HEATERS BLOCK DESIGN IMPROVEMENT

STANDARDIZATION AND TESTING REPORT

Department System design department

Date 11 February 2019
Prepared by RED

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Contents
1. Objective.................................................................................................3
2. Project Background.................................................................................3
2.1 Heater block..........................................................................................3
2.2 STN 5 at CT12 Machine..........................................................................4
3. Test apparatus.........................................................................................5
4. Test subject.............................................................................................5
5. Methodology...........................................................................................6
6. Result......................................................................................................7
6.1 Test 01...............................................................................................7
6.2 Test 02...............................................................................................7
6.3 Test 03...............................................................................................8
6.4 Test 04...............................................................................................8
6.5 Test 05...............................................................................................9
7. Discussion...........................................................................................12
8. Conclusion.............................................................................................13
9. Path Forward.........................................................................................14

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1. Objective

1. To investigate the maximum temperature for the heater block when total volume 67L in tank
water temperature is 80°C.

2. To measure the time taken for the heater block to reach the in tank water temperature at 80°C
with total volume 67L.

3. To suggest most suitable temperature for the new thermostat based on the testing result.

2. Project Background

2.1 Heater block

1. The heater block design has been improved. This improvement to ensure the heater block able
to withstands the temperature until 450°C (maximum temperature for cartridge heater).
2. The additional wire connector bracket has been added to ease the maintenance.
3. Heater cartridge has been change from 6 KW (3 Pcs x 2KW) to 3.75 KW (3 Pcs x 1.25 KW) to
decrease the watt density for the heater block.
4. The thermostat for this heater will be determined after the final result from this test. The new
thermostat specification must be followed the maximum temperature for the heater block.

OLD NEW
DESIGN DESIGN

Figure 1.0 the heater block design before and after modification.

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2.2 STN 5 at CT12 Machine

1. Process tank 05 at the CT12 machine is the DI Water Rinse 1 tank with micro bubble generator.
2. The total volume for this tank is 67 L.
3. The maximum set value for the in tank water temperature is 80°C. After the liquid temperature
reach this value, the heater automatically cut off.
4. This process tank using Iwaki magnetic pump 0.365KW and spurge pipe to do the circulation
process.
5. During the heater testing process, the heater and circulation pump is simultaneously on. The
circulation process makes the heat transfer uniformly to the entire in tank water.

Heater Block

Figure 2.0 the STN 05 schematic diagram and 3D model at the CT12 machine.

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3. Test apparatus

1. Heater block
2. 3 pcs Cartridge Heater with Bracket, 1 Phase x 240V x 1.25kW, Ø21.5mm x 250mm L c/w 2m
Fibreglass Wire, CE Certified
3. Temperature probe with Maltec-T Type K Spot-weld Thermocouple C/W 2 Meters Teflon G24
wire.
4. Chokoh Tape 0.13 MM X 18 MM Width X 10 Meters length. Max Temp: Up to 180 Degree
Celsius, 1 Roll = 10 Meters.
5. STN 5 CT12 Machine.
6. Stopwatch

4. Test subject

1. Heater block at Tank 05 (67 L) DI Water Rinse 1 at CT12 Machine

H1: Heater Cartridge 01

H2: Heater Cartridge 02

H3: Heater Cartridge 03

H1
H2
H3

Figure 3.0 the heater block.

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5. Methodology

1. The set value for heater at the recipe was set for 80°C.
2. The heater probe was attached the heater block by using chokoh tape.

Heater Probe

Temperature Monitor

Figure 4.0 the setup for heater probe.

3. Circulation pump and the heater block was turn on at the machine controller monitor
4. The time was recorded using stopwatch,
5. The temperature for the heater block was recorded by followed the result table as below:

Water Temp (°C) 25 30 35 40 45 50 55 60 65 70 75 80

Block Temp (°C)
Time (Min)

6. Repeat the step 1 to 5 for several variation parameter and condition.

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 6. Result

6.1 Test 01

H1

H2
Temp. Probe
H3

Figure 5.0 the heater probe placement.

Remarks: Open cover condition

Heater power: 3.75 KW.

Water Temp 2 30 35 40 45 50 55 60 65 70 75 80
(°C) 5
Block Temp (°C) 2 95 140 145 147 153 158 157 166 166 169 172
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Time (Min) 0 2.3 7 16 24 32 40 49 59 68 80 92

6.2 Test 02

H1

H2
Temp. Probe
H3

Figure 6.0 the heater probe placement.

Remarks: Open cover condition.

Heater power: 3.75 KW.

Water Temp (°C) 25 30 35 40 45 50 55 60 65 70 75 80

Block Temp - 29 167 175 176 173 172 174 176 178 178 17
(°C) 8
Time (Min) - 0 8 15 21 28 36 46 54 65 76 88

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 6.3 Test 03

H1

Temp. Probe H2

H3

Figure 7.0 the heater probe placement

Remarks: Open cover condition.

Heater power: 3.75 KW.

Water Temp 25 30 35 40 45 50 55 60 65 70 75 80
(°C)
Block Temp 26 140 149 147 149 151 152 158 157 170 182 182
(°C)
Time (Min) 0 7 15 23 30 38 48 56 67 78 86 98
H1 - - - - - - - - 330 340 340 351
H2 - - - - - - - - 332 334 334 343
H3 - - - - - - - - 330 330 359 356

6.4 Test 04

H1

Temp. Probe H2

H3

Figure 8.0 the heater probe placement.

Remarks: Close cover condition.

Heater power: 3.75 KW.

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 Water Temp 2 30 35 40 45 50 55 60 65 70 75 80
(°C) 5
Block Temp (°C) 2 114 149 154 160 155 160 165 168 172 177 180
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Time (Min) 0 4 16 26 35 44 50 58 68 76 86 97
H1 2 270 340 342 349 358 351 347 370 358 350 352
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H2 2 270 330 346 341 347 350 349 350 350 360 360
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H3 2 272 338 350 352 360 360 362 380 386 360 355
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6.5 Test 05

H1
Temp. Probe
H2

Figure 9.0 the heater probe placement.

Remarks: Close cover condition.

Heater power: 2.5 KW.

Water Temp (°C) 25 30 35 40 45 50 55 60 65 70 75 80

Block Temp (°C) 28 80 107 107 112 120 120 122 128 132 136 138
Time (Min) 0 8 11 24 38 54 72 92 116 144 185 233
H1 29 240 250 265 260 280 280 320 330 322 340 330
H2 29 300 310 290 280 290 310 330 320 321 360 360
H3 0 0 0 0 0 0 0 0 0 0 0 0

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 6.6 Test 06
Temp. Probe

H1

H2

H3

Figure 10 the heater when closed cover. Figure 11 the heater probe placement.

Remarks: Close cover condition, Attach probe at H3, Attach probe at block heater.

Heater power: 3.7 KW.

Water Temp (°C) 25 30 35 40 45 50 55 60 65 70 75 80

Block Temp (°C) 26 135 165 167 169 170 171 173 178 179 182 183
Time (Min) 0 5 13 20 25 32 41 50 58 68 80 98

6.7 Test 07

H1

Temp. Probe H2

H3

Figure 12 the heater probe placement.

Remarks: Open cover, Attach probe to heater block at top of H3, Attach probe at block heater.

Heater power: 3.7 KW.

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 Water Temp (°C) 25 30 35 40 45 50 55 60 65 70 75 80
Block Temp (°C) 25 130 140 148 147 158 163 163 167 170 174 176
Time (Min) 0 6 13 21 28 36 48 58 65 77 85 99
H1 25 275 295 337 345 347 351 358 360 362 369 371
H2 25 272 290 335 347 348 354 359 361 364 372 374
H3 25 280 300 332 349 355 358 363 364 367 380 382

6.8 Test 08
Temp. Probe

Figure 13 the heater when closed cover. Figure 14 the heater probe placement.

Remarks: Closed cover, Probe attach to inner heater cover.

Heater power: 3.7 KW.

Water Temp (°C) 25 30 35 40 45 50 55 60 65 70 75 80

Inner cover Temp 25 54 66 75 78 81 83 86 86 88 89 90
(°C)
Time (Min) 0 7 15 22 30 39 47 55 65 75 86 98

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7. Discussion

Based on the current testing progress result table above, the data has been converted to heater
block temperature versus time graph:

Graph description:

HBTT 01: Heater Block Temperature Test 01

WTT 01: Water Temperature Test 01

Figure 10 the Heater block temperature vs. time graph.

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 Based observation from the graph, the maximum heater block temperature when the total heater
power is 3.75 KW is 183 (°C) while total heater power for 1.25 KW is 138(°C). Total time taken for the
heater to heat the in tank water until the maximum temperature is measured. The heater power 3.75
KW take 98 minutes compare to 2.5 KW heater power 233 minutes.

Total duration time taken for the testing 01,02,03,04,06 and 07 slightly same this due to total power
used for this testing is 3.75 KW compare testing 05 used 2.5 KW. When the total power is reduced, the
heat transfer from heater block to tank surface also decreases. Thus testing 05 need longer time to
reach the desired in tank water for 80(°C). Apart from that, the total power 2.5 KW is not suitable to
implement in JKS machine. For the testing 08, when the in tank water temperature is 80(°C) at the 3.75
KW, the inner cover temperature is 90(°C) the inner cover temperature reading is represent the internal
environment temperature.

8. Conclusion

Conclusion for current testing progress:

1. The maximum temperature for the heater block when in tank water temperature 80°C with
total volume 67L is 183°C.
2. The time taken for the heater block to reach the in tank water temperature at 80°C with total
volume of water 67L is 98 minutes.
3. To minimum thermostat temperature specification able to use at this heater is 190°C.

9. Path Forward

1. New Thermostat selection from electrical department.

2. Heaters block testing for 6KW.

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