2”- 4” Long to Short Handle Conversion Kits

2”- 4” Long to Short Handle Conversion Kits
A226801, A437801
This instruction sheet describes the steps necessary to convert the
microprocessor controlled long handled 2” – 4” Heaters to short handles.
This instruction sheet covers 2 kits (2” and 4”) for rebuilding the following
8 different heaters:
Long
Short Handle
214903
214905
2mlmc Sidewall & Socket 100-120V Htr Assy
214904
214906
2mlmc Sidewall & Socket 200-240V Htr Assy
215503
215505
2mlmc Bp 100-120V, 50/60 Htr Assy
215504
215506
2mlmc Bp 200-240V, 50/60 Htr Assy
424311
424315
14mlmc Sidewall & Socket 100-120V htr Assy
424312
424316
14mlmc Sidewall & Socket 200-240V htr Assy
424313
424317
14pb Bp 100-120V, 50/60 Htr Assy
424314
424318
14pb Bp 200-240V, 50/60 Htr Assy
Contents of A226801 2” Long to Short Handle Conversion Kit
Item
Description
MAL00013
#6-19x1/2lg Torx T15 Pan Hdsc
MDL00243
.070dia Buna-N O-Ring Stock
MDL00248
O-Ring
MLM00010
2/12-4/18 Wire Nut
214701
Mlmc Htr Cover Plate Gasket
226701
Heater Handle Wld
437203
Small Htr Handle/Enclosure
43780101
Instruction Sheet
8163107
Model 215506 Part No Label
8163112
Model 214905 Part No Label
8163113
Model 214906 Part No Label
8163114
Model 215505 Part No Label
816382
Temperature Scale Label
Qty
2
1.333
1
1
1
1
1
1
1
1
1
1
1
Contents of A437801 4” Long to Short Handle Conversion Kit
Item
Description
MAL00013
#6-19x1/2lg Torx T15 Pan Hdscr
MDL00243
.070dia Buna-N O-Ring Stock
MDL00248
O-Ring
MLM00010
2/12-4/18 Wire Nut
436301
Cover Plate Gasket
437101
Heater Handle Wld
437203
Small Htr Handle/Enclosure
43780101
Instruction Sheet
8163108
Model 424315 Part No Label
8163109
Model 424316 Part No Label
8163110
Model 424317 Part No Label
8163111
Model 424318 Part No Label
816382
Temperature Scale Label
Qty
2
1.333
1
1
1
1
1
1
1
1
1
1
1
PH02773-1-18-05
PH02811-1-25-05
PH02811-1-25-05
Tool list for 2” – 4”:
•
•
•
•
•
3/16” hex wrench
5/64” hex L-key
Channel lock pliers
Medium width tip flat
screw driver
3/16” diameter x 5”
long punch or rod
Instruction Sheet: 43780101
•
•
•
•
•
•
Hammer
Torx T-15 driver
Wire cutters
Crimping tool
Small flat screw driver
1/2” open end wrench
PH02810-1-24-05
1
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2”- 4” Long to Short Handle Conversion Kits
A226801, A437801
Step 1
Unplug the heater and let it cool to room temperature. Protect the
butt plates from abrasion during this conversion. Using the Torx
Driver, remove all 7 screws holding the plastic housing together.
Gently work the housing open.
NOTE: During this conversion, do not discard any parts unless
instructed to do so.
PH02774-1-18-05
Step 2
Using the wire cutters, clip all three ground wires as near to the
wire nut as possible.
PH02777-1-18-05
Step 3
Note: Make note of the wire locations before disconnecting.
Using small flat screw driver, disconnect all the wires from the
terminal blocks. Unscrew the screws in the large terminal block to
loosen. Push the orange levers on the smaller terminal blocks to
release the wires.
PH02779-1-18-05
Step 4
Using torx driver, remove the screw holding the heater control
board in the housing.
PH02782-1-18-05
Instruction Sheet: 43780101
2
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2”- 4” Long to Short Handle Conversion Kits
A226801, A437801
Step 5
Using the 5/64 hex L-key, loosen the set screw in the
temperature adjustment knob and pull knob off the
potentiometer stem.
PH02783-1-18-05
Step 6
Use ½” open end wrench to loosen seal nut. Remove
potentiometer from housing half. Discard the lock
washer.
PH02785-1-18-05
Step 7
Use 3/16 hex wrench or equivalent to remove the two
screws holding heater handle weldment to the heater
body.
PH02787-1-18-05
Step 8
Unthread the thermometer from the heater, and remove
the thermometer and guard.
PH02788-1-18-05
Instruction Sheet: 43780101
3
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2”- 4” Long to Short Handle Conversion Kits
A226801, A437801
Step 9
Remove the heater handle weldment from heater body.
Discard the gasket, long plastic handle, and weldment.
PH02789-1-18-05
Step 10
At this point, you will have the pictured parts from the
original heater and the conversion kit with you at your
workbench.
PH02790-1-18-05
Step 11
Feed new gasket over wires to the top of the heater body.
Run the wires through the short heater handle weldment.
PH02792-1-18-05
Step 12
Attach short heater handle weldment and thermometer
guard to heater body using screws. Use high temperature
anti-seize compound on the screw threads. Be sure that
holes in short heater handle weldment align with holes in
heater body.
PH02794-1-18-05
Instruction Sheet: 43780101
4
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2”- 4” Long to Short Handle Conversion Kits
A226801, A437801
Step 13
Thread thermometer through thermometer guard into the
short heater handle weldment.
PH02795-1-18-05
Step 14
Slip small o-ring over wires onto the very end of the tube
on the short handle heater weldment.
PH02796-1-18-05
Step 15
Apply temperature scale label to the appropriate heater
handle half. Be sure that notch in the label engages the
key in the handle.
PH02797-1-18-05
Step 16
Put o-ring stock in the two grooves starting from power
cord seat. Trim to length.
PH02798-1-18-05
Instruction Sheet: 43780101
5
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2”- 4” Long to Short Handle Conversion Kits
A226801, A437801
Step 17
Apply the appropriate label to handle half. Be sure that the
label is oriented in the same direction as the MMI Logo.
PH02800-1-18-05
Step 18
Set heater control board onto locating bosses and fasten
using the single short torx head screw.
PH02782-1-18-05
Step 19
Push potentiometer into place in the right handle half. Be
sure that tab is properly seated in notch.
PH02802-1-18-05
Step 20
While holding potentiometer in place, flip handle half over
and fasten using seal nut.
PH02785-1-18-05
Instruction Sheet: 43780101
6
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2”- 4” Long to Short Handle Conversion Kits
A226801, A437801
Step 21
Seat the short heater handle weldment into the handle
half, making certain that the square piece is in the proper
notch and that the o-ring is properly seated in its groove.
PH02804-1-18-05
Step 22
Inspect the power cord. If it’s in good condition, push it
into its seat. Screw the line and neutral wires into the
appropriate terminal locations.
PH02805-1-18-05
Step 23
Strip the AC ground (green wire) and potentiometer
ground and trim and strip the heater body ground and
crimp together using the supplied Crimp junction.
PH02807-1-18-05
Step 24
Trim and strip the heating element leads and screw into
the proper terminal locations.
PH02809-1-18-05
Instruction Sheet: 43780101
7
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2”- 4” Long to Short Handle Conversion Kits
A226801, A437801
Step 25
Push orange levers down and insert potentiometer leads
into their proper locations. Trim back RTD wires and strip.
Push orange levers down and insert RTD wires into
terminal block.
Make sure all wire strands are
inside the terminal block holes to
prevent a short circuit.
PH02766-1-18-05
Step 26
Wire routing should be approximately as shown.
PH02767-1-18-05
Step 27
Flip heater handle over, match up and press together.
Grip firmly by handle and flip over. Fasten the handle
halves together using four ¾” long screws. The two 1/2”
long screws are used in the two holes nearest the heater
body.
PH02769-1-18-05
Instruction Sheet: 43780101
8
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2”- 4” Long to Short Handle Conversion Kits
A226801, A437801
Step 28
Reapply temperature control knob and tighten.
To calibrate heater:
1. Turn potentiometer shaft Counter-Clock wise to
fully closed position.
2. Affix knob to potentiometer shaft oriented such
that the pointer is between the ‘C’ and the degree
symbol (As seen in figure 1 below).
3. Tighten set screw.
4. Turn knob to approximately 500° F.
5. Plug in heater and allow 20 minutes to come to
steady-state.
6. Verify that the thermometer reads approximately
500° F.
7. Take temperature measurements on the butt
plates at the two positions shown in figure 2 below
and average. (Temperature measurements are to
be taken at the same time in the heating cycle.)
8. If necessary loosen set screw and adjust knob to
the average of the temperature range measured.
PH02783-1-18-05
Figure 1
Figure 2
Now you have a converted heater.
For parts information, refer to the assembly drawing listed
on the heater handle part number label. The drawing can
be viewed and printed via the Internet at McElroy
Manufacturing Inc’s web site:
www.mcelroy.com
PH02772-1-18-05
Instruction Sheet: 43780101
9
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