSPECTIONUnpack the ladder, ladder cáge and handrail. Check for damage that may have occurred during ship-

ment. Visually inspect the tank, particularly the tank jacket and insulation for damage that may haveoccurred during shipment. Report any damage to the driver delivering the tank.

SETTING TANK IN PLACE1. The tank level gauge float has been secured to the roof of the tank for shipment.

2. Install ladder, ladder cage, handrails and platform. Securely tighten all fasteners

A wnRNrNG

To avoid falls that could result in death orserious injury, do not climb over the guardrails on top of the tank for any reason.

A *lRNtNGKeep all guards in place when operating

I

9

CONNECTING POWER

480 volt three phase power with a neutral wire is required for power. Power connection and wiringshould be done by a qualif,red electrician to conform to local and national electric codes.

A DANGER

This equipment ís powered by high voltage electricity

A wnRNrNG

Keep all guards in place when operating.

A wlRNrNGTo avoid falls that could result in death orserious injury, do not climb over the guardrails on top of the tank for any reason.

A IMPORTANT

When filling the storage tank for the firsttime, carefully fill until the material levelraises to the top of the manhole collar. Thiswill cost the interior of the tank with a thinfilm of asphalt that will deter corrosion.

10

GENERAL OPERATING INSTRUCTIONS

HEATER OPERATION1. Do not operate the heaters unless there is at least 700 gallons of asphalt in the tank.

2. Turn the master power switch off and open the contro box door.

3 Set the desired temperature on the thermostat knob.

4. Close the control box door and turn the master power switch on.

5. The heaters will turn on and off automatically to maintain the set temperature.

6. The indicator light on the control box door will turn on whenever the heaters are on

A wnRNrNG

This equipment is powered by highvoltage electricity. Turn main power off atcontrol panel before making repairs oradjustments.

A *oRNrNGAll surfaces and equipment should beconsidered to.be hot. Wear insulatedgloves and protective clothing to preventburns.

A wlRNrNG

Keep all guards in place when operating

A wlRNrNG

The liquids stored in this tank are hot.Wear gloves and protective clothing whentransferring or handling hoses.

rll

OPERATI NG INSTRUCTIONS

Tank Gauge Liquid Level

Tank

Valve#1

WashouWentValve

Strainer

Motof FILL

€Valve

€#3+

DISCHARGE

ValvePump

#2520030 1

Operation Valve 1 Valve 2 Valve 3

Fill UsingStorage TankPump

Glose Open Close

UnloadingStorage Tank Open Close Open

Recirculation Open Open Close

11

PUMP TANK OPERATING INSTRUCTIONSFill from Transport Tanker Using Storage Tank pump

1. Connect the transport's hose to the outlet line on the transport tanker.

2. Connect the hose from the transport tanker to the 3 inch fill line on the storage fank. Be sure FillLine Valve is closed.

3. Open the Valve on the storage tank and on the transport tanker.

4. Start the pump on storage tank.

5. Watch the tank level gauge on the storage tank to protect against over filling the storage tank.

6. Close the valve on the transport tanker.

7. Clean the hoses as directed by the transport tanker operating instructions.

8. Close Valve on storage tank.

9. Shut offpump.

10. Disconnect the hose from the storage tank and install cap.

Step 3 OPENStep I CLOSE Step 2

If rru-

+DISCHARGE

Fill from Transport Tanker

A *nRNlNGAll surfaces and equipment should beconsidered to be hot. Wear insulatedgloves and protective clothing to preventburns.

A *oRNrNGDo not open valves unless you areprepared for asphalt to flow. The liquidsstored in this tank are hot.

A woRNrNG

The liquids stored in this tank are hot.Wear gloves and protective clothing whentransferring or handling hoses.

IIIIIIIIII

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Unloading Storage Tank W¡th Storage Tank Pumplnto Asphalt Distributors Or Kettles

1. Connect the hose to the discharge pipe on the storage tank pump.

2. Connect the other end to the distributor or kettle being loaded.

3. Open the valve between the storage tank and the pump on the storage tank.

4. Open the valve between pump and the hose.

5. Open the valve on the distributor or kettle being loaded if there is one.

6. Turn the pump switch forward.

7. Before the distributor or kettle is completely full, close the valve on the storage tank.

8. Shut off pump.

9. If there is a valve on the distributor or kettle, close it.

10. If you are loading the distributor or kettle through a top opening, raise the end of the hose above thelevel of the liquid in the distributor or kettle.

11. Open the valve between the storage tank and the pump,

12. Turn the pump switch to reverse, and draw the material from the hose and pump it back into thestorage tank to clean the hose.

13. If the hose is connected to piping on the distributor or kettle, crack open the hose connection or openthe breather vent valve on the distributor or kettle if there is one. This will allow air to flow throughthe hose to clean it.

14. Disconnect the hose from the distributor or kettle and raise the end so that any asphalt remaining inthe hose can drain back to the pump.

15. Once the hose is clean, close the valve between the storage tank and the pump.

16. Shut offpump.17. Close the valve between the pump and the hose.

3

WARNINGADo not open valves unless you areprepared for asphalt to flow. The liquidsstored in this tank are hot.

A wnRNrNG

All surfaces and equipment should beconsidered to be hot. Wear insulatedgloves and protective clothing to preventburns.

A WARNING

The liquids stored in this tank are hot.Wear gloves and protective clothing whentransferring or handling hoses.

Step 3 OPENStep 7 CLOSEStep 11 OPENStep l5 CLOSE

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DISCHARGE

Step 1 CONNECTStep 4 OPENStep 17 CLOSE

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Unloading Storage Tank

13

Cleaning Asphalt Pump

1. V/ith the 3" unloading hose connected to the pump discharge pipe, put the loose end of the hose in abucket

2. Check the area for sources of flame, lit cigarettes, torches or lighters. Extinguish all sources of flame.

3. Put the end of the small (3/8") hose which is attached to the breather vent valve in a bucket of dieselfuel or kerosene.

4. Open the breather vent valve between the pump and the hose.

5. Hold both hoses to avoid being splashed.

6. While holding the hoses securely, turn the pump switchto forward momentarily. This will draw thesolvent from the diesel fuel bucket, pump it through the pump and out into the catch bucket.

7, Shut pump off.

8, Drain the remaining solvent from the three inch hose into the catch bucket.

9. Close the breather vent valve between the pump and the 3/8" hose.

WashouWent Valve

3/8" Hose

Qnr-r-

Diesel Fuel Buckel Catch Bucket

Cleaning Asphalt Pump

A woRNrNG

Extinguish all sources of flame, litcigarettes, torches or lighters.

3u

UnloadingHose

A *nRNtNGAll surfaces and equipment should beconsidered to be hot. Wear insulatedgloves and protective clothing to preventburns.

A *aRNtNcDo not open valves unless you areprepared for asphalt to flow. The liquidsstored in this tank are hot.

(

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Recirculation

1. Check that the caps are on and locked on the fill and discharge lines.

2. Close the valve at the end of discharge line.

3. Open the valve in the fill line between the tank and pump.

4. Open the valve in the discharge line between the tank and pump.

5. Start pump.

Step 3OPEN

Step 1

CAP ON

f rrr-r-

DISCHARGE

Step 1

CAP ON

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+

Step 4OPEN

Step 2CLOSERecirculation

A wnRNrNG

Extinguish all sources of flame, litcigarettes, torches or lighters.

A wlRNrNG

Do not open valves unless you areprepared for asphalt to flow. The liquidsstored in this tank are hot.

A wlRNrNcAll surfaces and equipment should beconsidered to be hot. Wear insulatedgloves and protective clothing to preventburns.

)IIIIIIIIII

15

WIRING. MOTORS CONTROL PANEL5200299

6, 8, 9,10

1,3,5

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Thermowell 1,31,3

6,8,9, 10

6,8,9

To HeatTape

1 ,3,4,11

Heat Tapelnstallation 1,2,3, 12, 13, 14

LowLevel

ControlPanel

PumpCover

5HP

REF PART NO. QTY DESCRIPTION REF PART NO. QTY DESCRIPTION

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6700969 6

6700858 I6702282 767009't0 I0t44042 1

6700710 25ft6000698 6

6702304 25ft4100110 25fr

Connector-FEMT, 0.50IN, Lqd, Res.Cord Grip-Male, 0.50x90, Lqd, Res.Nut-Conduit, l/2 In SealingConnector-Femt, 0.50x90, Lqd. Res.Bushing-Pipe, 0.75x0.50NPT, PDConduit-FEMT, 0.50, Sealrite EFClamp-Tube, l5/l 6, Berg#l5 1 I -7Wire-l0GaAWG, White, Type TIIV/NWire-lOGa AWG, Black, Type TIIWN

Wire-lOGa AWG, Green, Type TIIWN'Wire Nuçl0GACover-Unilet K50 Form 35

Gasket-O.5 In Box #GK50-NUnilet-l/2 LB50-M

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6700349 I6't00023 I4100105 1

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PIPING, MOTOR & P2OO PUMP INSTALLATION

5200280

VALVE MARKER-TRANSFER3 S1 1764G3l,16-1/BCHANNEL-MTR&PUMP MTG HÚRIZ520028330

MT RH! ZIGM RT P& MPUEANN LCH29 I=200282 M ï N G! UN IPPUM&RM TD nNHC ELAN520028 I28 4

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PIPE_SCH40,3' X 5_5/8 LG '25 I=200276 PIPE-SCH40,3" X 6-1T/16 IG520027524 1

x 3-1/A LGPIPE_SCH40,3"520027423VALVE-GATE, HDSE 3 INCH660005 122 I

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E,D,ETNYRIL, 61061!REG¡N

E&f¡OI] NTT SCALE DVIGALL OIMENSIENS IN INCHES

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UNLESS SPECIFIEDBENO RELIEF SHTP

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PIPING,4'4I]TER & PzOO PUMP INSTAL.DRAWING TITLE

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INSULATION & HEAT SHIELD INSTALLATION

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INSULATION & HEAT SHIELD INSTALLATION

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REF REG PART NE DESCR IPTIDN

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ALL OIMENSIT1NS IN INCHES OE NET SCALE OWGt0Ö.

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INSULATIEN & HEAT SHIELI] INSTAL.

DRA\./ING TITLE

SER.NE:41099

SII'4 IE: 5200091

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ALL DIMDRAWING TITLE

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.xxxr.010ANGLESl O' 30'

DESCRIPTION

REVISIONS

REV

GENERAL NOTES.REMOVE ALL BURRSBREAK SHARP EDGESMINIMUM BEND RAD.

UNLESS SPECIFIEDBEND RELIEF SHOP

OPT I ON

A't o99

650038 5

SER. NO,

s rM. To,WEIGHT.

FINISH CHART

t\)N

2BKW UN IZ=D HEATTR KITWITH CONTROLS MOUNTED AND PREWIRED TO HEATERLOW LEVEL SENSOR SWITCHCONTROL PANEL TO I NCLUDE.MAIN DISCONNECT SWITCH WITH THROUGH DOOR OPERATORCONTROL POWER TRANSFORMER(FUSED)HEATER CONTACTORS AND INDIVIDUAL LOAD FUSES FOR EACH ELEMENTHEATER TEMPERATURE AND HI_LIMIT CONTROLS

5 HP REVERSING STARTIR WITH OVERLOAD PROTECTION FOR PUMP MOTOR

FWD/REV/STOP PUSH BUTTONS FOR PUMPALL COMPONENTS MOUNTED, PREW I RED AND FUNCT I ONALLY TESTEDU. L. L I ST I NG AS I NDUSTR I AL CONTROL PANEL12OV TEMpERATURE CONTROL FOR HEAT TAPE SOL l D STATT W/4" PROB

1 1sV RECEPTACLE(Gl F), 15 AMP

FOR 78" I.D. X 390" (SHELL) TANK6" HE I GHT BETWEEN HEATER AND CONTROL BOX

mIm¡xo)=oì¡orONG)c)(oxJ<Þ@ooT

PROCESS HEAT I NG COMPANY, I NC. PART NO 2BKW/48O VOLT,3 PHASE

PI PE-LEVEL I N DICATOR INSTALLATION

5200254

ReferenceLiquid Level-+l-

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3,4 Shell

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REF PART NO. ow DESCRIPTION REF PART NO. OTY DESCRIPTION

I Pipe-liquid Level, Bin-dicaror1 Coupling-pipe, l.O0npt, SteelI Ring-finishing, 1" Pipe6 Rivet-dr, 0.19,0.12 Grip, 0.17 Max

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4" INSULATIONL SHELL

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REF. PAFT NO. OTY DESCRIPTlON REF. PART NO. QTY DESCRIPTION

1 Sump Asm-4" Cleanout1 Plug-PP,SqHd,4.00NPT,PN

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SPECIFY UNIT SERIAL NO., PART NO., & PART DESCRIPTON 25

TANK GAGE ASSET¿|BLY

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REF PARÍ NO. QTY. DESCRIPT¡ON REF PART NO. ATY. DESCRIPf IONIa

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SPECIFY UN IT SERIAL NO. , PARÍ NO, , & PART DESCRIPT¡ON 27

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PIPE . LEVEL INDICATOR INSTALLATION

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1

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REF PART NO. QTY DESCRIPTION REF PART NO. QTY DESCRIPTION

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29

APPENDIX I

Remote Bulb Temperature Control

-L 55 Series

Remote Bulb TemperatureControllers

Pleøse read all hstructiotwl Líterature carcfully ond thoroughly before stafüng. Refer to the final þage for the lßting ofRec o¡nrnend.ed P rcctíc e s, Líahilitie s ønìI W ørr antie s.

GENERAL

Temperature variations sensed by the liquid-filled bulb are hydraulically transmitted throughthe capillary to a stainless steel diaphragmcapsule. The capsule operates a lever toactuate one or two snap-action switches.

Part I - lnstallationTools Needed

Drillwith #25 (.1495) and 5/16" bitsFlatblade screwdriver

LOCATE THE CONTFìOL WHERE SHOCK,VIBRATION AND AMBIENT TEMPERATUREFLUCTATIONS ARE MINIMAL.

l

i .,'t' The control can be mounted in any position.

ril I nel to accommodate #6-32 sc. Hole locations should al ign with

holes in mounti

@

Also, drill 5/16"ng bracketdiarneter ho

(seele to

figureaccommodate

control adjustment shaft. Note: maximum panelthickness is 1/2 inch.

250 (63s)

213 F4 R-AT

a7s lz2.2l

1.r50 G4.5)

Type E55AS (Mounting)Top View

656 (1ô,7)

1.313 (33.3)

#6-32NC - 2 HOLE4 PLACES(PANEL MT'G)

t. 7

UE..-F

U N ITED ELECTR ICCO NTR O LSlnstallation and Maintenancelnstructions

Surface Mounting (Types E55 and E55A)Mount using two enclosure mounting holes asshown.

(9 6;0)tB75 (4

z31g 150,71FOH

't56 5, õ)

ALL LIVE SUPPLY CIRCUITS MUST BEDISCONNECTED BEFORE WIRING THE

Fully immerse the bulb and 6" capillary in thecontrol zone. For best results it is generallydesirable to place the bulb close to - (but noitouching) the heating or cooling source in orderto sense temperature fluctuations quickly.Place the remäining capillary adjacenf to tñecontrol head so that it will sense the same ambi-ent temperatures. Factory calibration, unlessspe.cified othenrrrise, allows for 6" capillary tubein the sensed medium. If more than 6" w¡tt ¡eimmersed in the media, recalibration may benecessary, in which case follow procedures out-lined in Part ll.

"C" style bulbs (1/8" OD) can be coiled orshaped to fit the installation. Avoid sharp bendsand coils smaller than 2" radius. Do not bend"B".style bulbs (3/8" OD), Avoid bending orcoiling the capillary tube smaller than J/2"radius. Exercise caution when making bendsnear the capillary ends. lf a separable well orunion connector is used follow separate instruc-tions included.

Making Wirino ConnectíonsWire directly to switch terminals according toparticular requirements of the application. Fordual switch Types E55A and ESSAS, if switchesa¡e to be_ set apart, connect wiring so that switchNo. 2 will function at the higher temperature.

@

OLEARANOE+10 soREw2 HOLS

CONTROL. WIRE IN ACCORDANCE WITH

l-.500 112.71

MÆ(. PANELTI-IICKNESS

350 8el2.s31 163.3)

+6-32 TERi¿ SCBEW

NATIONAL AND LOCAL WIRING CODES.MAXIMUM RECOMMENDED WIRE SIZE IS#14 AWG.

Switch SettingsOn dual switch units, both switches are factoryset to actuate together within 5% of range(switch No. 2 set on dial) but may be set to actu-ate up to '100% of scale range apart. Eitherswitch may be set to agree with the dial. SeePart ll-Adjustments.

Start-Up ProcessTurn dial and knob to the desired temperaturesetting. Controller is ready for operation, Minoradjustments may be necessary to obtain betterset point accuracy after installing the unit in aparticular process. See Part ll-Adjustments.

Part ll - AdiustmentsTools Needed

1/16" Allen wrenchSmall screwdriver

f@l '.

rHE uNrr rs BErNc usED ro coN-v ÍRor- A PRocESS, PERFoRM oALIBRA-TION TEST AFTER ADJUSTMENT. UNIT MUSTREPEAT ON SUCCESSIVE ON.OFF CYCLES.

Test ThermometerUse añ accurate test thermometer (such as athermocouple) with its sensing area located nextto the sensing bulb.

StabilizationBefore making adjustments allow 5 minutesfor the thermãl system to adjust to the bathtemperature.

Set Point Referenceeonnect test lights to the terminals to indicateswitch operation.

Adjusting Single SwitchTyþes E55 and E55S

FL

2

55 Series controllers are standardly suppliedwith the No. 2 (higher temperature) switch set tothe dial. To adjust switch settings for thesecontrollers, follow the recalibration procedure.

Set the dial to the same temperature as the testbath. Using 1/16" allen head wrench, loosenknob set screw and remove dial, taking care notto rotate the shatt.

Adjusting Dual SwitchTypes E55A and E55AS

.500 {12,MAX, PANELTHICKNES S

+6-02 TÊRVL SCRFW

l-

350 88.9)2.s31 163.3)

Shaft has calibrated flat for easy dial replace-ment. Using 1/16" allen wrench, turn zeroadjustment, located inside adjustment shaft,until switch No. 2 actuates. Turn counter clock-wise for higher setting, clockwise for lower set-ting.

Replace dial on shaft. Do not secure. Turn dialto a higher setting equal to temperature differen-tial ('F or 'C) desired between switches No. 1

and No. 2. Remove dial for access to the No. 1

switch adjustment screw. Using a small screw-driver turn in or out the No. 1 switch adjustmentscrew (accessible through opening behind dial).Replace dial, tighten dial set screw to calibratedflat. Controller is ready for operation.

For single switeh units the only adjustmentneeded is the set screw adjustment in themiddle of the adjacent shaft.

Part lll - ReplacementsTools Needed

1/16" Allen wrenchSmall screwdriver

läù orscoNNEcr ELEcTRTcAL suppLyS2 so rHAT swrrcH coNTAcrs ANDTERMINALS ARE NOT ALIVE, REPLACEWITH IDENTICAL SWITCHES CNLY.

Enclosed Types

Remove cover and adjustment dial; thenremove two (2) flat head screws to dismountcontrol body from enclosure. Remove the largerectangular cover plate and rubber gasket fromthe bottom of the enclosure, and disconnectwiring from the switch terminals. lnsert the newswitch(es) and tighten screws, Recalibrate set-

!

General Layout, Exploded Mew

SwitchAdjustmentCover

CalibratedKnob and Dial

Knob Set ScrewEnclosure A,ccessto f1 SwitchAdjustment Screw

Enclosure

._ switch Adjustmentcover Screws

Compensat¡ng Disc(lnstallwith Curved

Compensating Bimetal\À,äs h e rs

DiaphragmLEV ET

{_ (Flipper ptate)

Zero Adjustment

Access to#1 SwrlchAdjustment

Control BodyMount¡ng Screws

calibrated Flat

b

4

Control Body

Actuating LeverExtension Spring

Capillary CIampMounting Screw

Side as Shown)

Used onStandardConsenatedUnits 0nly

\åL+dJ Th

Assm.

Switch li,,|

Locknuts

CapillaryClamp s1 Switch r

Adjustment Screw(Dual units 0nly)

S'#itch lnsulators

+--._Switch MountingScrews

ch Term¡nals

ountinq

----?+

Cover Plate/and Gasketìng

cMounting Scre,#s

ting(s). See Part ll-Adjustments. Rewire the newswitch(es) and place unit back in its enclosure.Reconnect electrical supply.

Skeleton Types

Remove the two (2) switch mounting screws;remove the switch(es). lnsert the new switch(es)and tighten screws. Recalibrate setting(s). SeePart ll-Adjustments. Rewire the new switch(es)and place unit back in its enclosure. Reconnectelectrical supply.

Dimensions

2r] 6¿) RAT

875 122.2)

1.750 (44.s)

t0ô0

Type E55AS (Mounting)

1875 l,r7

zSlo 158.¿

Type E55, E55A

.500 112MAX. PANELTHiCKNES S

{6-02 TERr,r SCSEW

6 (16,7)

r,s13 (33.31

#6-32NC - 2 HOLE4 PLACES(PANEL MT'G)

+t5ó

250 (6s5)

t. 75 +t.al

OLEAFANOE FOR+10 soREw2 HOLE

\

2 1

2.ssr (8o,sl350

CAPILLA.BY

Type E55AS

el

MAPl 0M696

RECOiIMENDED PRACTICES

Unrled Electric Controls Company recommends carefulconsideration of the following lactors when specifying andinstalling UE pressure and temperature units. Beforeinstall¡ng a unit, the Installalion and Maintenance instructionsprovided with unit must be read and understood.. To avo¡d damaging un¡t, proof pressure and maxtemperature limits stated in literature and on nameplatesmust never be exceeded, sven by surges ìn lhe system.Operat¡on of the unit up to proof pressure or max temperature isacceptable on a limited bas¡s (i.e.slart-up, testing) but continuousoperation must be restricted to the designated adiustable range.Excessive cycl¡ng at proof pressure or maximumlemperature lim¡ts could reduce sensor life.

. A back-up unit ìs necessary for applications where damagelo a primary unit could endanger life, limb or property. A highor low ¡imrt switch is necessary for applications wheredangerous runaway cond¡tion could result.. The âdiustable range must be selected so that incorrect,inadvertent or malicious sening at any range po¡nl can notresult in an unsaTe system condil¡on.. lnstall unit where shock, vibration and ambient temperaturefluctuat¡ons will not damage unit or affect operat¡on. Orientunit so that moisture does not enter the enclosure viathe electricâl connection.. Un¡t must not be altered or modilied after shipment.Consult UE ¡t modification is necessary.. Monitor operation to observe warning signs of possible damageto unit, such as drift in set point. Check unit immediately,. Preventative maintenance/periodic testing is necessary lor cnticalapplications where damage could endanger property/ personnel.. For all appl¡cat¡ons. a factory set unit should be tested before use.

Electrical ratings stated ¡n literature and on nameplate must not beexceeded. Overload on a switch can cause damage, possible on thef¡rst cycle. Wire unit according to local and national electrical codes,using wire size recommended in installation sheet.. Use only factory authorized replacement parts and procedures.. Do not mount unit ¡n ambient temp. exceeding published limits.. For remote mounted temperature units, capillary lengthsbeyond 10 feet can ìncrease chance of error, and may

requ¡re re-calibration of set poinl and indication.

LIMIT WARRANTY

UE warrants that the product thereby purchased is, upon delivery,free from defects in material and workmanship and that any suchproduct which is found to be defective in such workmanship or mater-ial w¡ll be repaired or replaced by UE (F O B. UE); provided, however,that lhis warranty applies only to equipment found to be so defectivewithin a period of 12 months after installation by buyer but not toexceed 18 months after delivery by the seller. Except for the limitedwarranty of repair and replacement stated above, UE disclaimsall warranties whatsoever with respect to the product, includingall implied warranties of merchantability or fitness for anyparticular purpose.

LIABILITY LIMITAT¡ON

The sole and exclusive remedy of buyer for any liab¡lity or sellerfor any clarm, including incurred in connection with (l) breach of anywarranty whatsoever expressed or implied, (ll) a breach of contract,(lll) a negligent act or acts (or negligent fa¡lure to act) committed byseller, or (lV) an act for which strict liability will be imputed to seller,is limited to the limited warranty or repair and replacement statedherein. ln no evenl shall the seller be liable for any special, indirect,consequential or other damages or like general nature, including,without lim¡tation, loss of prof¡ts or production, or loss or expenses ofany nature, incurred by the buyer or any third party.

UEUNITED ELECTRIC CONTROLSP.0. Box 9143, Wateriown, MA 02272-9143 USA

617 926-1000 Fax 617 926-2568

APPEi\DIX II

Temperature Controller, Fenwal

40018

r'a FEW

SNAPSWITCH ELECTRICAL RATINGSStandard Differential

15 A,125-250 VAC0.50 A, 125 VDC0.25 A, 250 VDC

Narrow Differential: 15 A,125-250 VACDielectrÍc Strength: Not less than 15OO VDC or lSOORMS-AC for one mlnute between the case andterminaÌs connected in parallel

ACTUÁfINGPIN

-L

8EI-LOWS EXPANDS PROVIOINGÂcfl./af¡NG FoRCE tO SWrTCllANO INOICATING MECHAN¡SMS

o

oGzoóoFUoñ

ACIUÁÍOÊ SPRING

OP:RATING AE!-LOWS

AClUÂTOR HOUSING

LOCK ÑUÎ

OFFSEIA0JUSTOA NUf

swrvELJotNl

EULB

CÀPILLAFV

Figure 1

BULB AND CAPILLARYMaterial: Type 316 Stainless Steel bulb and capillaryare standard. Copper capillary is available uponrequest.

INDICATINGTEMPERATURE CONTROLLER

INSTALLATION INSTRUCTIONS

PRINCIPTE OF OPERATIONControl action of these mechanical indicatingtemperature controllers is provided through theprinciple of lÍeuid volume change, See Figure 1.

With a change in temperature, the liquid in thesensing bulb expands and contracts, causing thebellows to actuate the switchrng mechanism.Ambient compensatron is provided by an expanda-ble push rod assembly mounted on top oi the leverarm which moves the pointer and switchingmechanism. Changes in ambie:nt temperaturesthrough a range of 0 to 150'F (- 18 to + 65"C)expand or contract this push rod assembly toprovide an operating balance for the expansion andcontraction of the bellows assembly within theactuator housing.

PROCESS DIFFERENTIALThe process differential is minimum when thenarrow differential switch ts used, when the fastestresponding (smallest diameter)bulb is used, whenthe narrowest scale range is used, and when thesensing bulb is installed in a suitably designedprocess and in a location which is close enough tothe heater or cooling device to sense temperaturechanges quickly.In general, it is difficult to predict the operatingdifferential of a given process. The differential can

SPECtFtCAT|Ot{SHOUSINGThe housing (and cover assembly) is made of diecast aluminum with a gray baked enamel finish. Itis designed to meet the requirements of NEMA Type4 and 12 (lEC IP65 and IP62). Neoprene or cork-neoprene gaskets seal all ports and covers. Eventhough the housing is watertight, a separate coveror shield is recommended to þrotect the controllerfrom exposure in outdoor applications.

!

3. Do not bend capiilary closer than 1 1/4 inch (32mm)to the actuator assembly. However, thecaplllary may be rotated 3ô0" at the actuatorassembly.

4. Where necessary, allow sufficient length toprovide strain relief loops in the capillary.

5. Mount bulb and capillary so as to avoid flexingdue to vibration.

WIRING

Awnnunc

closad :Clo¡ed Cl¡crrh=

Highvolt controilerthat cou/dcauseseve¡e in ld onlY be PerÍormed bYqualiÍied belore wiring Wire inaccordance with )ocal codes

Wiring EntranceEntrance for winng is provided by a knockout oneach side of the housing. Remove knockout byapplying one or two sharp blows with a metal orwooden dowel. Be careful not to damage switches.

To maintain the watertight and dusttight feature'ofthe Series 400 Controller, proper conduit connectorfittings should be used.

ln controllers with Explosion-proof Housing(Modification 110), a sepalate houstng for thesnapswitches and wiring is located on top of theconiroller. To maintain the explosion-proof featureof the housing (Class I, Groups C and D, or Class II,Groups E, 2), wiring mustenter the h that is screwedinto the 1/2 the housing. Foradditional a waterProofcompound on the pipe threads. To gain access tothe snapswitches in the housing, remove the knoband front panel of the controiler to expose the fourscrews on the front of the housing. Remove thesescrews and the housing cover,

for exampies of wiringunits respectively.made with generous loops

of wire so as not to impâir switch operation ormarked NO (open belowd NC (closed below setce on snapswitch when

maktng connections.

Controllers with additional snapswitches in the

lower compartment (S.F' 75)have prewired and

marked connections as follows:

-N-nltef iBotrve€n2and

Note: Switch 1 is nearest front of controller

SPECIFICATIONS Continued

Temperature ExPosure LimÍts. - izs"F ( - 115"C) minimum for instruments with

a top range limit of up to and including 200"F(100.c)

. - IOO"F ( - 75'C)minimum for instruments with a

top Iange limit of 300 through 500"F (150 through260"C)

. 25"F (5'C)minimum for instruments with a toprange limit of 700"F (370"C)

. Maximum temperature is 25F" (15C') above thetop range limit

Preèsure Exposule Limit: Bulb will withstand 400psi (2.75 MPa) over any temperatule range

INSTALLATIONCONTROLLER LOCATIONThe Series 400 Controller housing (including thecontroller mechanism and actuator assembly)should be mounted where the ambient tempelatureis within the limits of - 65 and + 150'F (- 55 and+ 65'C). The controller is ambient temperaturecompensated from 0 to 150'F (- 18 to +65"C). Thecontroller has high resistance tovibration' However,avoid mounting the unÍt in areas of extremevrbration if possible. If it is necessary to mount thecontroller in such a location, use a snapswitch witha maximum acceptable operating differential.

CONTROLLER MOUNTINGThe controller can be surface mounted by using the

three adjustable mounting brackets attached to the

case sides and bottom. Fasten with #10 hardware'Series 4OO Controllers (except those withModification ng)canalso be panel should be

6.500 in (tOS 68.28 mm)high. Four mounting holes are provided in theovãrhanging portion at the top and bottom of thecase. Thé holes will accept #B hardware and will be

hidden by the cover. A tempiate for the cutout andholes is located on Page 7.

BULB INSTÀLI,.ATIONTemperature limitations for the bulb and caPillaryare listed in the SPECIFICATIONS section' Foroptimum control, the bulb and 6 in (15 cm)ofcäpillary shouid be immersed in the process'

AwlRnlnc/n cont¡o/Je¡s with upper range llrnits ol 700'F (370C),

flunging the bu/Þ lrom a very cold temperature into a hot

þrocèss couta cause the buJb tc st¡etch or even rupture, since

i¡e ¡lu¡d is veryviscous at temperatures below 25"F (-4'C)

Acnurlon-Do not expose bulb to pressures greater .than 40O psi (2'75

MPa). Beyond th js po¡nt some creep ¡n the buJb structureoccu¡s wirich introduces offset into the system

CAPILI.ARY INSTALI.ATION1. Minimum bending radius is 1/4 inch (6 mm)'2. Do not bend capillary closer than 1/4 inch (6

mm)to the bulb-caPillary weld'

SERIES 4OO

t' -t

l

ecopyrtghl 1992 Krdde-Fenwal lnc

F

SERIES 400

^'...j

.tI

.J

)

WIRIHG Continued

NOa'lY

NC

H¡A]IXGto^D

- - --¡- --.i coouxc I¡ LOAD !

Figure 2A Figure 28

ADJUSTMEIITSKNOB TOROUE ADJUSTMENTKnob torque is adjustable by means of the set screwA in the front shaft bearing. See Figure 3, 4, 5 or 6

SWITCH ADJUSTMENTS

A,wann¡ncDjsconnect power when adjusting snapswitches to avordpossible elect¡ic shock.

Model 4O-7O2 (See Figure 3)When the set pointer is in exact alignment with thetemperature indicating pointer, the switch shouldbe midway between the Operate and Resetpositions. The Operate position is the point wherethe switch clicks on; the Reset positions is the pointwhere the switch clicks off. The relationship willusually be upset if the snapswitch is replaced, but itcan be easily restored as follows:1. Remove top cover.2. Bring set pointer (B) in alignment with indicating

pointer (C).3. Adjust screw (E) midway between the two

positions where switch (F) ciicks.4. Check the setting by placing a screwdrlver

under lever (D) and simulate temperaturechanges by moving the iever.

5. if necessary, trim the setting by slight adjustmentof screw (E).

Figure 3

Model 4O-7O3 (See Figure 4)This controller has two switches, either one ofwhich can be adjusted to operate when the pointersare in alignment. The other switch will either beabove or below the indicated settrng, depending onwhether it is used for overheat alarm, warm-up heator some other auxrliary'function, The proceduresare as follows:

Figure 4

For Differential Up To t 15% of Scale LengthA. When the upper setting is indicated by the set

pointer:1. Remove top cover.2. Bring set pointer (B) in alignment with

indicating pointer (C).3 Adjust screw (H)on the front switch to a point

midway between the two positions whereswitch (l)ciicks. This switch must always bethe upper of the two settings An attempt todo otherwise wiil cause the rear switch to beinoperative.

B. When the lower setting is indicated by the setpointer:1. Remove top cover2. Adiust set pointer (B)the differential amount

lower than the indicating pointer (C).3. Ad¡ust screw (H)on the front switch to a point

midway between the two positions whereswitch (l)cticks.

ADJUSTMENTS Continued

4. Bring set pointer (B) in alignment withindicating pointer (C).

5. Adjust screw (L)on the rear switch to a pointmidway between the two positions whereswitch (K)clicks.

For Wider Differentials (Up to 112 Scale Length)1. Remove front cover, top cover, and temperature

^^^t^òucilü.2. Adjust screws (H)and (L)to achieve 1/8 in (3

mm)between switch bracket and case shelf.3. Turn set pornter (B) to extreme left.4. Raise lever (F)with a screwdriver to move

indicating pointer (C) to midscale.5, Turn wide differentiai screw (G)so that rear

switch just actuates.6. Turn screw (G) counter-clockwise amount

shown in Table tr*r" ,

Differential Sc¡ewTurns

3-15%12-23%2341%4r-52%

Example: 125"F diferential in an instrument with50-700"F scale is approximately 20% of scalelength, since (125/650X1000Á) : approximately -

19%. Therefore turn screw 1 turn.

7 Repiace temperature scale.B. Align set pointer (B) with indicating pointer (C).

9. Determine which switch is to be indicated.10. Loosen set screw (P) and rotate pulley on shaft

untilthe switch to be indicated just actuates.Tighten set screw.

11. Check settings by simulating temperaturechanges with the screwdriver under lever (F).

Trim by adjustments to screws (H)and (L).

Model 4O-7O4 (See Figure 5)When set pointer (B) is in exact alignment withtemperature indicating pointer (C), the REARswitch should be midway between the Operate andReset positions. When set pointel (J) is in exactalignment with temperature indicating pointer (C),

the FRONT swilch shouid be midway between theOperate and Reset positions. The Operate positionis the point where the s:witch clicks on; the Resetpositions is the point where the switch clicks off .

The relationship wÍll usually be upset if thesnapswitch is replaced, but is easily restored asfolÌows:

1. Remove top coveI.2. Bring set pointer (B or J) in alignment with

indicating pointer (C).

3. Adjust screws (E) midway between the twopositrons where each switch clicks.

4. Check the setting by placing a screwdriverunder lever (D)and simuiate temperaturechanges by moving the lever.

5. If necessary, trim the setting by slight adjustmentof screws (E).

Figure 5

Explosion-proof Housing (See Figu¡e 6)When the set pointer (B) is in exact alignment withindicating pointer (C), switch (J) should be midwaybetween the Operate and Reset positions. TheOperate position is the point where the swrtch clickson; the Reset positions is the point where the switchclicks off. This relationship will usually be upset ifthe snapswitch is replaced, but is easily restored asfollows:

1. Remove knob, front cover, and dial. Use care tnremoving dial so as not to deform pointers.

2. Bring the set pointer (B) into alignment withindicating pointer (C).

3. Adjust hex head screw (D)to a position midwaybetween the two positions where the switchclicks.

4. Check the setting by placing a screwdriverunder lever (F)and simulatlng tempelatulechanges by movement of this lever.

5. If necessary, trim the setting by sltghtreadjustment of screw (D)

a

t

SER|ES 400

J{

-ì

s-/

SERIES 4OO

à ADJUSTMENTS Coniinued

Figure 6

CALIBRATION (See Figure 7)Every Senes 400 Controller is carelully calibratedand tested before shipment, but recalibration maybe required to nullify offsets resulting fromdifferences between bench calibration and actualprocess measurement.

Figu¡e 7

The enti¡e actuator assembly (C) can be moved tothe right or Ieft to inc¡ease or decrease, respectively,the rate of travel of the indicating pointer. This isdone by loosening screws (A) anO (B). Adiustmentof nut (E), after loosening locknut (D), raises orIowers the entrre bellows by a fixed amount.

To calibrate the controller, use one of the followÍngmethods:

Method 1 (When the controller is normally usedwithin a narrow range of temperatures)1. With the process (or calibration bath) at the

desired temperature, loosen locknut (D).2. Adjust nut (E)until the indicating pointeragrees

with the process temperature.3. Tighten locknut (D).

Method 2 (For maximum calibration accuracy overthe full temperature range)1. With the process temperature (or calibration

bath) near the center of the scale range. loosenlocknut (D).

2. Adjust nut (E)until the indicating pointer agreeswith the process temperature,

3. Tighten locknut (D).4. With the process temperature (or calibration

bath) near one end of the scale range, loosenscrews (A) and (B)and move the actuatorassembly Ieft or right untilthe indicating pointeragrees with the process temperature.

5. Repeat steps 1 - 3

MAINTENAT{CELUBRICATIONNo lubrication is required.

GI.ASS REPI.ACEMENT1. Remove broken glass and excess cement2. Line'window frame with Dow Corntng 732 RTV

Rubber Cement.3. Insert glass and apply light even pressure.4. Allow cement to cure before subjecting

controller to vibration or shock.

SNÀPSWITCH REPLACEMENTSnapswitches are unlikely to need replacementexcept when operated in a short ci¡cuit orcontinuously in a contamtnated atmosphere. Theprocedures for replacing snapswitches are astollows:

In Standard Housing (See Figure 8)1. Remove top cover.2. Remove switch and mounting bracket by

removing screw (A) and sliding switch to theright (away from screw (B),

3, If the switch wili not easily slide away fromscrew (B), reduce compression on the switch bydepressing lever (F) in Figure 4.

4. Insert new switch. Ensure that insulationremains intact and in position.

Figure I

t

J

MAINTENANGE Continued

In Explosion-proof Housing (See Figure 6)1. Remove knob and front cover to expose screws

(tr l.2. Remove four screws (G).3. Remove two screws (H), switch, and mounting

bracket.4. Insertnew switch. Ensure that insulation

remains intact and in position.

ACTUÀTOR ÀS SEMBLY REPLACEMENTIn the event that the liquid filled assembly has beendamaged, it is necessary to replace the entireactuator assembly. See Figure 7.1. Remove old assembly by removing screws (A)

and (B).2. Install new assembly. Tag on replacement

assembly shows proper positioning to provide1% accuracy. Position groove on actuatorhousing in relation to scale on housing asindicated on tag.

Note: If the oilginel actuator asssembly has a buJb larger thanO.375 in(9.53 mm), e.g.,a "C" style (coiled) bulb, itis necessaryto specify a packing gland (iÍ required) when teodeting theaatuatoÍ assembl¡

REPLÀCEMENT PARTS (See Figure 9)

Code Description Part Number

A Snapswitch(Na¡row Dilferential)

B Snapswitch(Standard Differential)

C SeU Tapping ScrewD LocknutE Adjustlng NutF Glass WindowG Front Cove¡ GasketH Front Cove¡ ScrewsI Top CoverJ Top Cove¡ GasketK Top Cover ScrewL Mountlng BracketM Mountìng Bracket Sc¡ewN l¡dicator KnobO Temperature Dial

06-125723-004

06-125723-00506-2501 12-01106-133426-00006-250025-03006-231187-00106-231193-00106-250025-04906-231869-00106-231835-00206-250042-04706-136919-O0O06-114829-00006-114789-003State completemodel numbe¡and temp. rangeSee Table 2.P Actuator Assembly

i

Þ

Õ

Figru¡e 9

Table 2

Where X : the following (See Figure 10)

0 = Style A Bulb; 6 ft (2 m) capillary1 : Style B Bulb; 6 Ít (2 m)capillary2 = Style C Bulb; 6 ft (2 m) capillary3 = Style D Bulb; 6 ft (2 m)capillary4 : Style A Bulb; 10 ft (3 m)capillary5 = Style B Bulb; 10 ft (3 m) capillary6 : Style C Bulb; 10 ft (3 m)capillary7 = Style D Bulb; 10 ft (3 m)capillary

Í0t2EO)

Bo

90

ñ\//\\wi,/ YEsi-:l

0t{

375 0tA{9 S)

250 0lAt6 35)

Figu¡e 10

093{2 36t Or^

SERIES 4OO

?

.213 (5.41) DlA. (#3 DRILL)(4) HOLES

MOUNT WITH(4) #8-32 SCREWS

+.0152.500

(63.5 1.38)

+-.0'15

1.312(33.33 *.38)

(

+.0156.625

(168.28 *.38)

.0157156181.76 +.38

FROPANELOUTLINE

î

+.015.687

r-.0155.125

(130.18 *.38)+-.015

6.500

E[:{MOUNTED TEMPLATE

in parentheses..

(165.10 *.38)

(17.45 * .38)

SERIES 400

¡

Th¡s literature is provided for inlormational purposes only. KIDOE-FENWAL. lNC. æsumes norespons¡b¡lify for the producl's su¡tab¡l¡ty lor a palicular appllcalion. The producl musl beproperly applied to perfom as descñbed here¡n

ll you need moro inlomatlon on this product, or it you have a quâstion, contact KIDOE-FENWAI- lNC., Ashtand, MA 01721. (SOS) SS1-2OOO.

KIDOE.FENWAL. INC

4OO MAIN STREET, ASHLANO, MA 01 721

TEL: (508) 881-2000 FAx: (SOB) Bg1-6729

06-L002204O0 5/95 @1995 Kidde-Fenwat, tnc. printed in U S A

@

APPENDIX III

Unitized Heater Kit

Process llealing Company, lnc2732 3rd Ave.SoullrP.O. Box 84585seaille, wA 98124

Unitized Heater Kitlnstal lalion and Operation

Every Process Healíng Company (PHCo) product is eflicient, safe and reliable. llproperly inslalled and mainlained PHCo producls will give you rnany years oldependable service. Should your healer be damaged when received, lile a claimwith lhe carrier immedialely.

WARNING!III!I! DANGER!!!!I!I

1. Read and undersland all lags and inslallation and

operaling instructions before commencing.

2. Welding arêa on tank should be thoroughly cleaned

3. Work area should be well venlilated.

4. Check that the electrical service will handle llre load

Unil must be adequately grounded.

5. All wiring should confornr lo requirenlents ol national anrJ

local electrical codes and or standards.

Only a licensed electrician should connecl pow€r to

partol and syslem.

6. Never expose heater tubes to air wilh power on. DANGER

OF EXPLOSION MAY EXIST.

7. Ca¡s should be used when working around lubes wherl

cleaning or installing. Walls are only 1/4" lhick.

B. lf there are any questions concerning lhe ralings

or instruclions please conlacl your dislributor or lhe

faclory. Phone (206) 682-3414 Fax (206) 682-1582

101'p1

These instructions cannot possibly cover €very

situation concerning the operation, inspeclion

adjustment and lest ol the equipment lurnished.

Process Heating Company (PHCo), in the lurnishing

ol this equipmenl and these instructions, must prosume

that the operating and mainlenance psrsonnel using this

equipmenl have sutficient technical knowledge and

experience to apply sound safety and operational

practices which may not be mentioned.

2. ln applications where PHCo lurnished equipment is to

be lntegrated with a process or olher equipment,

these instruclions should be lhoroughly reviewed to

determine lhe proper integration of the equipment

into the overall plant or system operational

procedures.

3. PHCo does not supply, recommend, or approve the various

syslems in which its products are or may be used.

Unless designed, manufaclured, and used properly,

various syslems may be inherenlly unsafe or dangerous.

The user should check and comply with all federal,

stale and local regulalions and other regulalions and

recommendalions such as: NFPA, UL, APl, OSHA, etc.

I

UI,IITIZED HEATER KIT-INSTALLATON & OPERATON

Preparatlon

1. Remove jacketing and insulation from section of tankheater is to be installed ihrough.

2. Mark location of opening of tank. Heater should be keptas low as possible in lank.

CAUTON!BEFORE BURNING OR WELDING ON TANK CLEAN THOROUGHLYAND KEEP WELL VENTILATED

lnstallatlon

1. Burn opening in lank slightly larger than heaterterminal box (snug fit). Fìemove slag and grind opening

smoolh.

2. Remove blocking and slide heater through opening in

lank. Stop at marked ,Weld line" on heater lerminalbox.

3. Heater tube support plales should be aflached to lankbottom. Level heater tubes and weld supports to lank.DO NOT weld heater tub€s to support plates.

4. Weld heater lerminal box to tank. Terminal box is 1/4"thick steel plate. Weld must be liquid tighl.

5. Tank discharge should be kept 2"lo 3" above healerlubes. Never €xpose heater lubes lo air with power on.

DANGER OF EXPLOSION MAY EXIST.

6. Re-install insulatíon and jacketíng around heaterterminal box.

7. Have licensed eleclrician conn€ct prop€r vohage andphase with properly sized conductors to main powerswilch. Unit must be adequately grounded. Check allelectrical connection for lighlness.

101-p3

r"ì'ari

10t-p2

Operatlon

1. Fill tank with desired malerial. Turn on power al main

switch.

2. Sel main índicating lemperature control lo proper tank

holding temp€rature.

3. Set Hi-Limil control 20lo 30 degrees above main conlrol

set poinl. Hi-Limit will act only in event of main

control lailure. Heatsr will continue to cycle at

Hi-Limit set point and red light on panel door will

indicate "Hi-Limit" condilion. Press light to resel

when condition is remedied.

4. lf unit is equipped with a time clod<, see instruction

sheet lor proper clock setling.

5. Heater operation is now complelely automatic. Check

electrical con nectíons periodically lor tightness.

Keep panel door closed tightly at all times.

6. Clean tank at iegular intervals. Heater tubes are 114'

thick steel pipe. Use care wilh jack hammers and chisels so as not lo rupture

tube wall.

.r... NOtg.

r.lrTerminalblock if provided is to ínter-lockheat "off'while olher loads are running.

(Remove jumper and conneci to terminals 11 & #2.1

CONTROL PANEL

ALL WIRING SHOULD CONFORTú TO REOUIREMENTS OF APPLþCABLE NATIONAL AND LOCAL ELECTRICAL CODES AND ORSTANDARDS,

Rating and voltage of the unh will be found on the name plate located onthe inside of door in the control panel, and conduit enclosed insulatedconductors of the proper gauge should be brought from the main circuitbreaker or fused disconnecl switch.

The controlling thermostat can be pre-set lo any desired temperaturewithin the thermostat dial range.

ll the control panel has been equipped with a time clock please refer to theseparale inslructions enclosed lor proper clock setting.

Your unit has also been equipped with an over-temperalure thermoslatthat should be set 20 - 30 degrees above main lemperalure control. ltsprimary function is to protect against over heating in lhe event ol maintemp€rature conlrol malfunction. The unit will cycle at lhis new tempera-ture and a red Hi-Limit warning light, on lhe outside of the control panel willlight. This light will remain on until the limit circuit is reset to alert person-nel that there is a malluncîion.

The cause of the malfunction should be investigated at once. Possibleteasons are:

1. Capillary rupture on the main lemperature conlroller

(indicated by temperature indicating pointer at far

left hand position).

2. "Over Ranging" of the main lemperature controller

(indicated by incorrect lemperature reading on the

scale).

3. Thermostat tsmperature setting is too high

4. Main lemperature controller out of calibration.

5. Over-Temperature lhermostat out of calibralion.

6. Heater magnetic conlactor locked ín closed position

because ol "welded" conlacts or mechanical bind.I01-p5

ïII

I

I

I

101-p4

Í,*)

DATE DESCRIPTION OF MAINTENANCE INITIALS

For Untrtlzed Haatars

Mainlenance checklist

1. Check electrical connections for tþhtness.

2. Tank should be cleaned ât regular intêrvals.

3. Check to be sure tþe control panel door is

tighlly c'losed at alltimes.

4. Be sure lo see that tank has adequate

insulation. lnsulation lends lo break down

in timE thus costíng dollars in lost

eflieiency

I:lI

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4¿r1r\'l¡.'r¡i'

10.1971O1-p6

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JÊN-øa-9aTHU1ø:.4aPRocESsHEÈrINl-cUf.lPÈN.rzuÞoìJzL3,dz

1 - Temperature Control1 - Hi Limit Control-Tenk heat1 - Low Limit Control1 - Heat Trace TemP Control1 - Heat Trace ThermocouPle1 . Hâet Traca/GFCI Trensformer1 - Contaclor-Heet traca1 - Heat Trecs Fues Block2 - Heat Trace Fuse1 - GFC¡ ReceptecJe1 - Control Relay1 - Disconnect1 - Contector-Tãnk heât1 - Contactor-Tanf< heat1 - Cont¡ol Trarsformer2 - Transformer Primary Fuse1 -Transformer Secondary Fusef - Resêt Llght1 - Light-Low LevelI - Light-Heat On1 - Push Button-Fonverd1 - Push Button-Reverse1 - Push Button-Stop3 - Tenk Heel Fuse Elocks9 - Tank Heat Load Fusa9 - Heatlng Elements'1 - sHP Reversing Motor Starterf - 5HP OvatloadI - 7.5HP Molor Starter1 -7.5HP Overload1 - Timê Clock1 - Enclosure

@ process Heatittg Company, Inc.p.o. Box 845Ê5 . Seãtgé, waahlngæn gg124-öSg5 ',Phons: (2OS) 6S2€/t14' Fax: (2OS) 682'1582

r * * t I I I a I t ¡ . . I r I ' '

I I '

t I I I I t ' ' '

¡ t'¡ I I I t ¡ t ¡ I t I t À | I t t i ' '

I ¡ I { '

r I t I t I r I t I I I '

i I I I t I ' ' ¡

List of part #s used on tho 2ekW 24AU 3Ph heat kit

Our Model# for this heater kit is U-2892724-23DescrÍPtion Perüt

Fenv/all 400, 0o-500"UE E55S.E23BCUE E55S€228CZytron - 12O-7 -Z\ 52'056Type J - 10'TFESouare "D" - 9740-251FSduare"D" 8910 DPA12Bussman 11250-30Bussman NON-104Leviton - 125V,6O1{¿204RH2B.12OVACc/H cc 3150Souare ''D" 8910 DPA¿3Sduare'D" 8910 DPA53Square "O" - TF100O1Bussrnsn FNQ*. 1.54Bussman FNt'/t, 1ATefemecanique ZB2-BWO62Telemecanlqua ZB28V06Te lemecanique ZB2-8V03TelemeceniqueZÊ2-BA2Tefsmecanlque ZB2-BA5Telemecanique ZB2-BL4Eussman H250^3OBussman NON-304PHCo R€.19272¿'-3Square "Ð" LC2D1801G6Square "Dn G\r2-Àr20Square "D" LC102510G6Sqtrare nD" G\f2-Nff2Tork E100Electromate E3613008

NOTES

Post.it'Fax Note 7671>¿Date

Co,co./D€ot.

nPhone Ë

@A Process Heatitg ComPanY, Inc-p.O. Bor 84SBS . Seatde, Waghlngton 98124.5S85 ' Phone: {206ì 6S2'3414' Far: (206) 682-1t82

rrrlti{ttt^ttttlltlaaalt"lr'rllt¡llltll¡l'lrltttl"'lll¡¡littttttlrll¡ttltr'ti¡

List sf part #s used on the 28kW 48OV 3Ph heat kit:

Oqr Model # for this høater ldt is U'269274a-2-3Dêscnptiôn Pert#

1 - Temperature Control1 - Hi Limit Conrol-Tank hêet1 - Low Limit ControlI - Heat Trace Temp Control1 - Heât Traee Thermocouple1 - Heat Trace/GFClTraneformer1 - Contactor-Heat trace1 - Heat Tracg Fuse Block2 - Heat Trace Fuse1 - GFCI Receptacle1 - Control Re{ayI - Disconned1 - Conbctnr-Tank heat1 - Contactor-Tank heat1 - Control fransformer2 - Transformer Pr¡mary Fuse1 - Trånsformer Secondary Fuse1 - Reset Light1 - Light.lo¡r Level1 - Light-Heat On1 - Push Button-Fonvard1 - Push Button-Reverse1 - Push Button-Stop.3 - Tank Heat Fuse Blocks9 -Tank Heat Load Fuse9 - Heeting Elements1 - 5HP Reversing Motor Sterter1 - sHP Overload1 - 7.SHP Motor Sterter1 - 7.5HP Overloed1 - Time Clock1 - Enclosure

NOIES

Fenwall400, 0"-500"UE E55S.E23BCuE E55S-F"?BCZytron - 12A-7-2152456TypeJ-1dTFESquara'Ð" - 9740-231FSquare'Ð" 8910 DPA12Bussman H250-30Bussman NON-104Leviton - 1 25V,60H2,204RH2B.12OVACCfH EHD3OSOSquare "D" 8910 DPA13Square "D" 8910 DPA'2SSquana "D'' - TF10OO1Bussman FNQ-R. .84Bussman FNM, 1ATelemecanique ZB2-8WO62Talemeeanique ZB2-8V06Teternecsnique ZB2-8V03TelemecaníqueZB2-BI.2Telemecanlque ZB2-BA5Telemecanique 282-8L4Bussman Bþ1603POBussman ICIK-154PHCo R3.192748-3Square "D" LC2D1801G6Square "D" GV2+t14Square nD" LC1D251OGGSquare uDn GV2-M16Tork E100Electromale 836L3008

e f 12ta9_

S I lJllnG[: TnHl(

CUI IIULE IH TNh{I( AS LÛT4 ÊS T}ÛSSIBLE

I,TELD SUPPÜRTS TOì'nHH tsoTTUl.l

t-rELD llIn-l Eß TU't'nHt( ilEnt)

APPENDIX IV

Process Heating Co. Warranty

ÍNc yeilt \f,/arron

Productslìilanufactured by

Process Heating ComPanYPHGo

and detivered to the initial user are subject to the following limited warranty:pHCo warrants lts Palrr:,ied Heating Elements to be free from defects in workmanship

and materials for a period of flve (5) years (one [1] year for drop-in-style) after the date-

of delivery to the initial user when operated under normal use and service and in

accorclance with prlnted lnstructions provided by PHGo. All other parts andcomponents provided by PHCo as part of the unit are wärranted to be free from

defects in material and workmanshlp for a period of one (1) year from date,of delivery

to the inltial user.

THE ABOVE WARRANTY IS SUBJECT TO THE TERMS ANDCONDITIONS ON THE REVERSE SIDE OF THIS DOCUMENT.

Unless olherwise agreed in wriling by Process Healing Company ("PHCo"), all of the following lerms and conditions shall apply lo ils transaction with you (the"buye/'):

1. LIMITED WARRANTY: DISCLAIMERS. PHCo waranls that the goods sold under this contract shall be lree lrom delects ln worknranship and materialsal the lime delivery is lendered. ll lhere is discovered any lailure of goods to ccrnlorm lo lhis limiled warranty wilhin one (1) tear after tender ol delivery (live(5) years in lhe case ol immersion type heating elemenls olher than drop-in style elemenls), and il Buyer notilies PHCo in wriling ol such facl wilhin lhirty (30)days following such discovery, PHCo at ils own expense eilher will repair the defeclive item, or replace it, or refund to Buyer lhe purchase price paid for thatitem (with lhe choice between repair, replacemenl or refund to be made solely by PHCo). The foregoing limited waranty and remedy are exclusive ol allolher warranlies, express or implied, and constitule PHCo's exclusive liability, ahd Buyels exclusive remedy, on accounl of any claim relating lo any ilemsold. PHCo DISCLAIMS ANY WARRANTY OF MERCHANTABILITY oH FINESS FOR ANY PARTICULAR PURPOSE. lf PHCo should elect to repair orreplace a delective item and if for any reason lhe repair ol replacement should lail in its essential purpose (which is to provide Buyer with a non-delectiveilem), then PHCo's liabilily neverlheless shall be limited to lhe purchase price charged by PHCo lor the goods. Pl'lCo shall have no llability on accounl of anyclaim asserled under r:rrrrciples of negligence or olher torl, breach of any stalutory duty, indemnity or contribution, or on any olher basis, if PHCo's liability onaccounl ol such claim would exceed or in any respect differ f rom its lialrililt' under lhe forgoing limited warranty and exclusive remedy.

2. LIABILITY OF PHCo UNDER THE FOREGOING LIMITED WARRANTY SHALL EXIST ONLY lF:a. The goods are ¡nstalled, operaled and lested in accordance wilh the PHCo approved installation and operalii,r,Inslnlclion,b. The goorls are used and mainlained in conlormily with inslallation and operallon instruclions approved or published by PHCo.c. Wrilten aulhorizalion musl be given by PHCo belore any wananty work is done.The above limited warranty shall be void and no lurther in effecl ¡l lhe goods are subject lo abuse, strain, impacl or loading lhat is grealer than their normal

3. LIMITATION OF LIABILITY. UNDER NO CIRCUMSTANCES SHALL PHCo OR ANYONE ELSE INVOLVEn lN THE MANUFACTURE oR SALE OF TIJE

GOODS BE LIAELE TO BUYER OR OTHERS FOR ANY SPECIAL, INCIDENTAL OR CONSEOUENTIAL DAMAGES, INCLUDING BUT NOT LIMITED TOLOST PROFITS, EVEN IF PHCo HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES, OR FOR ANY DAMAGES OR SUMS PAID BYBUYER OR OTHER TO THIRD PARTIES. THE FOREGOÍNG LIMITATION OF LIABILITY SHALL APPLY I'J!IETHER ANY CLAIM FOR ANY SUCH DAM-AGES IS BASED UPON PHINCIPLES Of- TjIJNTRACT, WARHANTY, NEGLIGENCE OR OTHER TORT, BREACH OF ANY STATUTORY DUTY. PRIN-CIPLES OF INDEMNITY OR CONTRIBUI ION, THE FAILUBE OF ANY LIMITED OR EXCLUSIVÍI NEMEDY TO ACHIEVE ITS ESSENTIAL PURPOSE, ORANY.OTHER BASIS.

4. AUTHORITY OF PHCo'S AGENTS. No aq ,rrt, employee or represenlative ol PHCo has any aulhority lo t¡ind PHCo to any other affirmalion, represcnla-lion, promise or warranly concerning the goods sold under lhis contract, unless it is in wrillllg and included as part of lhe lerms of lhis a contract.

5. MODIFICATION OF WAIVER. No subsequenl waiver or modificalion ol lhis Limited Warranty and Liability shall be etleclive unless lhe same is in writingand signed by lhe party againsl whom such waiver or modification ls asserled. No waiver in any one instance shall conslÍtule a wsi\, e¡ r¡l lhe same or anyother lerm or condilion on any subsequenl occasion. None ol lhe express lelntii ,:l lhis Limiled Wananty and Liabilily may be waived or varied by course oldeallng or usage of trade.

I,6. DISPUTES. Thls agreement shall be govemed by lhe laws ol ltrr, Slale of Washingrton wilhout telerenceto lts choice ol law rules. Any aclion lo enforceany ol lhe lerms or condilions ol lhis agreement may be commenced or mainlained at lhe option of eilher party ln any lederal or slate courl localed ín KíngCounty, Washíngton havlng jurisdiclion over lhe matler, and bolh paf íes conssnl ln advance to the exerc¡se by such coutts ol jurisdictlon over lhem person-ally. No action by either parly arising oul of or relating to lhis conlracl (including any aclion based upon principles of contracl, lort or olherwíse) may becommenced more lhan one (1) year alter lhe cause of aclion has accrued, and any aclion commenced by a parfy lhereafler shall be dismissed at lhe in-slance of lhe olher parly.

APPEI{DIX V

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