CCI Thermal Technologies FE2 User Manual

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Owner’s Manual

FE2 Series

Electric Forced Air Heaters for Hazardous Locations

ISO 9001

This manual covers the installation, maintenance, repair and replacement parts.

MODEL CODING

CCI Thermal Technologies Inc.

5918 Roper Road

Edmonton, Alberta

T6B 3E1 Canada

II2 G Ex d IIB T3 Gb

DEMKO 10 ATEX 0910365X

-20°C (-4°F) ≤ Tamb ≤ 40°C (104°F)

POCC CA. ГБ06.B00914

WARNING!

FE 2 - 2201 50 - 025

KILOWATT RATING

HERTZ

PHASE

VOLTAGE

2nd GENERATION

MODEL SERIES

READ ALL IMPORTANT NOTICES

Part No. 10525.Rev.8.00 Issue Date: November 2013 Printed in Canada

RuffneckTM and VacuCore® are registered trademarks of CCI Thermal Technologies Inc.

HEATER MAINTENANCE CHECKLIST

For Electric Forced Air Heaters

Heater Model: _________________________ Serial No.: ___________________________

Date of Maintenance: ___________________ Maintenance Done By: _________________

Comments: _________________________________________________________________

__________________________________________________________________________

WARNING

Disconnect heater from power supply at fuse box before opening enclosures or servicing heater.

Lock the switch in the “OFF” (open) position and/or tag the switch to prevent unexpected power application.

Verify that power has been disconnected at fuse box or main panel. Lock the switch in the “OFF” (open) position

and/or tag the switch to prevent unexpected power application.

This heater should only be serviced by personnel with heating and hazardous location equipment experience.

PREVENTATIVE MAINTENANCE GRID

Regular Service Severe Service

1 Month 3 Month 12

Month

Annual

Start Up

1 Month 3 Month 12

Month

X X

X X X X

X X X

X X

X X X

Clean:

Finned Tubes Fan Fan Guard Motor Louvers

Electrical

Check all terminal connections and conductors.

Inspect contactor contacts.

Check Fuses

Mechanical

Check for fluid leakage

Check all enclosures

Check motor shaft bearing play

Remove dust using compressed

Do not spray with water or solvents.

Do not immerse in water or solvents.

Tighten loose connections. Replace conductors with damaged insulation & frayed wiring. For

drilling rigs, this should be done with every rig re-location.

If badly pitted, burned or welded shut, replace with factory supplied contactor. For drilling rigs, this

should be done with every rig re-location.

The Correct fuse rating and type

are printed on the circuit board. Always ensure a backup fuse is available on the PCB. For drilling

rigs, this should be done with every rig re-location.

Inspect the Pressure Release Valve label indicator for signs of rupture and degradation. If any fluid leakage occurs from the heater, disconnect it from the power supply and have the core replaced immediately. For drilling rigs,

this should be done with every rig re-location.

The interiors of each enclosure

must be clean, dry and free of foreign materials. For drilling

rigs, this should be done with every rig re-location.

If the motor does not run quietly and smoothly and has excessive play replace the motor. For

drilling rigs, this should be done with every rig re-location.

air.

Annual

Start Up

Photocopy

this page

for reuse.

PERIODIC (before and as required during heating season)

Photocopy

this page

for reuse.

1. CLEAN

� Finned Tubes � Fan � Fan Guard � Motor � Louvers

2. CHECK

� Motor for smooth, quiet operation � Louvers for proper angle and tightness � All explosion-proof covers for tightness � Pressure relief device for signs of leakage. See

Figure 1 and refer to the ANNUAL Section (see below) item 2 for further instructions

Remove dust using compressed air. Do not spray with water or solvents.

Do not immerse in water or solvents.

ANNUAL (before heating season)

1. ELECTRICAL

Check all terminal connections and conductors. Tighten loose connections. Conductors with damaged

insulation must be replaced.

Inspect contactor contacts. If badly pitted, burned or welded shut, replace with factory supplied contactor. For

severe duty conditions such as arctic duty, CCI Thermal recommends the contactor be replaced every two years.

Check fuses. Fuse rating and type are on printed circuit board. Correct fuse must be in the active fuse clip. It is

recommended that a spare fuse be stored in the spare fuse clip.

Check all explosion-proof conduits. Replace damaged conduits. All threaded conduit connections must have

a minimum 5 turns engagement. Straight threaded conduit must protrude a minimum of 1/16” (1.6 mm) inside enclosures. Taper threaded connections must be at least hand tight.

Check electrical resistance on all load side legs. Reading should be balanced (± 5%).

2. MECHANICAL Check for fluid leakage. The heater core is vacuum charged and contains propylene glycol. Inspect the

Pressure Relief Valve label indicator for signs of rupture and degradation. If the paper is torn, disintegrated or otherwise compromised this is an indication that fluid has leaked from the core. If any fluid leakage occurs from the heater, disconnect it from the power supply and have the core replaced. A factory supplied exchange core can be shipped immediately from stock. Refer to the "Repair and Replacement" section for details.

Check all enclosures. Interior of enclosures must be clean, dry and free of foreign materials. Threaded covers

must be installed and hand tight.

Note: Enclosure joints are metal to metal. Do not use gasket material or sealant in joints. A grease is applied to

the joints at the factory and should be left intact.

Check motor shaft bearing play. Replace motor if play is excessive, or if motor does not run quietly and

smoothly. Motor bearings are permanently lubricated. Check fan. Replace immediately if cracked or damaged. Check louvers. Louver screws should be tight. Louvers shall not be fully closed or override stops. Check the tightness of all hardware. All nuts and bolts, including mounting hardware, must be tight. Turn heater on for a minimum of five minutes. Check for warm air exiting heater through louvers. Crackling or

pinging noises within heater during start-up are normal.

For assistance, please call

1-780-466-3178 (24 hrs)

IMPORTANT NOTICES

WARNING

Read and adhere to the following. Failure to do so may result in severe or fatal injury.

WARRANTY WILL BE VOID

1. Read and follow all instructions in this manual.

2. Heater is to be used only in atmospheres having an ignition temperature higher than the heater’s maximum rated operating temperature as shown on the heater data plate. Refer to applicable electrical codes for additional information.

3. Heater to be used only in the hazardous locations indicated on the heater’s data plate.

4. Heater is for dry indoor use only. Do not immerse in water. Do not store or use in areas exposed to rain or snow.

5. Heater is to be connected and serviced only by a qualified electrician experienced with hazardous location equipment.

6. Installation and wiring of the heater must adhere to all applicable codes.

7. Disconnect heater from power supply at fuse box before opening enclosures or servicing heater. Lock the switch in the “OFF” (open) position and/or tag the switch to prevent unexpected power application. Verify that power has been disconnected at fuse box or main panel. Lock the switch in the “OFF” (open) position and/or tag the switch to prevent unexpected power application.

8. This heater is equipped with a single bimetal over temperature high-limit. It is of the automatic reset type and therefore the heater may restart without warning. The heater is not to be operated with the high-limit disabled or disconnected from the control circuit.

9. Venting pressure of the pressure relief valve is factory set. Do not tamper with lock nut.

10. Do not tamper or remove warning label indicator on the PRV.

11. Operate the heater only while it is permanently mounted in an upright position. Refer to the “Installation - Mechanical” section for details.

12. Heater must be kept clean. When operating in a dirty environment, regularly clean the finned tubes, fan, and fan guard. Follow the recommended maintenance procedures. Refer to the “Heater Maintenance Checklist” section for details.

13. The heater core is vacuum charged and contains propylene glycol. If any fluid leakage occurs from the

heater, disconnect it from the power supply and have the core replaced with a factory supplied core. Refer to the “Repair and Replacement” section for details.

14. Do not operate the heater with any of the louvers fully

closed or overriding their stops.

15. Do not operate the heater in atmospheres corrosive to

steel or aluminum.

16. Do not operate heater in ambient temperatures above

40°C (104°F).

17. Unused apertures shall be closed with suitable blanking

elements. All cable entry devices and blanking elements

shall be certified in type of explosion protection flameproof enclosure “d”, suitable for the conditions of use and correctly installed.

18. Installer to provide certified Ex “d” sealing fittings and stopping boxes for the same gas groups as the apparatus.

19. The distance from the face of the seal closest to the enclosure (or intended end-use enclosure) and the outside wall of the enclosure (or intended use-enclosure), shall be as small as practical, but in no case more than the size of the conduit or 50 mm, whichever is the lesser.

20. Use factory approved replacement parts only.

21. See applicable electrical codes for seal requirements in field installed conduits. Factory installed conduits require no further sealing.

22. Crackling or pinging noises within the heater core during start up may occur. This is normal.

23. Air discharge near the bottom of the heater may be warmer than the top. This is normal.

24. If there are any questions or concerns regarding the heater, contact the factory. Refer to the last page of this manual for details.

25. Contact original manufacturer for information on the dimensions of the flame proof joints.

26. Heater must be permanently mounted in a level, upright position for operation. See mounting section or mounting instructions label located on the heater's control box.

PRV

PRV LOCK NUT

PRESSURE RELIEF VALVE (PRV) LABEL INDICATOR

FIGURE 1

TROUBLESHOOTING TIPS

1.0 Heater is not operating

1.1 Check all fuses in heater control box.

1.2 Check remote disconnect switch and circuit breaker.

1.3 Check voltage supplied to the heater – refer to the heater data plate for voltage requirements.

1.4 Check thermostat by turning it and check continuity with a multimeter.

1.5 Verify that there is a jumper wire present between terminals 5 and 6 on the terminal block located in the control box.

2.0 Contactor is chattering

2.1 Check supply voltage.

2.2 Check wiring connections. Tighten all loose electrical connections.

2.3 Check thermostat for continuity (See 1.4). If thermostat does not break continuity replace thermostat.

3.0 Contactor is burned or welded

3.1 Check the contactor for burn marks and blackening. Replace the contactor.

3.2 Check incoming power to the heater to ensure there are no voltage uctuations.

4.0 Heat exchanger is dirty

4.1 Clean the heat exchanger using compressed air.

5.0. PRV has released

5.1 If there are signs that the PRV has released uid, PRV indicator is broken, blackening around the PRV exit hole, or

there are uid stains visible on the top louver, shut the unit down immediately.

5.2 Check for restricted air ow, bad motor, broken thermostat or malfunctioned high limit.

6.0 Heater is cold on top and warm on bottom

6.1 The core may have lost its vacuum. Check the PRV for signs of loss of uid and verify that the PRV label indicator is not broken. If PRV has released, send the unit in for repair or replace the core.

6.2 If the PRV does not indicate loss of uid, the heater should operate normally. Check for loss of uid on a weekly basis as a minimum.

6.3 The ambient temperature may be too low. If the ambient temperature is very cold the top of the core will be colder

7.0 Unit cycles on high limit – unit turns on and turns off within less than 5 minutes.

8.0 The Ground Fault Interrupter (GFI) trips on the main panel, or heater blows fuses.

9.0 The fan is turning but very little air comes from the front of the heater.

than the bottom – this is normal.

7.1 Check and see if the PRV has released uid. Core may have lost most or all of its uid. If PRV has released, send the unit in for repair or replace core.

7.2 The core may be dirty, fan may not be working or may be turning the wrong way (the fan must rotate clockwise as seen from the front of the unit) objects may be stuck in the heat exchanger for drying or warming up – remove any items from the exchanger.

8.1 Check that you have a fuse of the proper amperage rating.

8.2 Check for loose or frayed wiring.

8.3 If condition is not observable, send heater in for repair.

8.4 Change sensitivity of GFI.

9.1 Check fan rotation and ensure that the fan turns clockwise as seen from the front of the heater. Refer to the Installation section below for more information.

9.2 Check motor winding resistance and verify that they are balanced.

9.3 Check fan blade set screws to ensure fan blade is not loose on the motor shaft.

INSTALLATION

The installation instructions provide a general guideline for the installation and wiring of the heater.

All applicable local codes must be adhered to.

MECHANICAL

LOCATION

For optimum heating, the heater should be installed as follows:

1. There are no obstructions that may impede the heater’s air inlet or discharge.

2. The air discharge is directed into open areas and not at occupants.

3. The air discharge is not directed at a thermostat.

4. The air discharge is directed across areas of heat loss, such as doors and windows (see Figure 2).

5. The air discharge is directed along and at a slight angle toward exterior walls (see Figure 2).

6. If equipment freeze protection is important, direct air discharge at equipment.

7. Air discharge streams support each other and create a circular air flow. It is not required that the heater’s air throw reaches the next heater (see Figure 2).

FIGURE 2

MAXIMUM TILT ANGLES

(EITHER DIRECTION)

0.5"

(12.7mm)

1" (25.4mm)

FIGURE 3

MOUNTING

1. The heater must be permanently mounted in a level, upright position for operation. See Figures 3, 4, and 5 for maximum tilt angles, installation clearances, and physical dimensions. For ease of installation, a variety of mounting kits are available from the factory.

2. The mounting structure must be strong enough to: a. support the heater’s weight, refer to the

“Specifications” section, b. provide sufficient stiffness to prevent excessive vibration, and c. withstand harsh situations such as transportable installations.

3. Do not install conduit below heater (see Figure 4 ).

22 5/8" [575mm]

2.5 - 10 kW12.5 - 20kW20.9 - 35kWDIM.

DIM

mm 198 195 196 3

in 7.75 7.69 7.71 0.13

mm 462 566 667 3

in 18.19 22.31 26.25 0.13

mm 686 787 889 4

in 27 31 35 0.19

mm 470 572 674 3

in 18.50 22.50 26.50 0.13

mm 494 596 697 10

in 19.44 23.44 27.44 0.38

mm 444 495 554 8

in 17.50 19.50 21.81 0.31

DIMENSIONAL TOLERANCES ± 3 mm (0.125")

UNLESS OTHERWISE SPECIFIED.

TOL ±

Ø5/8" [Ø15.9mm] MOUNTING HOLE (4 PLCS)

MOTOR JUNCTION BOX & OPTIONAL BUILT-IN THERMOSTAT

M25 OR M32 (FOR REMOTE ROOM THERMOSTAT, IF APPLICABLE)

MAX.

3 3/4”

9 5/16" 237

u6mm]

10 13/16"

u3/16

[274

u5mm]

9/16" 15mm

3" u1/4"

u6mm]

[76

u1/4"

8 1/16"

u6mm]

[206

1/4"

1 1/2" [38mm MAX.]

FIGURE 4

ELECTRICAL

WARNING

Disconnect heater from power supply at fuse box before opening enclosures or servicing heater.

Lock the switch in the "OFF" (open) position and/or tag the switch to prevent unexpected power application.

Verify that power has been disconnected at fuse box or main panel. Lock the switch in the "OFF" (open) position

and/or tag the switch to prevent unexpected power application.

Installation and wiring of the heater must adhere to all application codes.

GENERAL

1. Use only copper conductors and approved explosion- proof wiring methods during installation. Refer to the “Technical Data” table and heater data plate for conductor rating.

2. External overcurrent protection is required. Refer to the “Technical Data” table and heater data plate for voltage, frequency amperage, and phase. Supply voltage is to be within 10% of the data plate voltage.

3. The heater must be installed by qualified personnel in strict compliance with electrical codes.

4. All heaters come factory prewired and ready for direct connection to the power supply leads.

5. The heater must be individually fused, preferably with Class J time-delay fuses for maximum safety. Unless stated otherwise in your local code, fuse size shall be 125% of line current or next size larger.

FIELD WIRING

1. The supply conductors, ground conductor, and room thermostat conductors all pass through the M32 or M25 opening (see Figure 6) and are to be wired into the control enclosure (see Figure 7A).

2. Heater may be supplied with a factory installed built-in room thermostat (see Figure 8). On heaters not supplied with this option, it is recommended that a remote room thermostat be used. Connect the remote room thermostat conductors to the printed circuit board terminal block marked “TSTAT”. Any thermostat used with this heater must: a. be of an explosion-proof type, b. be rated 125V minimum, c. have a minimum 2 amp capacity, and d. open on temperature rise.

FIGURE 5

3. The internal grounding terminal in the control enclosure shall be used as the equipment grounding means. An external bonding terminal (see Figure 6) is provided for a supplementary bonding connection where local authorities permit or require such a connection.

M25 or M32 opening for field wiring

Air intake

Motor junction box

Rear View of Heater

Fan rotation

External Bonding

Air exits through louvers.

FINAL INSPECTION

1. Before application of electrical power:

a. Check that all connections are secured and comply with the applicable wiring diagram (see Figure 9) and code requirements, b. Confirm that the power supply is compatible with the data plate rating of the heater, c. Remove any foreign objects from the heater, d. Install all covers and verify that all enclosures are well secured, and e. Ensure that the fan rotates freely. See Figure 6 for proper direction of fan rotation.

Control Enclosure & Field Wiring

Connect supply conductors

to this side of contactor. Contactor load side terminals, this side for factory wiring only.

Printed circuit board’s terminal block

Control enclosure and cover

For a 1-phase heater, use these contactor terminals

Active and spare fuses (see parts list)

FIGURE 7A

FIGURE 6

Optional factory

installed built-in

room thermostat.

FIGURE 8

Remote Room

Thermostat

if applicable

Terminals marked

“T’STAT”

FIGURE 7B

TRANSFORMER

(tap must match heater voltage)

OPTIONAL

PILOT LIGHT

PCB

FUSE

1 2 3

ELEMENTS 220/230/240

CONTACTOR

MOTOR

TRANSFORMER

(tap must match heater voltage)

1 2 3

CONTACTOR

1 2 3

MOTOR

AUTO-RESET

TEMPERATURE

HIGH-LIMIT

(THERMOWELL)

AUTO-RESET

TEMPERATURE

HIGH-LIMIT

(AMBIENT AIR)

1-PHASE

WIRING SCHEMATIC

OPTIONAL

PILOT

LIGHT

AUTO-RESET

TEMPERATURE

HIGH-LIMIT

(THERMOWELL)

AUTO-RESET

TEMPERATURE

HIGH-LIMIT

(AMBIENT AIR)

OPTIONAL

REDUNDANT

TEMPERATURE

HIGH-LIMIT

OPTIONAL

REDUNDANT

TEMPERATURE

HIGH-LIMIT

OPTIONAL

ROOM

THERMOSTAT

OPTIONAL

ROOM

THERMOSTAT

PCB

FUSE

380 & 400 50Hz 440/480 @ 60Hz

415/440 @ 50Hz

WIRING SCHEMATIC

3-PHASE

ELEMENTS

TRANSFORMER

(tap must match heater voltage)

PCB

FUSE

OPTIONAL

ROOM

THERMOSTAT

FIGURE 9

OPTIONAL

PILOT

LIGHT

1 2 3

380 & 400 50Hz 440/480 @ 60Hz

ELEMENTS

415/440 @ 50Hz

CONTACTOR

AUTO-RESET

TEMPERATURE

HIGH-LIMIT

(THERMOWELL)

AUTO-RESET

TEMPERATURE

HIGH-LIMIT

(AMBIENT AIR)

3-PHASE

WIRING SCHEMATIC

OPTIONAL

REDUNDANT

TEMPERATURE

HIGH-LIMIT

CONTINUOUS FAN OPTION

FE2 TECHNICAL DATA FOR 50 HZ ELECTRIC AIR HEATERS

Temperature

Model

Voltage

Nominal

(V) (kW) (W) (A) (A) (AWG) (A) °C °F

FE2-220150-025 220 2.5 2270 1 2.5 11.4 14.3 14 15 10.0 18.0 12122 10557

FE2-220150-042 220 4.2 3950 1 2.5 19.1 23.9 10 25 17.4 31.3 12123 10557

FE2-220150-063 220 6.3 6050 1 2.5 28.6 35.8 8 40 15.2 27.4 12124 10557

FE2-220150-084 220 8.4 8140 1 2.5 38.2 47.8 6 50 20.5 36.8 12125 10557

FE2-220150-126 220 12.6 12100 1 2.5 57.3 71.6 4 75 14.7 26.4 12126 10558

FE2-230150-028 230 2.8 2480 1 2.5 12.2 15.3 12 20 10.9 19.6 12122 10557

FE2-230150-046 230 4.6 4320 1 2.5 20.0 25.0 10 25 19.0 34.2 12123 10557

FE2-230150-069 230 6.9 6610 1 2.5 30.0 37.5 8 40 16.6 29.9 12124 10557

FE2-230150-138 230 13.8 13230 1 2.5 59.9 74.9 2 80 16.1 28.9 12126 10558

FE2-240150-030 240 3.0 2700 1 2.5 12.5 15.6 12 20 11.9 21.4 12122 10557

FE2-240150-050 240 5.0 4701 1 2.5 20.8 26.0 10 30 20.7 37.2 12123 10557

FE2-240150-075 240 7.5 7200 1 2.5 31.3 39.1 8 40 18.1 32.6 12124 10557

FE2-240150-150 240 15.0 14400 1 2.5 62.5 78.1 2 80 17.5 31.4 12126 10558

FE2-380350-025 380 2.5 2260 3 1.1 3.8 4.8 16 5 10.0 17.9 12122 10557

FE2-380350-042 380 4.2 3930 3 1.1 6.4 8.0 16 10 17.3 31.1 12123 10557

FE2-380350-063 380 6.3 6020 3 1.1 9.6 12.0 14 15 15.1 27.2 12124 10557

FE2-380150-084 380 8.4 8100 3 1.1 12.8 16.0 12 20 20.4 36.6 12125 10557

FE2-380350-125 380 12.5 12030 3 1.1 19.0 23.8 10 25 14.6 26.3 12126 10557

FE2-380350-167 380 16.7 16220 3 1.1 25.4 31.8 8 35 19.7 35.4 12127 10557

FE2-380350-209 380 20.9 20230 3 1.1 31.8 39.8 8 40 11.9 21.4 12128 10557

FE2-400350-028 400 2.8 2500 3 1.1 4.0 5.0 16 5 11.0 19.8 12122 10557

FE2-400350-046 400 4.6 4350 3 1.1 6.6 8.3 16 10 19.2 34.5 12123 10557

FE2-400350-069 400 6.9 6670 3 1.1 10.0 12.5 14 15 16.8 30.2 12124 10557

FE2-400350-093 400 9.3 89770 3 1.1 13.4 16.8 12 20 22.6 40.6 12125 10557

FE2-400350-139 400 13.9 13330 3 1.1 20.1 25.1 10 30 16.2 29.1 12126 10557

FE2-400350-185 400 18.5 17970 3 1.1 26.7 33.4 8 35 21.8 39.2 12127 10557

FE2-400350-231 400 23.1 22420 3 1.1 33.3 41.6 8 45 13.1 23.7 12128 10557

FE2-415350-037 415 3.7 3510 3 1.1 5.1 6.4 16 10 16.3 27.8 12130 10557

FE2-415350-075 415 7.5 7240 3 1.1 10.4 13.0 14 15 18.9 32.7 12132 10557

FE2-415350-149 415 14.9 14510 3 1.1 20.9 25.9 10 30 18.1 31.7 12134 10557

FE2-415350-224 415 22.4 21820 3 1.1 31.2 39.0 8 40 13.1 23.0 12136 10557

FE2-440350-042 440 4.2 3950 3 1.1 5.5 6.9 16 10 17.4 31.3 12130 10557

FE2-440350-084 440 8.4 2740 3 1.1 11.0 13.8 14 15 20.5 36.8 12132 10557

FE2-440350-168 440 16.8 16310 3 1.1 22.0 27.5 8 35 19.8 35.6 12134 10557

FE2-440350-210 440 21.0 20340 3 1.1 27.6 34.4 8 35 11.9 21.5 12135 10557

Wattage

Heater

Wattage

Phase

Max. Motor

Total

Current

Nameplate

Current (A)

Circuit

Minimum

Wire

Supply

Ampacity

Maximum

Rise

Fuse Size

Core Kit

Contactor

Part Number

Part

Number

NOTES:

1. Minimum conductor size for 30˚C (86˚F) ambient. Derate conductor for ambient temperature. Use minimum 90˚C (194˚F) insulation.

2. Heater is functioning normally if at rated voltage the amp draw is within 10% of the value in this table.

3. Operation at lower voltages will result in reduced heat output and amp draw.

4. Add “T” to model number when adding a built-in thermostat.

5. Add "U" to model number for units with continuous fan option.

6. Add "A" to model number for units with stainless steel cabinet.

FE2 TECHNICAL DATA FOR 60 HZ ELECTRIC AIR HEATERS

Temperature

Model

Voltage

Nominal

(V) (kW) (W) (A) (A) (AWG) (A) °C °F

FE2-220160-025 220 2.5 2270 1 2.2 11.4 14.3 14 15 8.0 14.4 12122 10557

FE2-220160-042 220 4.2 3950 1 2.2 19.1 23.9 10 25 13.9 25.0 12123 10557

FE2-220160-063 220 6.3 6050 1 2.2 28.6 35.8 8 40 12.5 22.5 12124 10557

FE2-220160-084 220 8.4 8140 1 2.2 38.2 47.8 6 50 16.9 30.3 12125 10557

FE2-220160-126 220 12.6 12100 1 2.2 57.3 71.6 2 75 12.2 21.9 12126 10558

FE2-230160-028 230 2.8 2480 1 2.2 12.2 15.3 12 20 8.7 15.7 12122 10557

FE2-230160-046 230 4.6 4317 1 2.2 20.0 25.0 10 25 15.2 27.3 12123 10557

FE2-230160-069 230 6.9 6613 1 2.2 30.0 37.5 8 40 13.7 24.6 12124 10557

FE2-230160-138 230 13.8 13225 1 2.2 59.9 74.9 2 80 13.3 23.9 12126 10558

FE2-240160-030 240 3.0 2700 1 2.2 12.5 15.6 12 20 9.5 17.1 12122 10557

FE2-240160-050 240 5.0 4701 1 2.2 20.8 26.0 10 30 16.5 29.8 12123 10557

FE2-240160-075 240 7.5 7200 1 2.2 31.3 39.1 8 40 14.9 26.8 12124 10557

FE2-240160-100 240 10.0 9690 1 2.2 41.7 52.1 6 60 20.1 36.1 12125 10558

FE2-240160-150 240 15.0 14400 1 2.2 62.5 78.1 2 80 14.5 26.1 12126 10558

FE2-440360-042 440 4.2 3950 3 1.0 5.5 6.9 16 10 13.9 25.0 12130 10557

FE2-440360-084 440 8.4 8142 3 1.0 11.0 13.8 14 15 16.9 30.3 12132 10557

FE2-440360-168 440 16.8 16310 3 1.0 22.0 27.6 8 35 16.4 29.5 12134 10557

FE2-440360-210 440 21.0 20343 3 1.0 27.5 34.4 8 35 9.9 17.9 12135 10557

FE2-480360-030 480 3.0 2700 3 1.0 3.6 4.5 14 15 9.5 17.1 12129 10557

FE2-480360-050 480 5.0 4701 3 1.0 6.0 7.5 14 15 16.5 29.8 12130 10557

FE2-480360-075 480 7.5 7200 3 1.0 9.0 11.3 14 15 14.9 26.8 12131 10557

FE2-480360-100 480 10.0 9690 3 1.0 12.0 15.0 14 15 20.1 36.1 12132 10557

FE2-480360-150 480 15.0 14400 3 1.0 18.0 22.5 10 25 14.5 26.1 12133 10557

FE2-480360-200 480 20.0 19410 3 1.0 24.1 30.1 8 35 19.5 35.1 12134 10557

Wattage

Heater

Wattage

Phase

Max. Motor

Total

Current

Nameplate

Current (A)

Circuit

Minimum

Wire

Supply

Ampacity

Maximum

Rise

Fuse Size

Core Kit

Contactor

Part Number

Part

Number

NOTES:

1. Minimum conductor size for 30˚C (86˚F) ambient. Derate conductor for ambient temperature. Use minimum 90˚C (194˚F) insulation.

2. Heater is functioning normally if at rated voltage the amp draw is within 10% of the value in this table.

3. Operation at lower voltages will result in reduced heat output and amp draw.

4. Add “T” to model number when adding a built-in thermostat.

5. Add "U" to model number for units with continuous fan option.

6. Add "A" to model number for units with stainless steel cabinet.

PARTS LIST

FORCED AIR ELECTRIC HEATERS

FE2 PART NUMBERS

ITEM 2.5 - 4.6 kW 6.3 - 10 kW 12.5 - 20 kW 20.9 - 35 kW Description

1 ** Core

4 4075 4076 4077 Louver Kit, c/w Screws

8 4022 4023 4024 4025 Fan Blade

14 3737 Coupling, Motor

15 9500 3813 10389 Conduit, Motor

16 5371 Cover, Thermostat Enclosure

17 3813 Conduit, Control Enclosure

18 9314 9315 9316 Conduit, Element Enclosure

19 9679 Enclosure, Element

20 3510 Cover, Element Enclosure

22 12225 Enclosure, Thermostat, Metric

23 5032 Thermostat, Built-in-kit

24 - - - Enclosure, Control

25 ** ** ** Contactor

26 10556 (60HZ) 11295 (50HZ) Transformer

27 3809 Bracket, Printed Circuit Board

28 1876 Terminal, 6-14 Ga. Screw Lug

29 9357 Fuse, Buss MDQ - 1/2 Amp

30 3514 Assembly, Printed Circuit Board

31 9158 Cover, Control Enclosure

32 9267 Thermowell, Ambient High-Limit

33 - High Limit, Ambient Temperature

34 9289 Plug, 1" NPT Explosion Proof

35 - Temperature High-Limit Kit

37 Bus-Bar, Small Curved

38 Bus-Bar, Large Curved

39 7401 Terminal, 6-14 Ga Lug, 1/4 Mtg Hole

40 8646 Adapter, 1" NPT to M32

41 8644 Adapter, 1" NPT to M25

Painted: 9203

S.S.: 9507

Painted: 9191

S.S.: 9192

Painted: 9200

S.S.: 9513

Painted: 9197

S.S.: 9510

Painted: 3782

S.S.: 9212

Painted: 4078

S.S.: 9504

Painted: 3789

Painted: 3785

S.S.: 9206

Painted: 3788

Painted: 9354

S.S.: 9516

Provided with Core Kits**

Painted: 9204

Painted: 9193

Painted: 9201

Painted: 9198

Painted: 3783

Painted: 4079

1377

1699

S.S.: 9112

Painted: 3786

S.S.: 9111

Painted: 9355

S.S.: 9508

S.S.: 9194

S.S.: 9514

S.S.: 9511

S.S.: 9213

S.S.: 9505

S.S.: 9207

S.S.: 9517

Painted: 9205

S.S.: 9509

Painted: 9195

S.S.: 9196

Painted: 9202

S.S.: 9515

Painted: 9199

S.S.: 9512

Painted: 3784

S.S.: 9214

Painted: 4080

S.S.: 9506

Painted: 3787

S.S.: 9208

Painted: 9356

S.S.: 9518

Panel, Bottom

Panel, Left Side

Panel, Top

Panel, Right

Panel, Fan Shroud

Fan Guard Kit

220/230/240V 1PH 50HZ 220/230/240V 1PH 60HZ

380/400/415/440V 3PH 50HZ 440/480V 3PH 60HZ

Bracket, Motor Mount Right

Channel, Motor Mount

Bracket, Motor Mount Left

Panel, Element Enclosure Guard

Bus-Bar, Straight

** See technical data table for part numbers. NOTE: For items not shown, contact factory.

HEATER ASSEMBLY DIAGRAM

Optional built-in thermostat #23

replaces item #16

See control enclosure assembly diagram (below)

CONTROL ENCLOSURE

ASSEMBLY DIAGRAM

4041or

See high-limit assembly diagram

(below)

Optional built-in disconnect switch kit

HIGH LIMIT

ASSEMBLY DIAGRAM

BUS-BAR CONFIGURATION BUS-BAR CONFIGURATION BUS-BAR CONFIGURATION ALL 1-PHASE MODELS ALL 3-PHASE (EXCEPT 380V & 400V 50 HERTZ) 3-PHASE 380V & 400V 50 HERTZ MODELS ONLY

SPECIFICATIONS FOR ALL 50 HZ MODEL

Nominal kW 2.5 3.7 6.3 8.4 12.5 14.9 20.9 22.4

to 3.0 to 5.0 to 7.5 to 10 to 13.9 to 20 to 21 to 23.1

Max. Altitude (m) 3,658 2,438 3,048 2,134 3,048 2,134 3,048 2,134 (ft.) 12,000 8,000 10,000 7,000 10,000 7,000 10,000 7,000

Air Flow @ 21°C (m3/hr) 679 1189 2463 5096 @ 70°F (CFM) 400 700 1450 3000

Horizontal Air Throw (m) 4.0 7.6 10.7 18.2 (ft) 13 25 35 60

Max. Mounting Height (m) 2.1 3.0 3.0 6.1

(to underside) (ft) 7 10 10 20 Motor Power (hp) 1/4 1/2 1/2 (min) (kW) 0.373 0.373 0.373

Motor Speed (RPM) 1425 1425 1425

Fan Diameter (mm) 305 406 508 (in) 12 16 20

Net Weight (kg) 68.9 81.6 91.2 (lbs) 140 168 201

Shipping Weight (kg) 88.0 98.9 114.3

(lbs) 194 218 252

Temperature Code Rating T3 (200°C / 392°F)

Enclosures NEMA Type 7 & 9. For dry, indoor use only. Do not immerse in water. Do not store or use in areas exposed to rain or snow.

Motor Type Explosion-proof. Thermally protected. Permanently lubricated ball bearings. 1425 RPM

Fan Aluminum blade. Steel spider and hub with 5/8" (15.875 mm) bore.

Fan Guard Split design with close wire spacing. 1/4" (6.3 mm) dia. probe will not enter.

Mounting Holes Four 5/8" (15.9 mm) diameter holes at top of heater.

Heating Elements Three long-life, low watt-density, high grade metal-sheathed elements.

Temperature High-Limit Automatic reset type, snap-action bimetal, open on temperature rise. Rated 100,000 cycles at 10 amps, handles 0.128 amps.

Control Circuit 120V, 0.128 amps, 15VA. (Grounded)

Optional Built-in Thermostat Explosion-proof. 2°

Control Transformer Multi-tap primary, 120V secondary, 50VA.

Contactor 60 or 80 amp. Rated for 1,000,000 mechanical operations. 120V, 15VA coil (separately fuse-protected).

Heat Transfer Fluid

Cabinet Material 14 gauge (1.90 mm) (0.075") steel. Epoxy coated with five-stage pretreatment, including iron phosphate. Optional stainless steel.

Core Steel with integral aluminum fins, vacuum charged and hermetically sealed.

Conduit Material Heavy walled, 0.122" (3.1 mm) steel.

Overpressure Protection serviceable parts.

Operational Temperature Limitations -20°C to 40°C (-4°F to 104°F)

Storage Limitations -45°C to 80°C (-49°F to 176°F), short term to 120°C (248°F). Do not immerse in water.

Do not exposed to rain or snow.

Long-life formulated propylene glycol and water

Preset 100 psig (690 kPa) pressure relief valve, aluminum body, no field

C to 28°C

(36°

F to 82°F)

SPECIFICATIONS FOR ALL 60 HZ MODEL

2.5 3.7 6.3 8.4 12.5 14.9 20.9 22.4

Nominal kW to 3.0 to 5.0 to 7.5 to 10 to 13.9 to 20 to 21 to 23.1

Max. Altitude (m) 3,658 2,438 3,048 2,134 3,048 2,134 3,048 2,134

(ft.) 12,000 8,000 10,000 7,000 10,000 7,000 10,000 7,000

Air Flow @ 21°C (m3/hr) 850 1444 2973 6116

@ 70°F (CFM) 500 850 1750 3600

Horizontal Air Throw (m) 4.6 9.1 12.2 21.3 (ft) 15 30 40 70

Max. Mounting Height m) 2.1 3.0 3.0 6.1 (to underside) (ft) 7 10 10 20

Motor Power (hp) 1/4 1/2 1/2 (min) (kW) 0.373 0.373 0.373

Motor Speed (RPM) 1725 1725 1725

Fan Diameter (mm) 305 406 508 (in) 12 16 20

Net Weight (kg) 63.5 76 91 (lbs) 140 168 201

Shipping Weight (kg) 88 99 114 (lbs) 194 218 252

Temperature Code Rating T3 (200°C / 392°F)

Enclosures NEMA Type 7 & 9. For dry, indoor use only. Do not immerse in water. Do not store or use in areas exposed to rain or snow.

Motor Type Explosion-proof. Thermally protected. Permanently lubricated ball bearings. 1725 RPM

Fan Aluminum blade. Steel spider and hub with 5/8 in. (15.875 mm) bore.

Fan Guard Split design with close wire spacing. 1/4in. (6.3 mm) dia. Probe will not enter.

Mounting Holes Four 5/8 in. (15.9 mm) diameter holes at top of heater.

Heating Elements Three long-life, low watt-density, high grade metal-sheathed elements.

Temperature High-Limit Automatic reset type, snap-action bimetal, open on temperature rise. Rated 100,000 cycles at 10 amps, handles 0.130 amps.

Control Circuit 115 Volts, 0.130 amps, 15 VA. (Grounded)

Optional Built-in Thermostat Explosion-proof. 2ºC to 28ºC (36ºF to 82ºF)

Control Transformer Multi-tap primary, 115 V secondary, 50 VA.

Contactor 60 or 80 amp. Rated for 1,000,000 mechanical operations. 120 Volts, 15 VA coil (separately fuse - protected).

Heat Transfer Fluid Long life formulated ethylene glycol and water

Cabinet Material 14 ga. (1.90 mm) (0.075in.) steel. Epoxy coated with five-stage pretreatment, including iron phosphate.

Core Steel with integral aluminum fins, vacuum charged and hermetically sealed.

Conduit Material Heavy walled, 0.122 in. (3.1 mm) steel.

Overpressure Protection Preset 100 psig (690 kPa) seep pressure relief valve, aluminum body, no field serviceable parts.

Operational Temperature Limitations -20ºC to 40ºC (-4ºF to 104ºF)

Storage Limitations -45ºC to 80ºC (-49ºF to 176ºF), short term to 120ºC (248ºF). Do not immerse in water. Do not store or use in areas exposed to rain or snow.

REPAIR & REPLACEMENT

Disconnect heater from power supply at fuse box before opening enclosures

or servicing heater. Lock the switch in the “OFF” (open) position and/or tag the

Verify that power has been disconnected at fuse box or main panel. Lock

the switch in the “OFF” (open) position and/or tag the switch to prevent

1. After repairing any component:

a. check that electrical connections are correct and secure (see Figure 9), b. remove any foreign material from enclosures, c. install and secure all covers, d. ensure that all fasteners are tight, e. remove all foreign objects from heater, and f. ensure air exits through louvers and fan rotates counterclockwise when viewed from rear of heater (see Figure 14).

The heater core is vacuum charged and not field repairable. For core removal:

1. Remove cabinet bottom and element enclosure cover.

2. Disconnect all wires entering element enclosure (see Figure 10).

3. Slightly loosen all cabinet bolts shown in Figure 10, to prevent the core from binding.

4. With an assistant supporting the weight of the core, remove the 3 core

mounting bolts. Carefully lower the core out of the cabinet (see Figure 11).

5. To return core to factory, use crate supplied with exchange core to protect the element terminals and plate threads.

6. To reinstall, lift the core up into cabinet while an assistant guides the

element wires into the element enclosure conduit.

7. Position the core and tighten the 3 core mounting bolts. Tighten the

remaining cabinet bolts.

switch to prevent unexpected power application.

unexpected power application. Heater surfaces may be hot.

TEMPERATURE HIGH-LIMIT

1. Remove temperature high-limit assembly and clean the inside of the

thermowell (see Figure 12). A clean thermowell will ensure good

thermal contact.

2. Use only a factory supplied temperature high-limit to ensure safe operation.

3. Apply a small drop, 3/32” (2mm) diameter, of heat sink compound to the

center of the metal cap but do not spread. This is critical for proper thermal contact between the temperature high-limit and the thermowell (see

Figure

4. Reinstall the temperature high-limit assembly with the snap ring and spring

into the thermowell without damaging the insulating tube. Secure in place with the cotter pin (see Figure 13).

12).

WARNING

CORE

Loosen bolts only, do not remove.

Conduit Junction Enclosure

Thermowell

{

Remove this core mounting bolt & two others on the opposite side.

Loosen bolts only, do not

}

remove.

Control Enclosure

Element Enclosure

FIGURE 10

FIGURE 11

3/32”

(2 mm)

Drop

FIGURE 12

MOTOR, FAN & FAN GUARD

1. Remove bolts holding the motor to the motor mount. On units with a built

in thermostat, remove the bolts on the back of the thermostat enclosure.

2. Remove conduit #1 located between motor junction box and control

enclosure by turning it in the direction illustrated (see Figure 14). Note conduits #1 and #2 are not interchangeable and have left hand

threads on one end, this end is indicated by a machined groove.

3. Remove the 2 piece fan guard assembly (see Figure 15).

4. Lift the motor assembly off the motor mount.

5. Before removing the fan, measure and record the location of the fan hub on the motor shaft (see Figure 16). If difficult to remove, use a gear puller on the fan hub.

6. To reassemble, place motor assembly onto motor mount and fasten the fan guard to cabinet.

7. Simultaneously engage and tighten both ends of conduit #1 into enclosures. Leave a 1/16” to 3/16” (1.6 to 4.8 mm) gap between the motor and fan guard (see Figure 16). Adjust conduit #2 to center the fan in the shroud.

8. To ensure a minimum 5 thread engagement, threaded ends of conduits must protrude a minimum of 1/16” (1.6 mm) into enclosures. The groove on conduit #2 must not be more than 7/8” (22 mm) from motor coupling (see Figure 14).

9. Bolt motor to motor mount. Manually spin the fan blade to ensure fan rotates freely.

10. Air must exit through louvers and fan must rotate counterclockwise when viewed from rear of heater (see Figure 14).

Air inlet

7/8” (22 mm) (From groove to face of coupling)

Rotation

Remove

Install

Conduit #2

Install

Remove

Conduit #1

FIGURE 13

FIGURE 14

FIGURE 15

FIGURE 16

PRINTED CIRCUIT BOARD

1. After removing the printed circuit board (P.C. Board) bracket assembly from the control enclosure, separate the P.C. Board from the bracket

by cutting off the plastic spacers (see Figure 18).

2. Reinstall a new factory supplied P.C. Board onto the mounting bracket using new non-conducting spacers of the same length. Spacers are supplied with a new P.C. Board. Reinstall the control circuit ground

wire to the printed circuit board bracket (see Figure 9).

INDUSTRIAL CONTACTOR

1. Replace with a factory supplied contactor of the same rating.

TRANSFORMER

1. Replace with a factory supplied transformer of the same rating.

2. On the new transformer, select primary wires to match heater voltage. Ensure that the correct transformer secondary lead is grounded

(see Figure 9). Individually terminate all unused wires using closed end connectors.

FUSE

1. Replace fuse with one of the same type and rating as indicated on P.C. Board or refer to parts list. An extra fuse should be stored in the clips marked “SPARE”.

HEATING ELEMENTS

1. Heating elements are an integral part of the vacuum charged core. A factory exchange core can be shipped immediately from stock. Refer to “Core” section for details.

CABINET PANELS

1. Bolt-on cabinet panels are individually replaceable.

1/16” to 3/16” (1.6 to 4.8 mm)

THERMOSTAT COVER

SCREWS

1. Replace thermostat cover bolts with four plated steel hex head bolts, M6 x 20mm long property class 9.8, 720MPa minimum yield strength.

FIGURE 17

FIGURE 18

NOTES

5918 Roper Road, Edmonton, Alberta, Canada T6B 3E1

Phone: (780) 466-3178 Fax: (780) 468-5904

PLEASE ADHERE TO INSTRUCTIONS PUBLISHED IN THIS MANUAL.

Failure to do so may be dangerous and may void certain provisions of your warranty.

For further assistance, please call:

24 Hr. Hotline: 1-800-661-8529

(U.S.A. and Canada)

Please have model and serial numbers available before calling.

WARRANTY: Under normal use the Company warrants to the purchaser that defects in material or workmanship will be repaired or replaced without charge for a period of 36 months from date of shipment. Any claim for warranty must be reported to

authorized repair or replacement within the terms of this warranty.

Subject to State or Provincial law to the contrary, the Company will not be responsible for any expense for installation, removal from service, transportation, or damages of any type whatsoever, including damages arising from lack of use, business interruptions, or incidental or consequential damages.

The Company cannot anticipate or control the conditions of product usage and therefore accepts no responsibility for the safe application and suitability of its products when used alone or in combination with other products. Tests for the safe application and suitability of the products are the sole responsibility of the user.

This warranty will be void if, in the judgment of the Company, the damage, failure or defect is the result of:

• vibration, radiation, erosion, corrosion, process contamination, abnormal process conditions, temperature and pressures, unusual surges or pulsation, fouling, ordinary wear and tear, lack of maintenance, incorrectly applied utilities such as voltage, air, gas, water, and others or any combination of the aforementioned causes not

• any act or omission by the Purchaser, its agents, servants or independent contractors which for greater certainty, but not so as to limit the generality of the foregoing, includes physical, chemical or mechanical abuse, accident, improper installation of the product, improper storage and handling of the product, improper application or the misalignment of parts.

manufacturing defects apparent within 30 days from the date of installation.

The Company neither assumes nor authorizes any person to assume for it any other obligation or liability in connection with the product(s).

The Purchaser agrees that all warranty work required after the initial commissioning of the product will be provided only if the Company has been paid by the Purchaser in full accordance with the terms and conditions of the contract.

The Purchaser agrees that the Company makes no warranty or guarantee, express, implied or statutory, (INCLUDING ANY WARRANTY OF

MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE) written or oral, of

the Article or incidental labour, except as is expressed or contained in the agreement herein.

LIABILITY: Technical data contained in the catalog or on the website is subject to change without notice. The Company reserves the right to make dimensional and other design changes as required. The Purchaser acknowledges the Company shall not be obligated to modify those articles manufactured before the formulation of the changes in design or improvements of the products by the Company.

The Company shall not be liable to compensate or indemnify the Purchaser, end user or any other party against any actions, claims, liabilities, injury, loss, loss of use, loss of business, damages, indirect or conse-

es (including legal expenses), costs, obligations and causes of action of any kind arising wholly or partly from negligence or omission of the user or the misuse, incorrect application, unsafe application, incorrect storage and handling, incorrect installation, lack of maintenance, improper maintenance or improper operation of products furnished by the Company.

Edmonton

1-800-661-8529 (780) 466-3178 F 780-468-5904

Oakville

1-800-410-3131 (905) 829-4422 F 905-829-4430

Orillia

1-877-325-3473 (705) 325-3473 F 705-325-2106

Greensburg

1-800-473-2402 (812) 663-4141 F 812-663-4202

Houston

1-855-219-2101 (281) 506-2310 F 281-506-2316

Denver

1-855-244-3128 (303) 979-7339 F 303-979-7350

DIRECTIVE 2003/108/EC AMMENDMENT TO THE DIRECTIVE 2002/96/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL on waste electrical and electronic equipment (WEEE).

1. The equipment that you bought is WEEE marked and has required the extraction and use of natural resources for its production. It may contain substances that could impact health and the environment. As such it is a requirement not to dispose of WEEE marked equipment as unsorted municipal waste and to collect such WEEE marked equipment separately.

2. In order to avoid the dissemination of those substances in our environment and to diminish the pressure on natural resources, we encourage you to use the appropriate take-back systems in your area. Those systems will reuse or recycle most if not all of the materials of your equipment in a sound way.

3. The crossed-out wheeled bin symbol on this equipment invites you to use those systems.

4. If you need more information on collection, reuse and recycling systems in your area, please contact your local or regional waste management administration.

CCI Thermal Technologies FE2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual