®
Chromalox
SERVICE REFERENCE
Installation Instructions
DIVISION
4
SECTION GS, GT
SALES
REFERENCE
PD442-2
(Supersedes PD442-1)
161-562650-001
DATE
DECEMBER, 2004
Chromalox Type GS and GT Series
Over-The-Side Immersion Heaters
GSL3 or GTL3
GS or GT
GENERAL
the chemical composition of the corrosive solu-
tion, character of the materials entering the solu-
tion, and controls which he maintains on the
process. Chromalox cannot warrant any electric immersion
heater against failure by sheath corrosion if such failure is the result
of operating conditions beyond our control.
FIRE/EXPLOSION HAZARD: This heater is not
intended for use in hazardous atmospheres where
flammable vapors, gases, liquids, or other com-
bustible atmospheres are present as defined in
the National Electrical Code. Failure to comply can
result in explosion or fire.
1. Heater Construction Characteristics
A. High quality resistance wire held in place by ceramic core and
magnesium oxide in various sheath materials.
Chromalox type GS and GT over-the-side immersion heaters
are designed primarily for corrosive baths and available in a vari-
ety of sheath materials. 316 stainless steel and titanium sheets are
standard.
B. Medium and low watt densities.
C. Epoxy filled cavity to prevent entry of contaminants.
D. Over-temperature protection.
E. Flexible conduit 3’ long with 6” leadwire extension.
Sheath corrosion can result in a ground fault
which, depending upon the solution being heated,
can cause an explosion or fire
The system designer is responsible for the safety
of this equipment and should install adequate
back-up controls and safety devices with their
electric heating equipment. Where the conse-
quences of failure could result in personal injury
or property damage, back-up controls are essen-
tial.
IMPORTANT: It is the responsibility of the pur-
chaser of the heater to make the ultimate choice
of sheath material based upon his knowledge of
© 2010 Chromalox, Inc.
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OPERATION
1. Do not operate heater at voltages in excess of that stamped on the
3. Sludge should not be allowed to build-up to the point where it
contacts heater, as this can lead to premature heater failure.
Sludge legs are standard on L-shaped heaters. Heater must not be
operated in sludge.
heater since excess voltage will shorten heater life.
2. Always maintain a minimum of 2” of solution above the heated
portion of the element to prevent exposure of the effective heated
length. If the heater is not properly submerged, it may overheat,
create a hazard of fire and shorten heater life. Do not operate
heater if dry.
MAINTENANCE
1. Heaters should be checked periodically for coating and corrosion
buildup and cleaned if necessary.
2. Tank should be checked regularly for sediment around the ele-
ments, as sediment can act as an insulator and shorten heater life.
3. Check for loose terminal connections.
ELECTRIC SHOCK HAZARD. Disconnect all power
before installing or servicing heater. Failure to do
so could result in personal injury or property dam-
age. Heater must be installed by a qualified per-
son in accordance with the National Electrical
Code, NFPA 70.
4. If corrosion or moisture is indicated in the terminal housing,
check the conduit layout to correct the conditions that allow cor-
rosion or moisture to enter the terminal housing.
THERMAL FUSE INSTALLATION/REPLACEMENT
Grounded Electric Immersion Heaters are practical, efficient
and safe when used properly and installed in tanks that have prop-
er solution levels, good ventilation, trained operators and safe-
guards such as liquid level controls and Thermal fuse over-tem-
perature sensors.
ELECTRIC SHOCK HAZARD. Disconnect all power
before installing or servicing heater. Failure to do
so could result in personal injury or property dam-
age. Heater must be installed by a qualified per-
son in accordance with the National Electrical
Code, NFPA 70.
Thermal fuse systems help reduce the hazards created by low
liquid levels and when properly seated and wired, they will cut
off the power to the heaters, thus avoiding the extreme tempera-
tures resulting if solution levels are low enough to expose heater
hot zones.
The Thermal fuse device must be properly installed and these
procedures followed or heater failure or fire may result.
Single Use Fuse (F) —
A liquid level control is a must as an additional safety feature
to help minimize the possibility of fire.
Sensor consists of a one-time thermal fuse which is standard
on all GS and GT over-the-side heaters.
1. Make sure all electrical power to the heater is shut-off.
2. Unscrew the head cover. Remove the wire nuts from the fuse
leads and save for re-use.
3. Remove the “Sealing Putty” and pull the Thermal fuse out of its
well. Clean the “putty” out of the well and save for re-use.
4. Check the Thermal fuse and the inside of the well to see if it is
wet. If wet inside, dry out well. Immerse the tube into the solu-
tion. If moisture appears again inside the well DO NOT use the
heater! Call the factory for further advice.
The F thermal fuse is wired in series with the controller. To
operate properly the fuse must be fully seated to the bottom of the
thermowell tube. When the fuse “blows”, shut off the main power
to the heater, remove the spent fuse and install the new fuse. Refill
the tank to proper level prior to turning power back on.
Replacement thermal devices must be purchased from Chromalox.
Resettable Fuse (RF) —
Sensor consists of a Bi-metallic thermostatic sensor, an audi-
ble alarm, alarm relay, and reset button.
5. If the removed Thermal fuse is dry, proceed by using it as a guide
to cut and strip the wires of the new Thermal fuse.
6. Re-connect the Thermal fuse leads to the extension leads using
the original wire nuts.
The RF System operates on the same principle as the F
except that the sensor does not “blow”. It operates as a Bi-metal-
lic thermostat which “opens” and sounds the alarm. The reset but-
ton must be pushed to re-activate the heater and control, after the
solution level in the tank has been raised to the proper level.
7. Re-insert the Thermal fuse into the well making sure it is “fully
seated” to the bottom of the well.
8. Re-seal using the original “sealing putty” or an RTV type sealant.
9. Replace the head cover, return the heater to the tank.
10. Turn the power back on.
Thermal Fuse Temperature System —
Be sure and satisfied that your process bath tanks are as well
protected as possible from tank leaks, excessive evaporation, tank
refill failures, and worker error.
FIRE/SHOCK HAZARD: Before replacing fuse,
make sure the cause of the “failure” has been
detected and corrected.
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THERMAL FUSE INSTALLATION/REPLACEMENT (con’t.)
Thermal Fuse Replacement Protection Devices
Model Number
Used On
F, FM, FH
RF, RFM, RFH
Standard OTS Heater
FL, FLM, FLH
RFL, RFLM, RFLH
L-Shaped OTS Heater
F Amp Capacity - 25 Amps; RF Amp Capacity - 5 Amps;
Blank (low) Temp = 180˚F; M (Medium) Temp - 230˚F; H (High) Temp = 300˚F.
(Max Process Temperature)
Medium temp. most common for this style heater.
RF sensors require additional control components which include a Relay,
Audible Alarm, and Manual Reset Pushbutton.
Specify 120 or 240 V when ordering.
Limited Warranty:
Please refer to the Chromalox limited warranty applicable to this product at
TA - Q0 - EF
Litho in U.S.A.
2150 N. RULON WHITE BLVD., OGDEN, UT 84404
Phone: 1-800-368-2493
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