Watlow ELECTRIC MANUFACTURING COMPANY

Allgemeine Erklärung

Der Zweck dieses Produkthandbuchs („Handbuch“) ist für Watlow Electric Manufacturing Company („Watlow“), Ihnen bestimmte Empfehlungen, Ratschläge und Anforderungen bezüglich Ihres Kaufs und der Verwendung der/des unten beschriebenen Produkts/Produkte („Produkt“) zu vermitteln. Dieses Handbuch soll keine erschöpfende Liste von Empfehlungen, Ratschlägen oder Erfordernissen für den Gebrauch der Produkte sein. Wenn Sie zusätzliche Informationen über die Produkte von Watlow wünschen, besuchen Sie bitte die Website von Watlow (http://www.watlow.com) oder wenden Sie sich an den Kundenservice von Watlow (1-800-WATLOW2). Um den richtigen Gebrauch des Produkts sicherzustellen, sollte jeder Nutzer der Produkte dieses Handbuch sorgfältig lesen. FALLS DIE HIERIN ENTHALTENEN INFORMATIONEN NICHT BEFOLGT WERDEN, ÜBERNIMMT DER NUTZER DAS GESAMTE RISIKO UND DIE HAFTUNG FÜR EINE SOLCHE UNTERLASSUNG.

Inhaltsverzeichnis

• Allgemeine Erklärung 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**Allgemeine Erklärung** This section provides an overview of the manual's purpose, which is to offer recommendations, advice, and requirements for the use of Watlow products. It emphasizes that the manual is not exhaustive and directs users to the Watlow website or customer service for additional information. It also stresses the importance of reading the manual carefully to ensure proper product usage and that the user assumes all risk and liability for any omissions. * **Produktbeschreibung** This section describes the MULTICELL™ Heaters, designed for a wide range of heating applications requiring high temperature performance, independent zone control, and interference fit. It notes that these heaters are primarily designed for main power supply and operate at 50 or 60 Hz, with optional DC operation. It highlights the importance of calculating operating current for proper wire sizing and component selection. It also mentions that a nominal temperature range is not provided as the heater is a component within the user's system. * **Sicherheitsangaben** This section details the safety labels used in the manual: GEFAHR (Danger), WARNUNG (Warning), and WARNUNG – Stromschlaggefahr (Warning – Electric Shock Hazard). Each label is explained with its associated meaning and the potential consequences of not adhering to the warnings. * **Sicherheit (allgemein)** This section outlines general safety requirements and recommendations for product use. It includes warnings about ensuring the installer uses appropriate Personal Protective Equipment (PPE) and that the device should not be used by individuals with impaired sensory or mental capabilities, or lack of experience, unless supervised. * **WARNUNG – Stromschlaggefahr** This section provides a warning about electrical hazards associated with the heaters. It advises users to read the document thoroughly before installation and wiring, and to understand all points. It also mentions that the component operates hot and users should assess their own risk regarding contact with hot surfaces. It also notes that additional lifting equipment may be necessary due to the weight of some heaters. * **WARNUNG – Stromschlaggefahr** This section reiterates the warning about electric shock hazards, stating that installation and maintenance must be performed by a qualified electrician in accordance with national and local safety standards. It also emphasizes not to interrupt the protective conductor/grounding, as this can create a hazardous situation. * **ACHTUNG** This section provides a caution regarding the product's compliance with the EMC Directive. It recommends that users ensure their equipment complies with all European directives, including the EMC Directive, if the equipment into which the heater is installed falls under its scope. * **WARNUNG** This section states that it is the user's responsibility to ensure the heater is correctly selected and installed for the intended application. It warns that using the heater in an application for which it was not designed could lead to equipment damage or personal injury. It provides an example of a immersion heater being unsuitable for heating gases due to its high power density. It also emphasizes that heater components must be connected according to the manufacturer's installation instructions and used only in suitable applications. * **Typische Anwendungen** This section lists typical applications for the MULTICELL™ Heaters:
  • Isothermische Warmformgebung
  • Bodensanierung
  • Warmschmiedegesenke
  • Beheizte Platten
  • Superplastisches Formen (SPF)
  • Beheizte Platten (einzelne und mehrere Zonen)
  • Warmbehandlungsprozesse
  • Superplastisches Formen mit Diffusionsschweißen
  * **ACHTUNG** This section advises users to ensure that the temperature of the element's end seal remains within its temperature class. * **WARNUNG** This section warns users to prevent live conductors from coming into contact with liquids or people. It also states that original enclosures, covers, sensors, and user controls must be used correctly for safe operation and that the product is not designed for hazardous locations. * **Vor der Installation** This section provides general safety instructions and requirements for preparing the product for installation. It advises users to inspect the product for damage incurred during shipping, storage, or handling, and to contact their Watlow representative if they have any concerns. It also emphasizes confirming that the correct heater has been ordered and will be used. * **ACHTUNG** This section cautions that elements may come into contact during shipping and minor adjustments may be needed. It warns against bending elements excessively, as this can affect dielectric strength. It also notes that dielectric testing may be required due to weather or humidity conditions, referring to the Megohmmeter test in the installation section. * **Installation** This section states that proper selection and installation of the heater will ensure efficiency, safety, and longevity. It provides instructions and requirements for installation and reiterates the warning about the installer using appropriate PPE. * **(Megohmmeter-) Vorprüfung des Isolationswiderstandes** This section details the megohmmeter test for checking insulation resistance. It warns that the described procedures should only be performed by properly trained personnel, and if electrical current is involved, by a qualified electrician. It explains that plastic packaging should only be removed when the product is ready for installation and use. It describes how to perform the RISO test using a 500 VDC megohmmeter to measure insulation resistance between the connection and the casing, with a minimum acceptable value of 50 Megohms at room temperature. It also provides options for drying the elements if the RISO value is low, with specific temperature and time limits to avoid damaging the connections. * **Schutz der Heizelemente vor Übertemperatur** This section strongly recommends using automatic temperature controllers for regulating the heating process and protecting the heater from over-temperature. It specifies that high-temperature limiters must have appropriate independent approval and be used within their rated classification. It also suggests that high-temperature limiters with temperature feedback and relays, independent of the heater's control system, can be used to automatically interrupt the circuit when temperatures become too high. * **Page 9** This page discusses the heat transfer mechanism of the Multicell heater, which is primarily through radiation. It suggests that heat transfer can be improved by oxidizing the plate installation holes before operating the heaters at temperatures above 538 °C (1000 °F). It recommends using temperature controllers and thyristor power controllers for optimal performance and longevity, advising against the use of on/off electromechanical controllers for process temperatures above 982 °C (1800 °F). It provides guidelines for controlling temperature rise rates for high-temperature applications, including initial heat-up, production idle, and cool-down rates. It also discusses the importance of maintaining a minimum idle temperature to prevent moisture absorption and the need to re-test insulation resistance after any maintenance that involves cooling the system. * **Page 10** This page continues the discussion on temperature control and rise rates. It provides specific recommended rise and soak times for different temperature points. It also includes a warning that it is the user's responsibility to ensure the safety of the installation and that the heating system operates as intended. It advises installing a high-temperature safety limit in systems where an over-temperature fault could cause fire hazards or other risks. It also notes that some heaters are equipped with thermocouples or thermostats, but the user is responsible for their proper use in the control or protection circuit. A caution is given regarding component failure in a temperature control loop, which could lead to product damage, melting, or fire. It recommends regular functional tests of all temperature limiters to mitigate this risk and advises against using piston and capillary thermostats due to their slow response time. * **Page 11** This page provides a caution regarding the alignment of the heater, emphasizing its importance for intended heat transfer and safe operation. It advises consulting design documentation for correct alignment and checking for any alignment markings. It also stresses the importance of ensuring sufficient space for heater expansion without compromising heat transfer. Another caution is given to ensure all mounting parts are securely tightened. * **Page 12** This section covers electrical enclosures and protection of electrical connections. It warns that if an enclosure is provided, the user is responsible for determining the correct type of electrical or connection enclosure based on national or local safety standards. It highlights that failure to use a suitable enclosure could damage the heater and endanger personnel. It also states that any enclosure openings must be properly sealed to maintain the environmental rating. The section also advises keeping connection enclosures below 93 °C (200 °F) unless otherwise specified and discusses standard enclosures (NEMA Type 1 / IP20) for non-hazardous environments, as well as enclosures for wet conditions. It also advises positioning enclosures to minimize the risk of impact from falling or moving objects and protecting connections from moisture or vapor. * **Ausrichtung und Montage** This section provides a warning to avoid incorrect handling and installation of individual parts, such as lifting the heater by its lead wires or contacting the fiberglass insulation. * **Page 13** This page reiterates the importance of proper heater alignment for heat transfer and safe operation, advising consultation of design documentation and checking for alignment markings. It also emphasizes providing adequate space for heater expansion and ensuring all mounting parts are securely tightened. A warning is issued regarding the high temperatures generated by electric heaters, stressing the need for safe placement to minimize fire hazards and keeping flammable materials away from the product. It also states that the product is not suitable for hazardous locations. * **Verdrahtung** This section provides a warning that the user must ensure the installer uses appropriate PPE. It also warns that installation and wiring must be done by a qualified electrician according to safety standards. It advises that for heaters without insulated lead wires, users must ensure exposed conductive surfaces are covered with insulating material. * **Page 14** This page continues the discussion on wiring. It reiterates the warning about using qualified electricians and appropriate PPE. It also advises on covering exposed conductive surfaces with insulating materials like heat-shrink tubing or ceramic beads. * **Page 15** This page contains warnings about electric shock hazards. It reiterates the importance of not interrupting the protective conductor/grounding. It also explains that electric heaters can be a source of stray currents and that a ground fault is a common failure mode. It recommends installing a residual current device (RCD) to protect against electrical leakage and ensure safe operation. It also emphasizes the user's responsibility to properly size and ensure the grounding conductor's impedance is low enough for safety. * **Page 16** This page provides warnings regarding the proper sizing and installation of supply lines for the heater, based on current, electrical rating, ambient temperature, and environmental conditions. It specifies that supply lines should be routed in rigid or flexible conduits that match the electrical enclosure's classification. It also reiterates the need to cover exposed conductive surfaces with insulating material for heaters without insulated lead wires. It provides torque specifications for terminal connections and advises on ensuring proper bend radii for conductors to prevent damage. It also mentions that the heater can operate over 2,000 meters without frequency adjustment and that products with non-metallic components are intended for indoor or shaded outdoor use. It lists various connection options and notes that a green grounding connection is available in enclosed units for easy identification. * **Page 17** This page contains warnings about electric shock hazards. It states that the applied voltage must be equal to or less than the rated voltage specified on the heater's nameplate. It also advises that for voltage-switchable units, users must check the provided wiring diagram to ensure correct wiring for the available line voltage. It further warns that supplied thermostats are for pre-control only and that users should consult the wiring diagram for permissible thermostat wiring. It strongly recommends using a disconnect switch or circuit breaker for maintenance to isolate the heater. * **Inbetriebnahme** This section provides instructions and requirements for the initial startup of the product. It lists several points to check with the power supply turned off, including tightening of electrical connections, securing mounting parts, proper installation of disconnect devices and fuses, correct voltage, equal phase-to-phase voltage, acceptable megohm values, installation of temperature controllers and safety limiters, proper grounding, correct gas flow for in-line heaters, and proper installation into plate holes. It also includes a warning to ensure the system is regulated correctly before leaving it unattended after restart, as failure to do so could lead to overheating, equipment damage, fire, or personal injury. * **Fehlerbehebung** This section provides information on possible causes and solutions for functional problems with the product. It states that this is not an exhaustive list and advises contacting the Watlow representative for any questions regarding product performance. It also includes a warning that troubleshooting should only be performed by qualified personnel due to high voltages when the heater is in operation, and that users are responsible for ensuring appropriate PPE is used. * **Page 20** This page presents a troubleshooting table with problems, causes, and solutions. Problems include no voltage at the heater, blown fuses, insufficient power, and shutdown/alarm at the upper limit. Causes and solutions involve checking switches, fuses, heater resistance, connections, condensation, line voltage, current, gas flow, and kW output. * **Vorbeugende Instandhaltungsmaßnahmen** This section provides warnings about preventive maintenance. It reiterates the need for the installer to use appropriate PPE. It warns about potential burns when removing or replacing heaters above room temperature and advises wearing suitable heat-protective clothing for SPF press operations. It also reiterates that preventive maintenance on a live heater should only be performed by qualified personnel and that all power to the heater must be shut off and locked out before commencing. It also warns that the heater and system may remain hot after power is shut off and that the equipment should be allowed to cool before maintenance. * **Page 22** This page discusses how thermal cycling, corrosion, and vibration can degrade the heating system and electrical interfaces. It advises following the system designer's guidelines for periodic checks of the installed heater and electrical connections. It recommends regularly checking line connections (every 6 months) to ensure they are tight and free of oxidation, and re-tightening them if necessary. It also advises inspecting enclosures for rust, dirt, or dust, cleaning them, and checking the condition of the sealing gasket if the enclosure is moisture-tight. It also notes that thermal cycling can loosen sealed connections and cause leaks, recommending inspection and tightening of related connections or replacement of seals as needed. * **Ersatzteile** This section advises users to contact Watlow representatives directly for spare or replacement parts. It provides the Watlow website (http://www.watlow.com) as a resource for locating distributors. It also instructs users to provide the part number found on the product's marking, nameplate, or label when ordering. * **Entsorgung und Recycling** This section states that heaters are classified as electrical components according to RoHS and WEEE directives and must be recycled accordingly, following national end-user regulations. * **Allgemeine Geschäftsbedingungen und Rücksendung von Produkten** This section outlines Watlow's general terms and conditions for purchase and use of products, including warranty obligations and payment terms. It advises customers to contact Watlow customer service for a Return Material Authorization (RMA) number before returning any product for repair or replacement. It lists the information required for processing returns, such as customer name, part number, quantity, reason for return, and contact information. It also specifies that unused products returned for credit require prior approval and an RMA number, and that all returns must be shipped freight-free. It also details conditions for returning stocked items, including restocking fees for modified items and a requirement for a date code no older than 2 years.
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