HHS-WWH HOPPER HEATING SYSTEM WRAP-WOUND HEATER INSTALLATION INSTRUCTIONS HHS-WWH PRODUCT SPECIfICATIONS Power density Standard wattages up to 4650 W/m² (3.0 W/in²) Voltage range (nominal) 120 to 600 VAC Maximum exposure 760ºC (1400ºF) temperature Maximum maintain 500 C (932 F) temperature (power on) Minimum installation 20ºC ( 4ºF) temperature Typical heater set point 120-150ºC (248-300ºF) Dielectric strength Up to 2,200 VAC Power leads* 5.0m (16 ft.) long, moisture resistant, high-temperature stainless steel overbraid with a standard heater ground wire * Lead wire length can be customized to align with the project design requirements. DESCRIPTION The Raychem Hopper Heating System Wrap-Wound Heater (HHS-WWH) is designed for the poke tube and throat portions of Electrostatic Precipitator (ESP) hoppers, baghouse hoppers and material / dust-collector hoppers and is intended to complement the HHS heater modules. It is highly recommended for all HHS-WWH heaters to be used in conjunction with a temperature control device. These instructions describe the procedure for installation, storage and handling of HHS-WWH heaters. Carefully follow all directions. For technical assistance, contact Pentair Industrial Heat Tracing Solutions at PTMinfome@pentair.com ADDITIONAL / OPTIONAL MATERIALS REQUIRED Cleaning / prep supplies Wire ties Junction box Temperature controller and sensor Insulating materials LIMITED WARRANTY Pentair offers 1 year limited standard warranty for the Raychem HHS-WWH. Safety Alert symbol The symbol above is used to call your attention to instructions concerning your personal safety. It points out important safety precautions. It means ATTENTION! Become Alert! Your Personal Safety is involved! Read the message that follows and be alert to the possibility of personal injury. WARNING: Read and understand this entire manual before operating or servicing these heaters. Failure to understand how to safely operate these heaters could result in an accident causing serious injury or death. These heaters should only be operated by qualified personnel and any individual who has not read and understood all installation instructions is not qualified to install this product. Additional copies of this manual are available upon request. WARNING: The HHS-WWH heater must be installed correctly to ensure proper operation and to prevent shock or fire. Read these important warnings and carefully follow all the installation instructions. All electrical wiring must follow local electrical codes. Ground fault equipment protection must be used on each heater branch circuit to minimize the danger of fire if the heater is damaged or improperly installed and to comply with Pentair design requirements, agency certifications and national electrical codes. Damaged heaters and connections must be replaced. Do not attempt to repair or energize if damaged. Only qualified personnel are allowed to connect electrical wiring. Disconnect all supply power at the source before making any power connections. It is highly recommended to never operate heaters without a temperature control device. The end-user is responsible for providing a suitable disconnecting device. The end-user is responsible for providing a suitable electrical protection device. Final installation / wiring is to be inspected by the authority who has jurisdiction in the area that the heater is installed. Approvals and performance are based on the use of specified parts only. Do not use vinyl electrical tape or substitute parts. Read and understand this entire manual before operating this electric heater. Leave these installation instructions with the user for future reference. Failure to observe these warnings may result in personal injury or damage to the heater. CAUTION: Never handle the heater while it is in operation; always disconnect the heater from the power source and allow for proper cooling prior to handling. Inspect heater before use and do not use a heater with torn or worn surfaces. If spillage of foreign matter onto the heater occurs, disconnect from the power source and clean after the heater is allowed to cool. Never operate a heater without an appropriate heat sink. (Device being heated is considered a heat sink). Do not operate the heater above the rated temperature value. Fasten the heater to the heated surface using approved methods only. Do not repair damaged or faulty heaters. Do not crush or apply severe physical stress on the heater or lead wire assembly. Avoid hazards or unsafe practices which could result in personal injury or property damage. 1 / 6
DANGER: Do not immerse the heater in liquid. Keep volatile or combustible materials away from the heater when in use. Use the heater only in approved locations. Keep sharp metal objects away from the heater. Failure to observe these warnings may result in electric shock, risk of fire, and personal injury. HHS-WWH STORAgE 1. Keep each heater in its original packaging until you are ready to install it. 2. Store the box in a cool, dry environment. 3. Avoid stacking heavy objects on the box, which could damage the HHS-WWH heater. 4. If any heaters are exposed to moisture, please contact Pentair technical support. HHS-WWH Handling IMPORTANT: This heater is an electrical device. Handle it with the same care you would use with any electrical device and carefully follow these instructions. Do not install any damaged heaters. If a heater is damaged, replace the complete heating module and cold leads. 1. All HHS-WWH heaters are usually packaged with each respective hopper. Utilize the layout drawings to match and position each respective heater to the correct hopper. 2. To avoid mechanical damage do not lay the heater where it can be stepped on or struck by tools or equipment. Hopper Surface Preparation 1. Inspect the hopper surface. To provide maximum heat transfer efficiency, verify the installation area is free of: Sharp edges or protrusions (weld splatter, rough seams, etc.) Rust and corrosion Grease and oil Obstructions, such as instrument lines, electrical wiring or conduit, hopper support, or reinforcements 2. The heater surface should be clean prior to installing the heaters. 3. Check that the desired placement of the heater will not cause damage to the heater through impact shock or by neighboring moving parts. Heater Preparation 1. Check for suspected damage to the HHS-WWH heater prior to installation and document any identified damages for settlement with the delivery service. Do not install the heater if it is damaged. 2. Verify that all parts are received against the packing list. 3. Confirm voltage / wattage rating of the heater is appropriate for the power supply device or temperature controller as the heater is designed to work at a specific voltage to heat properly. For additional information, contact Pentair. 4. Confirm that the heater maximum exposure temperature rating is suitable for the environment. The temperature of the internal heating element may run up to 25% higher than the external surface of the outer sheath. 5. HHS-WWH exposure temperature range: 20ºC to 760ºC ( 4ºF to 1400ºF) HHS-WWH maximum continuous exposure / maintenance temperature: 500ºC (932ºF) HHS-WWH maximum intermittent exposure temperature (power off): 760ºC (1400ºF) 2 / 6
Heater Installation Ensure the hopper surface is clean before securing the HHS- WWH to the hopper. The flexible heater can be installed on both a flat and/or curved surface. For a flat surface, lay the heater onto the surface to be heated. For a curved surface, wrap the heater onto the surface to be heated. The length of one entire side of the heater must be in full contact with the surface. Ensure the heater is not kinked or twisted; or that any portion of the heater is hanging free from the surface. Do not overlap the HHS-WWH heater on itself. Attach the heater to the surface by using the mechanical wire ties, as supplied in the standard HHS-WWH bill-of-materials. Ensure that the attachment method does not cause damage to the heater. IMPORTANT: The HHS-WWH heater must be installed with good contact to the hopper surface. Inadequate contact may result in lower heater efficiency. It is highly recommended to connect the HHS-WWH heater to an external temperature control device, and it is not recommended to turn on the heater without a temperature controller. During installation, heaters should not be left exposed to rain, snow or moisture. It is recommended to perform a heating system inspection and the necessary electrical tests before thermally insulating the heaters. IMPORTANT: Reference H59848 for the separate Hopper Heating System (HHS) installation instructions. Connecting to a Power Source The heater must be connected to an external control device and should be operated with some form of temperature control. 1. Install and connect the primary temperature control device as shown in the installation instructions. The wiring schematics provided on the next page are for reference only. See Pentair project specific heater layout and wiring drawings for actual heater wiring. 2. De-energize all power sources before connecting heaters. The heater ground is the lead wire with green insulation. Ensure that the lead wires can reach the distance to the terminal / junction box. 3. The heater is designed to operate at a specific voltage ±10%. Refer to the label on the heater for the proper operating voltage and wattage information. Failure to operate the heater at the specified voltage could result in overheating of the heated surface, or personal injury. Also note lower-than-rated voltage will result in under-heating. 4. All electrical connections must be made by qualified personnel and in accordance with all applicable codes and regulations. Proper Personal Protective Equipment (PPE) should be utilized during installation. Component approvals and performance ratings are based on the use of Pentair specified parts only. 5. Ensure the heater is protected by a properly rated circuit breaker or fuse as specified on the design or installation drawing. 6. Two lead wires (same color) should be connected to the power source (or temperature control device) directly, through a junction box, or to a connector that is mated to a receptacle connected to the power source. HHS-WWH heaters are non-polarized, allowing either wire to be connected to the neutral or hot. The third wire (if applicable), designated by the color green (or a green stripe) should be connected to the ground wire. 7. Locate the temperature sensors exactly as per the project drawings. 3 / 6
Ground Fault Protection All HHS-WWH heater circuits are required to be protected with a ground fault circuit interrupter (GFCI). This device will minimize the risk of fire or shorting by shutting off the power to the circuit whenever a significant ground-fault current is detected. Suitable circuit breakers with ground-fault protection can be purchased through Pentair. CONNECTINg HHS-WWH HEATERS IN PARALLEL Power Supply 240VAC Power Supply 415V/230VAC L N L1 L2 N Thermostat Contactor HHS-WWH HHS-WWH CONNECTION DIAGRAM WITH THERMOSTAT CONNECTION DIAGRAM WITH CONTACTOR IMPORTANT: Ground fault protection devices, although required are not normally displayed in typical single or parallel wiring diagrams similar to those shown above. Contactors in the diagrams shown above should be controlled by a temperature control device. HHS-WWH SYSTEM CONTINUITY AND ELECTRICAL INSULATION RESISTANCE (MEggER) TESTS Continuity of each heater should be checked upon removal from packaging and again after installation. Verify that the measured resistance in ohms agrees with the value printed on the label (with a +/- 10% measured resistance tolerance at 20ºC). Electrical insulation resistance (IR) should be checked on each heater unit after installation; measure the resistance between the heater element lead wires and a nearby ground point (e.g., metal heater cladding or welded stud on the hopper wall) at 500 VDC for 1 minute. All IR values should be greater than 20 megaohms. HHS-WWH SYSTEM PERfORMANCE TESTINg This test verifies that the system is working properly. 1. When the heaters and controls are installed and connected to power, and the hopper surface is thermally insulated, turn the circuit breaker on. 2. Set the primary temperature control device temperature about 20 C higher than the maintain / ambient temperature. This action energizes the heaters. 3. Allow the heater(s) to be powered for about five minutes, then measure the voltage and current. Note these values in the maintenance log as a reference for future maintenance checks. 4. Lower the temperature control device set point to ensure that the heater shuts off. 5. Switch off. 6. Set the primary temperature control device to the desired set point. 4 / 6
HHS-WWH SYSTEM MAINTENANCE and Troubleshooting It is the responsibility of the end user to ensure that the final installation meets all local, state and federal codes and regulations. Please read this manual prior to contacting Pentair, as this manual is designed to answer the most commonly asked questions. If you are unable to identify the problem or need additional assistance, please contact Pentair Industrial Heat Tracing Solutions at PTMinfome@pentair.com. Perform a continuity test on each HHS-WWH heater at least once a year. The frequency of inspections and tests should depend on the severity of the environment and operating conditions. Where multiple heaters are connected in parallel, disconnect and individually test each heater. A performance test should also be done once a year. Check the temperature control device at that time. Things to look for include the following: Control switching at the proper temperature. Signs of corrosion around or near the lead wire connection point. Any mechanical damage to the heating element. Symptom Possible Cause Solution 1. No heat / No current A. Loss of power (voltage) A. Restore power to the heater circuit (check circuit breaker and electrical connections). Terminations, if not done properly, can cause EPD-type breakers to trip unexpectedly B. Controller set point too low B. Adjust set point C. Heater Open C. Check the resistance measurement between the two lead wires. If no reading, repair or replace the heater D. Controller failure D. Repair the sensor or controller 2. Circuit breaker tripping A. Circuit breaker underrated A. Verify rating of the circuit breaker with respect to the heater output. If breaker is underrated, replace the breaker B. Ground fault B. Check insulation resistance between power leads and the ground lead of the heater. If the value is less, replace the heater 3. Low system temperature A. Controller set point too low A. Adjust set point B. Temperature sensor located too close to the heater C. Wet insulation material and / or insulation thickness is different than designed B. Relocate sensor C. Replace insulation; increase insulation thickness (if dry) D. Low voltage (check at power connection point) D. Adjust voltage to meet design requirements 4. High system temperature A. Controller on continuously A. Adjust set point or replace sensor B. Controller failed with contacts closed B. Replace the temperature controller 5 / 6
WWW.PENTAIRTHERMAL.COM NORTH AMERICA Tel: +1.800.545.6258 Fax: +1.800.527.5703 Tel: +1.650.216.1526 Fax: +1.650.474.7711 thermal.info@pentair.com Europe, Middle East, Africa Tel: +32.16.213.511 Fax: +32.16.213.603 thermal.info@pentair.com UAE Tel: +971.4.378.1700 Fax: +971.4.378.1777 PTMinfome@pentair.com NOIDA-INDIA Tel: +91.120.464.9500 Fax: +91.120.464.9548 PTMinfome@pentair.com MUMBAI-INDIA Tel: +91.22.6775.8800/01 Fax: +91.22.6775.8997 PTMinfome@pentair.com Pentair is owned by Pentair or its global affiliates. All other trademarks are the property of their respective owners. Pentair reserves the right to change specifications without prior notice. 2017 Pentair. 6 / 6