FAQ

Coil insulators are recommended for all metal coils that will be installed in an electrified plating tank. The coil insulators are simply pipe couplings fabricated from a non-conducting material. The purpose of the coil insulators are to prevent a stray voltage from traveling to the immersion coil and give the coil an anodic or cathodic charge, either of which could result in corrosion or plate-out on the coil.

The purpose of the ground connection is to minimize the chance of a shock hazard for an operator or equipment. A ground connection on an electric immersion heater is required by the National Electric Code and is also a required part of the UL Listed construction.

Often enough to avoid buildup, although frequency varies upon application, solution, frequency of use, etc. Contact your chemical supplier for specific cleaning instructions.

When energized, the surface temperature of an electric immersion heater is much higher than the bulk liquid temperature. Since the tank walls are not the source of heat, they are typically the same temperature as the bulk liquid temperature. In addition, the heater sheath is much thinner than a typical metal tank wall. When you consider that many chemicals are more aggressive or react more quickly at elevated temperature (such as on the surface of an electric immersion heater), the heater sheath may be subject to chemical attack when the tank wall is not.

Almost all of our electric heaters are UL listed (cULus, which includes CSA approval for Canada) and CE compliant. Our temperature controllers are UL Listed, and many of them are also CE compliant. There are a few exceptions, so please refer to the product data sheet or the web page pertaining to a specific product to verify its approvals.

Most phosphate baths have the tendency to “build up” onto heated surfaces, such as the surface of an electric immersion heater. This buildup acts as an insulation layer, inhibiting the heat from moving into the liquid and resulting in an overheat condition inside the heater. For heating phosphate baths, Process Technology recommends the DAS Series phosphate heater, or a derated heater (we offer derated metal over-the-side heaters, derated metal L-shaped heaters, derated triple tube metal over-the-side heaters, and derated triple tube metal L-shaped heaters). Both a phosphate and derated heater will result in a reduced rate of buildup.

Yes. There is no price difference for making a heater with a short riser, but there may be a cost adder for a longer riser. Please contact our customer service department for more information.

Amp-hour meters are used to track the amount of amp-hours used in a plating tank. Using an amp-hour meter to track the consumption of amp-hours can help measure the amount of metal that is plated onto a batch of parts, calculate the depletion of plating metals in the plating chemistry, and calculate the amount of emissions emanating from the tank. In the United States, non-resettable amp-hour meters are required for measuring emissions in chrome plating process tanks.

No. For a recommended annual calibration of your amp-hour meter, we suggest you contact our customer service department who can quote the calibration charges, the lead time for the procedure, and facilitate the return of the meter to our factory for calibration.

The calibration instructions are included in the temperature controller instruction manual (except for the DLC series controllers). Temperature controller installation manuals are also available online on our Technical page.

The “UUU” message typically denotes a bad temperature sensor. If you have a replacement temperature sensor available, try replacing the sensor on the controller. If this does not correct the error message, please contact our service department for additional support. You may also want to visit our comprehensive page of downloadable .pdf files including manuals for controls.

Our industrial electric immersion heaters are designed to heat a variety of non-flammable aqueous (mostly water) process chemistries. Metal heaters are designed and built with a standard watt density of approximately 35W/sq. in. These heaters perform well when the process chemistry has a viscosity and heat capacity close to that of water. However, certain process chemistries (i.e. concentrated sodium hydroxide, glycols, oils) have a higher viscosity and/or lower heat capacities. Therefore, they are unable to absorb the heat and move it away from the surface of the heater quickly enough. For process chemistries like this, we recommend “derated” heaters - a heater with a watt density below 20W/sq. in. PTFE-covered heaters with a standard watt density of 10W/sq. in. area are already considered to be derated.

The heater sheath overtemperature “protector” fuse is a required safety device. It is designed to detect when the heater sheath exceeds a predetermined temperature, and trip. The protector must be wired such that when it trips all of the heaters operating in that tank are shut off.

Yes, we have changed our designations for protectors in our model numbers and assigned a part number for replacements. For example PII is now P2. Click here for a cross reference chart.

The LCBA5 liquid level control can be added to any temperature control box as a field upgrade.

Wiring Instructions (Note: The following procedure should only be performed by qualified personnel):

1. 1. Turn off power to the control box and apply any lockout/tagout devices as required. Open the door.
2. 2. Add three new wires to provide power to the circuit board, connected as follows:
   1. a. Add a green wire from the GND terminal on the LBCA5 board to one of the green ground terminals inside the control box.
   2. b. Add a wire from the COM terminal on the LCBA5 board to an open position on terminal block #1.
   3. c. Add a wire from the 120V terminal on the LCBA5 board to an open position on terminal block #3.

   

3. 3. Modify the control wiring to integrate the level control output to the heater control circuit as follows:
   1. a. Disconnect the lead wire for the electric heater’s over temperature protector from terminal block #5.
   2. b. Extend this wire to the LCBA5 box and connect it to the COM terminal for the output switch.
   3. c. Add a new wire from the N/O position on the LCBA5 circuit board to terminal block #5 in the control box.

   

Test the wiring by making sure that when the LCBA5 level control detects no liquid the heater will not energize.

The LCBA5 liquid level control can be added to any temperature control box as a field upgrade.

Wiring Instructions (Note: The following procedure should only be performed by qualified personnel):

    1. Turn off power to the control box and apply any lockout/tagout devices as required. Open the door.
    2. Add three new wires to provide power to the circuit board, connected as follows:

       a.  Add a green wire from the GND terminal on the LBCA5 board to one of the green ground terminals inside the control box.
       b.  Add a wire from the COM terminal on the LCBA5 board to an open position on terminal block #1.
       c.  Add a wire from the 120V terminal on the LCBA5 board to an open position on terminal block #3
 

3. Modify the control wiring to integrate the level control output to the heater control circuit as follows: a. Disconnect the lead wire for the electric heater’s over temperature protector from terminal block #5. b. Extend this wire to the LCBA5 box and connect it to the COM terminal for the output switch. c. Add a new wire from the N/O position on the LCBA5 circuit board to terminal block #5 in the control

Test the wiring by making sure that when the LCBA5 level control detects no liquid the heater will not energize.

The ESP liquid level control can be added to any temperature control box as a field upgrade. Please note that this method of wiring does not provide a low-level indicator light for the operator.

Wiring Instructions (Note: The following procedure should only be performed by qualified personnel):
1. Turn off power to the control box and apply any lockout/tagout devices as required. Open the door.

2. Disconnect the lead wire for the electric heater’s over temperature protector from TB5.

3. Using a wire nut, make a connection between the disconnected wire and one of the ESP lead wires (polarity and wire color does not matter here.)

4. Attach the remaining ESP lead wire to TB5.

5. Calibrate the ESP per the instructions provided in the product manual.

Test the wiring by making sure that when the ESP level control detects no liquid the heater will not energize.

The T-DRA15-1 temperature controller is rated to control a 120V electric heater which draws 12-amps or fewer. 

Note: The wiring instructions provided below illustrate using wire nuts. Be sure that the wire nuts or terminals used for the wiring are rated for the supply voltage, amp draw of the heater, and the number of wires which will be connected by them.

Note: The following procedure should only be performed by qualified personnel

Wiring Instructions for an “A” series electric heater (ex: SA, TA, LSA, LTA series) The “A” series electric heaters come with a 3-conductor cord:

1. 1. Make sure supply power is turned off. Apply any lockout/tagout devices as required.  
2. 2. Use a screwdriver to remove the front face of the T-DRA15-1 controller, revealing the wire terminals inside.
3. 3. Connect 120V “hot” from the supply power to the 120 and C terminals in the T-DRA15-1 controller as seen in the figure. You may use a wire nut or terminals to facilitate wiring.
4. 4. Connect 120V “neutral” from the supply power to the COM terminal in the T-DRA15-1 controller.
5. 5. Connect the black wire from the electric heater to the NO terminal in the T-DRA15-1 controller.
6. 6. Connect the white wire from the electric heater to the neutral wire from the supply power. You may use a wire nut or terminals to facilitate wiring.
7. 7. Connect the green ground wire from the heater to a green ground wire from the supply power.

 

Wiring Instructions for a standard electric heater with a P1 protector.The standard electric heaters come with a flexible conduit and 5-wires; two black, two yellow and one green:

 

1. 1. Make sure supply power is turned off. Apply any lockout/tagout devices as required. 
2. 2. Use a screwdriver to remove the front face of the T-DRA15-1 controller, revealing the wire terminals inside.
3. 3. Connect 120V “hot” from the supply power to the 120 and C terminals in the T-DRA15-1 controller as seen in the figure. You may use a wire nut or terminals to facilitate wiring.
4. 4. Connect 120V “neutral” from the supply power to the COM terminal in the T-DRA15-1 controller.
5. 5. Connect one of the black wires from the heater to one of the yellow wires from the heater. It does not matter which black or yellow wires are selected.
6. 6. Connect the remaining yellow wire from the electric heater to the NO terminal in the T-DRA15-1 controller.
7. 7. Connect the remaining black wire from the electric heater to the neutral wire from the supply power. You may use a wire nut or terminals to facilitate wiring.
8. 8. Connect the green ground wire from the heater to a green ground wire from the supply power.  

RTD Temperature sensors come in 2-wire, 3-wire and 4-wire types. The third and fourth wires are connected in parallel to the other wires, which allows the measuring device to detect and compensate for the resistance of the lead wires.

How to connect a 2-wire RTD sensor to the input connections for a 3-wire RTD sensor:

1. 1. Attach the two sensor wires to the input connections for the different sides of the sensor.
2. 2. Add a short loop of wire connecting the third connection point to the appropriate wire connection.

  

Regulation mode describes how the power supply will operate in regards to the output load and desired voltage and current settings. The individual plating process will determine which mode to use.

There are three regulation modes available in all power supplies:
 

Voltage : The output voltage is regulated to the setpoint while the output current will vary according to the load. For example, barrel plating processes often use voltage regulation.

• To set a power supply to voltage regulation mode, set the output voltage to the desired setting (i.e. 8 VDC) and the current to the maximum value.

Current  : The output current is regulated to the setpoint while the output voltage will vary according to the load. For example, rack plating processes often use current regulation.

• To set a power supply to current regulation mode, set the output current to the desired setting (i.e. 150 Amps) and the voltage to the maximum value.

Crossover : In this mode both current and voltage outputs are set at a desired level (i.e. 6 VDC, 95 Amps). The output will either be current regulated or voltage regulated depending on output load. The crossover point is defined as the point where the power supply switches from one regulation mode to the other. See illustration below.  

Three single-phase heaters of the same wattage and voltage can be wired in DELTA to create a balanced three-phase load.

Wiring Instructions:

1. 1. Physically install the electric heaters and the temperature control box in the desired locations. Run the heater conduits into a suitable junction box or directly into the temperature control box.
    
2. 2. Connect the ground wires from all three heaters to a ground terminal.

   Arrange the heater wires to the load-side of the switching contactor (positions T1, T2, and T3) as follows :

   a. The two heater wires from heater 1 go to positions T1 and T3
   b. The two heater wires from heater 2 go to positions T1 and T2
   c. The two heater wires from heater 3 go to positions T2 and T3

 

The result is a balanced three-phase load for the power circuit. There will be two heater wires per position on the switching contactor, which is the allowable limit for these devices.

If there is a need to connect more than one DELTA group to a single temperature controller, then a junction box or a branch fuse box is required.

The DTX2400 power supply has an output which can be connected to an external light or buzzer to provide a remote alarm.

Wiring Instructions:

1.  The alarm output is located on the DB25 connector on the rear of the unit. The 24VDC output is on pin 24, while the alarm output is on pin 18.  A LED type indicator can be wired as shown. The load must be less than 20mA.
    


2. 2. Digikey carries an audible alarm (P/N 668-1248-ND) that works well. Black wire to pin 18 and red wire to pin 24
   
    


3. A screw terminal adapter is available to facilitate wiring without soldering. The adapter is item # 024-0419-25.
   
   
   Programming Instructions:
   
   1. Adjust the End of Cycle Settings as follows for the desired effect. To access Press System>User Sets
4. 1. a. None = No alarm
   2. b. Enable EOC Alarm = will enable alarm output on pin 18.
   3. c. Enable EOC Window = the main display on the front of the unit will flash
   4. d. Enable EOC Window and Alarm = both b and c.

The DQ15D-series temperature controller has a second output relay and set point which can be used to operate a solenoid valve for a cooling load. This output is not usually pre-wired at the factory. Here are the steps to wire a 120V solenoid valve to this output.

Wiring Instructions:

1. 1. Install a new wire from any open position on terminal block #7 to the COM position of the SP2 relay on the back of the DQ15D temperature control module.
2. 2. Connect one of the solenoid wires to the N/O output position of the SP2 relay on the back of the DQ15D temperature control.
3. 3. Connect the other solenoid wire to any open position on terminal block #1.
4. 4. Adjust the SP2 set point on the DQ15D controller to the desired setting.

The DQ15D temperature controller has two set points; SP1 for heating and SP2 for cooling. The SP2 output relay is not pre-wired to any terminals. Here are the steps to wire a 120V solenoid valve to this output:

Wiring Instructions:

1. Install a new wire from any open position on terminal block #7 to the COM position of the SP2 relay on the back of the DQ15D temperature control module.
2. Connect one of the solenoid wires to the N/O output position of the SP2 relay on the back of the DQ15D temperature control.
3. Connect the other solenoid wire to any open position on terminal block #1.
4. Adjust the SP2 set point on the DQ15D controller to the desired setting.

    

The calculation for the amp draw of electric heaters is slightly different for single-phase and three-phase heaters.

Amp draw calculation for single phase heaters:

Amps = Heater Watts (W) ÷ Voltage (V)
Example: 6000W ÷ 208V = 28.8 amps

Amp draw calculation for three phase heaters:

Amps = Heater Watts (W) ÷ Voltage (V) ÷ 1.73
Example: 6000W ÷ 208V ÷ 1.73 = 16.7 amps
 

This table shows different calculations for Watts, Amperes, Volts or Ohms based upon Ohm’s Law.

When considering a pulsed DC power supply, it is important to understand the peak current, average current and duty cycle. Understanding these terms and how they relate to each other will help with power supply selection and setup. The following explains each and their relationship to each other.

Below is an example of a basic pulsed DC output

 

Peak Current: The output current the power supply will regulate during the pulse on time

Duty Cycle: = On Time ÷(Time Period)

Average Current: = Peak Current X Duty Cycle

The DC equivalent (effective current) is used for calculating amp minutes and total power.

Frequency: = 1 ÷ (Time Period)

Example:

 

Average Current: = 1ms ÷ (1ms + 2ms) = .33 Duty Cycle

= 1 Amp X .33s = .333 Amps Average

Frequency: = 1 ÷ 3ms or 1 ÷ .003s = 333Hz

The calculation for the resistance of an electric heater is slightly different for single-phase and three-phase heaters. Please note that the exact resistance of an electric heater may vary by a few percent due to manufacturing tolerances. Your heater may measure a little higher or lower than the calculation below (within 10%).

Resistance calculation for single phase heaters:

Ohms = (Voltage (V))² ÷ Heater Watts (W)
Example: (208V)² ÷ 6000V = 7.2 Ohms

Resistance calculation for three phase heaters:

Ohms = [(Voltage (V))² ÷ Heater Watts (W)  ] x2
Example: [(208V)² ÷ 6000V] x2 = 14.4 Ohms

This table shows different calculations for Watts, Amperes, Volts or Ohms based upon Ohm’s Law.